January 1980 FORM: OM-1092A Effective With Style No. HK-33 ALE COPY RETURN TO IFOLDER MODEL SPOO L-PAK OWN ERS MANUAL HilliER MILLER ELECTRIC MFG. CO. 718 S. BOUNDS ST. P.O. Box 1079 APPLETON WI 54912 USA ADDITIONAL COPY PRICE 30 CENTS NWSA CODE NO. 4579 PRINTED IN U.S.A. ~ L- ~~P %..~ t,~&P ~ ~J~ LIMITED WARRANTY EFFECTIVE: JUNE 1, 1979 This warranty supersedes all previous MILLER warranties and is ex clusive with no other guarantees or warranties expressed or implied. LIMITED ( .d WARRANTY-Subject to the terms and conditions hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants to its Distributor/Dealer that all new and unused Equipment furnished by Miller is free from defect in workmanship and material as of the time and place of delivery by Miller. No warranty is made by Miller with respect to engines, trade accessories or other items manufactured by others. Such engines, trade accessories and other items are sold subject- to All the warranties of their respective manufacturers, if any engines are warranted by their manufacturer for one year from date of original purchase, . Except to as specified below, Millers warranty does not components having normal useful life of less than such spot welder tips, relay and contactor MILLERMATIC parts that come in contact with the year, as including wire apply one defect in workmanship or material. required to honor warranty claims on warEquipment in the event of failure resulting from a defect within the following periods from the date of delivery of Equipment to the original user: Miller shall be ranted / a matter of general policy only, Miller may honor claims original user within the foregoing periods. ) In the case of Millers breach of warranty or any other duty with respect to the quality of any goods, the exclusive remedies therefore shall be, at Millers option (1) repair or (2) replacement writing by Miller in appropriate cases, (3) repair or replacement at an authorized Miller service station or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at Customers risk and expense. Upon receipt or, where authorized in the reasonable cost of of notice of apparent defect or failure, Miller shall instruct the claimant on the warranty claim procedures to be followed. ) (~ (1) points, welding nozzles and nozzle insulators where failure does not result from As submitted by the ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND GUARANTY OR REPRESENTA ANY IMPLIED WARRANTY, PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING TION AS TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX CLUDED AND DISCLAIMED BY MILLER. 1. 2. Arc welders, power sources and components Original main power rectifiers (labor . . 3 years 1 year B0days 4. All other Millermatic Feeders 5. Replacement Batteries or repair parts, exclusive of labor . 1 year 60 days 6 months 6. EXCEPT AS EXPRESSLY MILLER WRITING, only) 3. Allweldinggunsandfeeder/guns - 1 year provided that Miller is notified in writing within thirty (301 days of the date of such failure. BY MILLER INTENDED IN FOR BY COMMERCIAL/INDUSTRIAL PURCHASE USERS AND FOR OPERATION BY PERSONS TRAINED AND MAINTENANCE USE AND OF EXPERIENCED IN THE WELDING TO, AND MILLERS . ARE ULTIMATE EQUIPMENT AND CONSUMER USE. MILLER ~ PROVIDED PRODUCTS NO RESELLER NOT FOR CONSUMERS ) OR WARRANTIES DO NOT EXTEND IS AUTHORIZED TO EXTEND WARRANTIES TO, ANY CONSUMER. .....-~ ? SECTION 1 Dimensions Height Width Depth - - INTRODUCTION (Inches) Weight (Pounds) 19 23 -9-1/2 - 17-3/4 Figure 1-1. Specifications 1-1. 1-4. GENERAL prepared especially for use in familiar izing personnel with the design, installation, operation, main informa tenance, and troubleshooting of this equipment. All tion presented herein should be given careful consideration to assure optimum performance of this equipment. This manual has been 1-2. Before the equipment is put into operation, the safety sec at the front of the welding power source or welding tion generator manual should be read completely. This will help avoid possible injury due to misuse or improper welding applications. The following definitions apply to CAUTION and PORTANT blocks found throughout this manual: RECEIVING-HANDLING Prior SAFETY installing this equipment, clean all packing material around the unit and carefully inspect for any damage that may have occurred during shipment. Any claims for loss or damage that may have occurred in transit must be filed by the purchaser with the carrier. A copy of the bill of lading and freight bill will be furnished by the carrier on request if ~M to CAUTION from to file occasion oper~g, Under this and main heading, installation, or practices will be found that if carefully followed may create a hazard to per- tenance claim arises. not procedures sonnel. I When requesting information concerning this equipment, it is essential that Model Description and/or Stock Number and Serial (or Style) Numbers of the equipment be supplied. 1TAl 1-3. I DESCRIPTION I Under This unit is designed to enable Spoolmatic guns to utilize 12 inch spools of wire. The unit is used in conjunction with the Spoolmatic guns and WC series weld controls or with the MM200 welding power BRAKE OPERATION BRAKE The heading, installation, operating, and main tenance procedures or practices will be found that if not carefully followed may result in damage to equip I ment. I source. SECTION 2 2-1. this lockout - INSTALLATION (Figure 2-1) should be set to ON for normal operation. This will prevent wire backlash when the gun trigger is released and wire feed ceases. The BRAKE lockout should be set to OFF for loading and threading welding wire. 2-2. INSTALLING SPOOL-PAK TO WELD CONTROL OR WELDING POWER SOURCE CAUTION Ensure that all electrical power to the welding power and the weld control unit is completely disconnected prior to installation of the Spool-Pak. source 1. 2. receptacle RC1 into plug PLG 1 of the Spool-Pak control box. Insert brake control the rear The to remaining end of a. the brake control cable is attached the contactor control power on in the weld control or welding source. black and white Attach the No. 5 and 2 on terminal strip Control Contactor 11 the or across receptacle RC2. Attach the green lead to ground. For leads WC-l to models: terminals C-049 184 Figure 2-1. Component Location OM-1092 Page 1 b. For WC-lI, WC-Ill & WC-IV models: Attach the black and white leads to terminals No. 42 and 43 on termin al strip iT. Attach the green lead to ground. c. For MM200: Attach terminals No. 3 and 4 green lead to 2-4. WELDING WIRE SPOOL INSTALLATION WELDING WIRE THREADING (Figure 3-1) FNrI the on & black and white leads to terminal strip iT. Attach the TL ground. Place the Spool-Pak BRAKE in the OFF position and keep the interconnecting conduit as straight sible during the following procedures. INSTALLING SPOOL-PAK TO SPOOLMATIC GUN 2-3. 1. Remove gun spool 2. Pivot the tension arm 1. Release spring tension on Spool-Pak spool rotating the cover locking knob clockwise. 2. Remove Spool-Pak spool arm 3. outward. remove onto Depress the the welding wire spool, the wire spool. 4. 4. Slip the ring retainer off 5. Remove the inlet guide by pushing the inlet guide towards the rear of the gun. Retain inlet guide and retainer ring for future reuse. 6, the inlet guide. by cover. adapter block into gun wire spool in block with the rib in the gun case. Slide on the two spring loaded stops on the retaining the Spool-Pak wire spool spindle and remove retaining ring. Slide spool of wire onto the hub so that the wire feeds off the bottom of the spool. The spool turns in a counterclockwise direction. aligning groove 5. Rotate the spool until the hole in the spool aligns with the pin in the hub. Slide the spool onto the hub until it seats against the back flange of the hub. 6. Replace retaining ring. 7. 7. cover upward and pivot the mounting Retract the welding wire and pos cover. ring 3. as Route outlet guide and interconnecting conduit through the hole in rear of gun case (on early Spoolmatic models the hole will need to be altered so the conduit can be routed straight out the rear of the Cut off any portion of the welding wire that is or is deformed. not straight 8. gun). Thread the welding wire into the interconnecting conduit inlet guide and push wire forward until it passes through the gun drive rolls and enters the wire guide liner. 8. Depress securing pin lever and insert outlet guide from Spool-Pak interconnecting conduit through adapter 9. block and into gun drive housing. 9. Release securing pin lever and secured. ensure outlet guide is 10. Open 11. Depress securing pin lever on adapter block and insert remaining end of interconnecting conduit. 12. Release securing pin lever and conduit is secured. side access door on Pivot the mounting tension arm down. arm in the gun in and pivot the 10. Replace 11. Place the Spool-Pak BRAKE in the ON position and rotate the wire spool clockwise to take up the wire slack. 12. To Spool-Pak. gun spool cover. replace the Spool-Pak spool cover, align notches tip cover down under spring. Tighten spring tension by rotating the cover locking knob counter and ensure interconnecting clockwise. SECTION 3- MAINTENANCE CAUTION Ensure, that all electrical power to the and the weld control unit disconnected before attempting any work on the Spool-Pak. source I 3-1. welding power is completely inspection or I INSPECTION AND UPKEEP Usage and shop conditions will determine the frequency and type of maintenance. Inspect equipment 1. as Repair or replace, as particular attention connections, and areas where the cable equipment. follows: required, all cable and conduit. Give to frayed and cracked insulation, or Control Box I conduit enters 2. Remove grease and grime from from electrical parts and cable. 3. interconnecting conduit with compressed air when changing wire. This will remove any metal chips components; moisture A-049 182-A Purge the and dirt that may Page 2 have accumulated. Figure 3-1. Brake Adjustment 3-2. BRAKE ADJUSTMENT (Figure 3-1) and slide bracket up or down. Sliding the bracket down will increase the brake pressure, thereby causing the spool to stop Spring tension the wire from proper stopping faster. Some small slippage of the brake is necessary to keep snapping as the wire feed motor coasts. When the proper spring tension is obtained, tighten the screw. BRAKE may be adjusted to ensure of the wire spooi. Loosen screw (Figure 3-1) on the SECTION 4 TROUBLESHOOTING - The following chart is designed to diagnose and to provide remedies for some of the troubles that may develop in this unit. CAUTION I It Hazardous voltages are present on the internal dr cuitry of this unit as long as power is supplied to the welding power source and weld control. Disconnect power before attempting any inspection or work on the inside of the unit. Troubleshooting of internal circuitry should be performed by qualified personnel PROBABLE CAUSE BRAKE Wire backlash at end of weld. lockout assumed that proper installation has been made, Use this chart in Conjunction with the circuit diagram while performing troubleshooting procedures. If the trouble is not remedied after performing these procedures, the nearest Factory Authorized Service Station should be contacted. In of equipment malfunction, the manufacturers all cases recommendations should be strictly followed. only. TROUBLE is according to Section 2 of this manual, and that the unit has been functioning properly until this trouble developed. in SUGGESTED CHECK AND/OR REMEDY wrong Ensure BRAKE is set to ON for normal operation. position. ~ Brake control RC1 receptacle Ensure that RC1 is secure in plug PLG1. loose. ~ Brake spring tension adjusted. . Dirt Wire feeds erratically. in not properly interconnecting conduit and/or wire guides. Adjust brake spring tension (see Section 3-2). Blow dirt Out of conduit and/or wire guides using compressed air. Ensure that conduit is secured in adapter blocks. conduit Interconnecting in adapter blocks. not and/or weld See gun and/or weld control Owners and/or Replace conduit and/or wire guides. secure ~ Problem in gun Manual. control. ~ Interconnecting wire guides ~ conduit worn. WIDE SLOT WH~ I 507 ~BSi 1 TO 503 GRN. ~~~ CONTACTOR CONTROL CIRCUIT 502 > PLG1 BLK _____________ RC1 A-081 643 Figure 4-1. Circuit Diagram OM-1092 Page 3 January 1980 FORM: OM-1092A Effective With Style No. HK.33 MODEL SPOO L-PAK PARTS LIST 4 CD CD 9 Cd, a m I- 0 N C, I- C- N Cs., C C- Cd) N N .0 E CD N In N In IC C CD IC CD LI. 0 Cv) N 0 Cv, I N CC) C,) C C 0) N 0 C) C Cv, OM-1092 Page 1 ID Item Dia. Factory No. Mkgs. Part No. Figure A Description Main 1 081 427 2 058 427 3 010 909 4 010 910 5 056068 6 081 729 7 081 726 Quantity Assembly COVER, spool RING, retaining NUT, steel self - 1 - - spool locking hex 3/8-16 WASHER, flat steel SAE 3/8 KEY,steel 1/8x 1/8x 1/2 1 2 2 - 2 1 26 019 609 SHAFT, spool COLLAR, locking hub HUB,spool SPRING, compression (used with 8 inch spool) RING, retaining internal 5/8 x 0.042 GRIP,handle SPRING,compression0.2400Dx 1 BAR, cam brake SPRING, extension 3/8 ID x 1/2 OD x 27-5/8 inches long RECEPTACLE, twistlock flange midget 3P3W 10 amp CORD, control (consisting of) CONNECTOR BODY, twistlock midget 3P3W 15 amp CORD, portable No. 18 3/c (order by foot) SPOOL PAK BRAKE ASSEMBLY (See Page 3) PANEL, side upright PIN,cotterl/8x3/4 SOLENOID, ll5voltsac60hz TUBING, nylon 0.138 ID x 3/16OD x 1/8 LOCKOUT, brake BRACKET, tension spring BLANK, snap in 3/8 dia KNOB, pointer 27 081 120 BASE 1 28 081 121 29 058968 30 081 129 ADAPTER,conduit RING,retainerE LEVER, release cover 2 31 081 730 32 081 518 33 081 732 34 081 128 058428 8 057 745 9 081 664 10 604423 11 057544 12 081 733 13 081 642 14 PLG1 039 871 15 RC1 081 765 16 603 031 17 604 825 18 Figure 19 081 124 605394 20 21 B BS1 081 660 22 081 736 23 081 125 24 047 162 25 010 104 - 1 - - - 4 1 1 1 . 25 ft. . 1 - - - 1 2 1 1 2 2 4 2 - PIN, adapter conduit CONDUIT, 1/16 aluminum wire GUIDE, outlet wire 2 - x 10 feet (consisting of) - 1 1 . 35 604 612 36 058 720 37 081 731 38 605 669 .BODY,connector SCREW, set steel socket hd 8-32 x 1/8 CONDUIT, 1/16 aluminum wire x 10 feet w/fittings GUIDE, inlet wire LATCH, spring knurled head 39 081 132 LEVER, release 40 000 366 RING, retainer E 1/4 - 2 1 2 . 1 . - 1 . - - cover x 1/4 groove 1 1 BE SURE TO PROVIDE MODEL AND STYLE NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-1092 Page 2 Item Factory No. Part No. Figure B Description Quantity Spool Pak Brake Assembly 51 081 123 52 024 801 53 081 764 54 081 734 55 081 727 56 081 659 57 081 738 58 081 133 59 081 728 60 081 737 BLOCK, bearing support BEARING,ball BAND, brake TUBING, mirdrene 1-1/8 ID x 1/16 waIl x 1-1/8 DRUM, brake SPRING, extension 1/4 ID x 1/32 wire x 2 TUBING, steel 5/16 OD x 17 ga wall x 9/32 LEVER, brake LINK, connecting solenoid TUBING, steel 5/1600 x 17 ga wall x 1-5/8 . - 2 2 1 1 1 1 2 1 1 1 BE SURE TO PROVIDE MODEL AND STYLE NUMBERS WHEN ORDERING REPLACEMENT PARTS. 51 52 54 < 60 56 Figure Page 3 B Spool Pak Brake Assembly TB-049 248 i Factory Part No~ Description Common Hardware 000 419 602 070 602075 605 138 604 804 081 661 602 112 602 154 602 004 601 954 602 189 602 199 602 198 SCREW, machine steel flat hd 4-40 x 1-1/4 SCREW, machine steel truss hd 6-32 x 3/8 SCREW, machine steel round hd 6-32 x 1 SCREW, machine steel round hd 6-32 x 1-1/4 SCREW, sheet metal hexagonal washer No. 8 x 3/8 SCREW, machine steel round hd 8-32 x 2-3/4 SCREW, machine steel round hd 10-24 x 1-1/4 SCREW, self tapping hexagonal washer hd 1/4-20 x 1/2 SCREW, cap steel socket hd 1/4-20 x 3/4 SCREW, cap steel hex hd 1/4-20 x 3/4 SCREW, set steel socket hd 5/16-18 x 1/4 WASHER, lock steel external tooth No. 6 WASHER, lock steel split No. 6 - - - - - - - - - - - - - 20i WASHER, lock 602 203 602 207 WASHER, lock WASHER, lock 602 241 WASHER, flat 601 859 601 860 NUT, steel NUT, steel 601 865 NUT, steel 601 892 RlVET~blind 1/8diax 1/4 602 - - - - - - - steel external tooth No. 8 steel split No. 10 steel split 1/4 steel SAE 1/4 hex machine screw 6-32 hex machine screw 8-32 hex full finish 1/4-20 BE SURE TO PROVIDE MODEL AND STYLE NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-1092 Page 4 .