Miller MW250 User manual

OM-154 501T
March 1999
Processes
Gas Metal Arc (MIG) Welding
®
Flux Cored Arc (FCAW)
Welding
Description
Arc Welding Power Source And Wire
Feeder
MW250
For Warranty Claims And Technical Support, Contact:
Milweld Inc., National Distributor
P.O. Box 338, Hortonville, WI 54944-0338
Tel 920-779-0916 Fax 920-779-0924
TABLE OF CONTENTS
The following term is
used interchangeably
throughout this manual:
MIG=GTAW
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
OM-154 501T
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Installing Work Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Gun Polarity Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Installing Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Electrical Service Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Positioning Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Installing Wire Spool And Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Center Baffle Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Circuit Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Fuses F1 And F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Changing Drive Rolls And Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Aligning Drive Rolls And Wire Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_5/97
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable − do not use work clamp or work cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Keep your head out of the fumes. Do not breathe the fumes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-154 501 Page 1
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-154 501 Page 2
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
D
OVERUSE can cause OVERHEATING
D
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
D
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-154 501 Page 3
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-154 501 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 2 − SPECIFICATIONS
2-1. Specifications
Specifications
Description
Type Of Output
Direct Current/Constant Voltage (DC/CV)
Rated Weld Output
200 Amperes, 28 Volts DC, 60% Duty Cycle (See Section 2-2)
Type Of Input Power
Single-Phase; 60 Hz; At 200 Or 230 Volts AC
Input Amperes At Rated Output
46 A At 200 V, 40 A At 230 V
Maximum Input Amperes While Idling
1.2 A At 200 V, 1 A At 230 V
KVA/KW Used At Rated Output
9.5 kVA/8.3 kW
Maximum KVA/KW Used While Idling
0.24 kVA/0.17 kW
Max. Open-Circuit Voltage
42 Volts DC
Control Circuit Voltage At Gun
24 Volts DC
Welding Processes
Gas Metal Arc (GMAW) And Flux Cored Arc Welding (FCAW)
Calculated Speed Range At No Load
128 To 1051 ipm (3.2 To 266.9 mpm)
Wire Diameter Range
.030 To .045 in (0.8 To 1.1 mm) Flux Cored Wire, .023 To .045 in (0.6 To 1.1 mm) Hard Wire
Overall Dimensions
Length: 37 in (940 mm); Width: 19 in (483 mm); Height: 30-1/4 in (768 mm)
Weight
Net: 225 lb (102 kg); Ship: 271 lb (123 kg)
Welding Gun
Rated Output (Air Cooled)
200 Amperes At 60% Duty Cycle Using CO2 Shielding Gas (See Section 2-2)
Cable Length
15 ft (4.5 m)
2-1. Volt-Ampere Curves
Volt-ampere curves show minimum and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall between curves shown.
va_curve1 − 4/95 − SB-049 424-D
OM-154 501 Page 5
2-2. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
UNIT
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
60% Duty Cycle At 200 Amperes
Y Exceeding duty cycle can
damage unit and void
warranty.
6 Minutes Welding
4 Minutes Resting
GUN
60% Duty Cycle At 200 Amperes Using CO2
6 minutes Welding
4 minutes Resting
GUN
60% Duty Cycle At 180 Amperes Using Mixed Gas
6 minutes Welding
4 minutes Resting
rduty1 5/95 − sb-150 215
SECTION 3 − INSTALLATION
3-1. Installing Work Clamp
1
2
Work Cable
Boot
Slide boot onto work cable. Route
cable out front panel opening from
inside.
4
3
Negative (−) Output Terminal
Connect cable to terminal and
cover connection with boot.
5
4
5
Hardware
Work Clamp
Route cable through clamp handle
and secure as shown.
2
1
Close door.
3
Tools Needed:
1/2, 3/4 in
OM-154 501 Page 6
Ref. ST-800 918-B
3-2. Installing Gas Supply
1
Cylinder Bracket
2
S-Hook
Crimp between small hole in bracket and chain.
1
3
Chain
4
Snap
Crimp onto open end of chain.
Obtain gas cylinder and chain to
running gear.
2
3
4
11
To Gas
Regulator/
Flowmeter
5
Cap
6
Cylinder Valve
Remove cap, stand to side of valve,
and open valve slightly. Gas flow
blows dust and dirt from valve.
Close valve.
7
Cylinder
8
Regulator/Flowmeter
Install so face is vertical.
9
Gas Hose Connection
Fitting has 5/8-18 right-hand
threads. Obtain and install gas
hose.
10 Flow Adjust
Typical flow rate is 20 cfh (cubic feet
per hour). Check wire manufacturer’s recommended flow rate.
Make sure flow adjust is closed
when opening cylinder to avoid
damage to the flowmeter.
5
11 CO2 Adapter
12 O-Ring
6
Install adapter with O-ring between
regulator/flowmeter and
CO2
cylinder.
8
7
OR
5
Argon Gas Or
Mixed Gases
6
9
10
7
11
12
CO2 Gas
Tools Needed:
5/8, 1-1/8 in
ssb3.2* 5/94 − ST-154 623 / Ref. ST-149 827-B / Ref. ST-158 697-A
OM-154 501 Page 7
3-3. Gun Polarity Connections
1
Polarity Changeover Label
2
Wire Drive Assembly
3
Positive (+) Output Terminal
4
Negative (−) Output Terminal
Always read and follow wire manufacturer’s recommended polarity.
Shown As Shipped − Set For Electrode
Positive (DCEP) For Solid Steel Or
Aluminum Wires (GMAW Process).
5
Wire Drive Assembly Lead
To Positive (+) Output Terminal
Circuit Breaker CB1 (see
Section 5-2).
Close door.
5
1
2
Work Clamp Lead To
Negative (−) Output Terminal
GUN POLARITY
CHANGEOVER CONNECTIONS
Reverse Lead Connections − For Electrode
Negative (DCEN) For Flux Cored Wires
(FCAW Process). Drive Assembly
Becomes Negative
S-144 449-D
Tools Needed:
3
3/4, 11/16 in
4
Ref. ST-801 103-B
3-4. Installing Welding Gun
1
1
Wire Drive Assembly
2
Gun Securing Knob
3
Gun End
Loosen securing knob. Insert gun
end through opening until it bottoms
against drive assembly. Tighten
knob.
4
4
Gun Trigger Plug
Insert into receptacle, and tighten
threaded collar.
3
Close pressure assembly. Close
door.
2
Ref. ST-801 101-B
3-5. Electrical Service Requirements
Input Voltage
200
230
Input Amperes At Rated Output
46
40
Max Recommended Standard Fuse Or Circuit Breaker Rating In
Amperes
70
60
Min Input Conductor Size In AWG/Kcmil
8
8
89 (27)
117 (36)
8
10
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil
Reference: 1996 National Electrical Code (NEC).
OM-154 501 Page 8
S-0092J
3-6. Positioning Jumper Links
200 VOLTS
2
3
Check input voltage available at
site.
1
Jumper Links Access Door
Open door.
230 VOLTS
2
3
Jumper Link Label
Input Voltage Jumper Link
Move jumper link to match input
voltage.
Close and secure access door.
1
S-153 980
Close side door.
Tools Needed:
3/8 in
Ref. ST-801 100-B
OM-154 501 Page 9
3-7. Connecting Input Power
Have only qualified persons make
this installation.
1
1
3
4
3
Line Disconnect Device Of
Proper Rating
2
230 Volts AC Wall Receptacle
3
Input Conductors
4
Grounding Conductor
Select size and length using 3-5.
Conductor rating must comply with
national, state, and local electrical
codes.
3
2
Install and connect grounding
conductor and input conductors in
conduit or equivalent between wall
receptacle and deenergized line
disconnect device.
6
Connect grounding conductor first,
then line input conductors.
For Plug Connection
Be sure grounding conductor goes
to an earth ground.
1
5
Overcurrent Protection
Select type and size using 3-5.
Install into deenergized line disconnect device (fused disconnect
switch shown).
6
Input Power Plug
Turn off unit Power switch, and connect plug to wall receptacle.
5
4
3
Tools Needed:
ssb2.2 12/94 − Ref. ST-154 619-B / Ref. ST-149 405-B
OM-154 501 Page 10
3-8. Installing Wire Spool And Adjusting Hub Tension
1
Wire Spool
2
Gun Contact Tip
If necessary, cut welding wire off at
contact tip, and retract wire onto
spool and secure.
1
2
3
Retaining Ring
4
Compression Spring
Remove ring and pull off spool.
Compression spring is used with 8
in (200 mm) spools.
5
Hub
6
Hub Pin
Slide spool onto hub so wire feeds
off bottom. Turn spool until hub pin
fits hole in back of spool. Reinstall
retaining ring.
7
Hub Tension Nut
Grasp spool in one hand and turn
while using a wrench to adjust hub
tension nut. When a slight force is
needed to turn spool, tension is set.
6
5
Thread welding wire (see Section
3-9). Close door.
4
7
3
Tools Needed:
15/16 in
Ref. ST-801 103-B / Ref. ST-072 573-B
OM-154 501 Page 11
3-9. Threading Welding Wire
Tools Needed:
4
2
3
5
Wire Spool
2
Welding Wire
3
Inlet Wire Guide
4
Pressure Adjustment Knob
5
Drive Roll
6
Outlet Wire Guide
7
Gun Conduit Cable
Lay gun cable out straight.
7
1
1
6
4 in
(102 mm)
6 in
(150 mm)
Open pressure assembly.
Pull and hold wire; cut off end.
Push wire thru guides into gun;
continue to hold wire.
Tighten
Close and tighten pressure
assembly, and let go of wire.
Remove gun nozzle and contact tip.
Turn On.
WOOD
Press gun trigger until wire
comes out of gun. Reinstall
contact tip and nozzle.
Feed wire to check drive roll pressure.
Tighten knob enough to prevent slipping.
Cut off wire. Close
and latch door.
Ref. ST-801 103-B / ST-154 251 / S-0627-A
OM-154 501 Page 12
SECTION 4 − OPERATION
4-1. Front Panel Controls
1
Wire Speed Control
Use control to set wire feed speed.
2
1
2
Voltage Control
Use control and Voltage Range Selector (see 4-2) to set arc voltage.
Step 6 of Low range and Step 1 of
High range overlap.
3
Pilot Light
4
Power Switch
Use switch to turn unit On and Off.
The pilot light comes on when unit
is turned on.
5
Work Clamp
Use wire brush or sandpaper to
clean metal at weld joint area.
Connect work clamp to clean,
paint-free location on workpiece, as
close as possible to weld area.
3
4
Tools Needed:
5
Ref. ST-154 622-B / ST-184 596 / Ref. ST-154 251
OM-154 501 Page 13
4-2. Center Baffle Controls
1
DO NOT SWITCH
UNDER LOAD
WIRE MODE
FULL
1
2
Wire Mode Switch
For better control of wire speed use
Low position when wire speed is
between 90 and 670 ipm. Use Full
position when wire speed is between 150 ipm and 1030 ipm.
2
Voltage Range Selector
Place switch in desired position.
See inside rear cover for settings.
LOW
VOLTAGE RANGE
20−30V HIGH
10−20V LOW
Ref. ST-801 103-B / S-171 601
OM-154 501 Page 14
SECTION 5 − MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance
. Maintain more often
Y Disconnect power
before maintaining.
during severe conditions.
3 Months
Clean And
Tighten
Weld
Terminals
Repair Or
Replace
Cracked
Cables And
Cords
Replace
Damaged Or
Unreadable
Labels
6 Months
Blow Out Or
Vacuum Inside
Remove drive roll and
carrier. Apply light coat
of oil or grease to drive
motor shaft.
5-2. Circuit Breaker CB1
1
1
Circuit Breaker CB1
If CB1 opens, wire feeding stops.
Check gun liner for blockage or
kinks, and check for jammed wire,
binding drive gear, or misaligned
drive rolls. Allow a cooling period
before resetting CB1.
Ref. ST-801 103-B
OM-154 501 Page 15
5-3. Fuses F1 And F2
Turn Off unit and disconnect input
power.
1
Fuse F1 (See Parts List For
Rating)
F1 protects the 115 volts ac winding
of transformer T1. If F1 opens, all
weld output stops and pilot light PL1
goes out.
2
2
Fuse F2 (See Parts List For
Rating)
F2 protects the 24 volts ac winding
of transformer T1. If F2 opens, all
weld output stops.
1
Ref. ST-800 928-B
5-4. Changing Drive Rolls And Wire Inlet Guide
1
2
Loosen screw. Slide tip as close to
drive rolls as possible without
touching. Tighten screw.
5
3
Securing Screw
Inlet Wire Guide
2
3
Anti-Wear Guide
Install guide as shown.
4
Drive Roll
Install correct drive roll for wire size
and type.
1
5
Drive Roll Securing Nut
Turn nut one click to secure drive
roll.
Tools Needed:
5/64 in
4
7/16 in
ST-150 227-C
5-5. Aligning Drive Rolls And Wire Guide
4
2
Correct
Incorrect
5
3
6
View is from top of drive rolls looking down with pressure assembly
open.
1
2
3
4
5
Drive Roll Securing Nut
Drive Roll
Wire Guide
Welding Wire
Drive Gear
Insert screwdriver, and turn screw
in or out until drive roll groove lines
up with wire guide.
Tools Needed:
Ref. ST-801 412-A
OM-154 501 Page 16
5-6. Troubleshooting
Welding Trouble
No weld output; wire does not feed.
Remedy
Check input power connections (see Section 3-7).
Reset circuit breaker CB1 (see Section 5-2).
Replace fuse F1 and/or F2 (see Section 5-3).
Replace building line fuse or reset circuit breaker if open (see Section 3-7).
Secure gun trigger plug in receptacle or repair leads (see Section 3-4).
Thermostat TP1 open (overheating). Allow fan to run; the thermostat will close when the unit has cooled
(see Section 2-2).
No weld output; wire feeds.
Connect work clamp to get good metal to metal contact.
Low weld output.
Connect unit to proper input voltage or check for low line voltage (see Section 3-7).
Wire Drive/Gun Trouble
Remedy
Electrode wire feeding stops during Straighten gun cable and/or replace damaged parts (see Section NO TAG).
welding.
Adjust drive roll pressure (see Section 3-9).
Readjust hub tension (see Section 3-8).
Clean or replace wire inlet guide or liner if dirty or plugged (see Section 5-4).
Replace drive rolls if worn or slipping (see Section 5-4).
Secure gun trigger plug in receptacle or repair leads (see Section 3-4).
Check and replace F1 and/or F2 (see Section 5-3).
Check and clear any restrictions at drive assembly and liner (see Section 5-3).
Have nearest Factory Authorized Service Agent check drive motor.
Check relay CR1, and replace if necessary.
OM-154 501 Page 17
SECTION 6 − ELECTRICAL DIAGRAM
SB-173 544-E
Figure 6-1. Circuit Diagram For Welding Power Source
OM-154 501 Page 18
Notes
OM-154 501 Page 19
SECTION 7 − PARTS LIST
11
9
2(Fig. 7−2)
1
12
10
8
7
3
6
5
13
4
14
15
16
17
22
18
21
19
ST-155 610-E
20
Figure 7-1. Main Assembly
NOTE: All items indented by a dot(s) are included with the item listed directly above.
Item Part
No. No.
1
2
3
4
5
6
7
146 168
083 526
072 802
Fig 7-2
171 658
602 250
186 758
171 213
148 808
150 783
049 399
116 996
605 227
134 834
149 332
152 742
048 420
037 957
037 956
605 886
605 884
171 600
026 947
152 862
Description
Enclosure Panel
Housing Rcpt & Sockets
Housing Plug & Pins
Baffle w/Cmpts
Transformer, 200/230
Washer
Wheel
Stabilizer
Rear Panel w/Cmpts
· Fan Motor
· Fan Blade
· Speed Nut
· Gas Valve
· Nylon Nut, .750
· Hose
· Hose Clamp
· Rectifier
· · Capacitor
· · Diode, RP
· · Diode, SP
· · Washer, .750
· · Half Nut, .750-16
· · Thermostat, NC
· · Stand-Off
· · Grommet
OM-154 501 Page 20
Item Part
No. No.
8
9
10
11
12
13
14
15
16
17
18
19
20
21
009 970
143 810
169 654
044 426
602 387
146 165
089 899
146 167
134 464
+170 513
188 911
146 161
135 390
121 614
091 685
605 741
008 999
193 632
160 775
035 897
097 924
048 282
079 534
128 755
Description
· Rectifier Bracket
· Rear Panel
· Tank Bracket
· Cable Clamp
Cylinder Chain
Side Panel, LH
Latch
Side Panel
Warning Label
Wrapper
Cord Set
Base
Axle
Retaining Ring
Resistor
Clip
Caster
Jam Nut
Front Panel w/Cmpts
· Light
· Potentiometer
· Knob
· Receptacle w/Sockets
· · Terminal, female
· Switch, DPST
Item
No.
Part
No.
153 197
148 956
175 060
155 418
184 596
174 839
144 127
057 357
143 974
22
192 121
144 108
600 318
130 750
Description
· Selector Switch
· Switch Handle
· Front Panel
· Front Control Panel
· Control Plate
· Nameplate
· Cover, module opening
· Bushing, 1.125mtg
· Handle
See gun Owner’s Manual
for information and
warranty
Regulator/Flowmeter
Hose, 5ft
Weld Cable
Ground Clamp
+When ordering a component originally displaying a precautionary label, the label should
also be ordered.
Be sure to provide Model and Serial Number
when ordering replacement parts.
1
2
3
4
5
10
6
12
11
7
13
8
30
9
14
29
28
15
16
19
20
17
27 (Fig.7−3)
18
21
26
22
25
24
23
ST-155 609-F
Figure 7-2. Baffle w/Components (Fig 7-1 Item 2)
NOTE: All items indented by a dot(s) are included with the item listed directly above.
Item Part
No. No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
058 427
085 980
605 941
186 437
057 971
057 745
186 435
186 436
177 307
174 812
186 998
083 147
082 902
185 643
184 584
Description
Retaining Ring
Nut
Flat Washer
Spring, .845 OD
Keyed Washer
Spring, 2.430 OD
Hub, spool
Brake Washer
Support Reel
Baffle
Kit Capacitor
Grommet
Strip, mtg center
Strip, mtg LH & RH
Capacitor
Item Part
No. No.
16
17
18
185 642
186 355
114 786
134 201
173 002
*012 658
18
*073 426
19
20
21
165 896
135 558
165 745
083 431
011 609
171 610
15
Description
Insulator
Contactor
Link
PC Card Stand-Off
Motor Speed Control Card
· Fuse, mintr gl slo-blo
2A 125V
· Fuse, mintr gl slo-blo
5A 125V
Connector & Sockets
Connector & Sockets
Connector & Sockets
Circuit Breaker
Toggle Switch, SPDT
Selector Switch
Item
No.
22
23
24
25
26
27
28
29
30
Part
No.
186 058
188 910
038 618
039 047
039 046
123 750
071 971
174 861
148 956
144 933
021 469
Description
COVER, dust range switch
Terminal Assembly, pri 2V
· Link
Output Terminal, red
Output Terminal, black
Capacitor
Cover
Drive Assembly, (Fig 7-3)
Switch Handle
Access Door
Danger Label
♦OPTIONAL
*Recommended Spare Parts
Be sure to provide Model and Serial Number
when ordering replacement parts.
OM-154 501 Page 21
See Table 6-1
Drive Roll & Wire Guide Kits.
. Hardware is common and
13
9
not available unless listed.
8
10
11
7
14
12
6
5
4
3
16
2
26
25
1
23
24
22
15
16
21
20
19
18
ST-148 529-H
Figure 7-3. Wire Drive And Gears (Fig 7-2 Item 27)
Item Part
No. No.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
Screw, .250-20 x 1.25
Carrier, drive roll
Spacer
Spring Pin
Housing, adapter
Fastener
Cupped Washer
Spring
Knob
Pressure Lever
Hinge Pin
Cotter Hair Pin
Cover, motor
602 009
172 075
166 072
010 224
182 788
085 242
085 244
010 231
085 243
166 071
079 634
151 828
173 616
OM-154 501 Page 22
Item Part
No. No.
14
15
16
18
19
20
21
22
23
173 435
193 633
193 634
193 635
079 633
601 966
604 538
124 778
173 619
174 609
174 610
192 029
Description
Motor (consisting of)
Key, woodruff .118 x .380
Washer, wave
Ring, rtng ext
Fitting, hose 3/16tbg
Screw, .375−16 x 1.25
Washer, flat
Knob
Carrier, drive roll
Screw, M 4−.7 x 12
Screw, M 6−1.0 x 20
WASHER, flat .250 x .437
Item
No.
Part
No.
24
25
26
173 620
602 243
602 213
056 192
♦056 193
045 127
053 700
Description
Bushing
WASHER, flat .438 x 1.00
WASHER, lock .380 x .683
Wire Guide, .023/.025 &
.030-.035
Wire Guide, .045
Guide, anti-wear
Roll, drive V-groove .035
♦OPTIONAL
*Recommended Spare Parts
Be sure to provide Model and Serial Number
when ordering replacement parts.
Table 7-1. Drive Roll And Wire Guide Kits
IMPORTANT: Base selection of drive rolls upon the following recommended usages:
1. V-Grooved rolls for hard wire.
2. U- Grooved rolls for soft and soft shelled cored wires.
3. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).
4. V-Knurled rolls for hard shelled cored wires.
5. Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination with
U-Grooved).
Wire Diameter
Drive Roll
Part No.
Type
Inlet
Wire Guide
087 131
087 130
V-Grooved
056 192
0.8 mm
079 594
053 695
V-Grooved
056 192
.035 in.
0.9 mm
079 595
053 700
V-Grooved
056 192
.045 in.
1.2 mm
079 596
053 697
V-Grooved
056 193
Fraction
Decimal
Metric
.023/.025 in.
.023/.025 in.
0.6 mm
.030 in.
.030 in.
.035 in.
.045 in.
Kit No.
Ref. S-0026-B/7-91
OM-154 501 Page 23
Warranty
Effective January 1, 1999
(Equipment with a serial number preface of “KK” or newer)
This limited warranty supersedes all previous manufacturers
warranties and is exclusive with no other guarantees or
warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
below, warrants to its original retail purchaser that new
equipment sold after the effective date of this limited warranty
is free of defects in material and workmanship at the time it is
shipped from factory. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING
THE
WARRANTIES OF
MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, manufacturer will
repair or replace any warranted parts or components that fail
due to such defects in material or workmanship.
Manufacturer must be notified in writing within thirty (30) days
of such defect or failure, at which time manufacturer will
provide instructions on the warranty claim procedures to be
followed.
Manufacturer shall honor warranty claims on warranted
equipment listed below in the event of such a failure within the
warranty time periods. All warranty time periods start on the
date that the equipment was delivered to the original retail
purchaser, or one year after the equipment is sent to the
distributor.
1.
5 Years Parts − 3 Years Labor
2.
3 Years — Parts and Labor
*
*
*
*
*
3.
Original main power rectifiers
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
1 Year — Parts and Labor
*
*
*
*
*
*
*
*
*
*
*
*
*
Motor Driven Guns (w/exception of Spoolmate 185)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
Robots
Water Coolant Systems
HF Units
Grids
Spot Welders
Load Banks
SDX Transformers
Running Gear/Trailers
Field Options
(NOTE: Field options are covered under the limited
warranty for the remaining warranty period of the
product they are installed in, or for a minimum of one
year — whichever is greater.)
Limited Warranty shall not apply to:
1.
Items furnished by manufacturer, but manufactured by
others, such as engines or trade accessories. These
items are covered by the manufacturer’s warranty, if
any.
2.
Consumable components; such as contact tips, cutting
nozzles, contactors, relays, brushes, slip rings, or parts
that fail due to normal wear.
3.
Equipment that has been modified by any party other
than manufacturer, or equipment that has been
improperly installed, improperly operated or misused
based upon industry standards, or equipment which has
not had reasonable and necessary maintenance, or
equipment which has been used for operation outside of
the specifications for the equipment.
MANUFACTURER’S PRODUCTS ARE INTENDED FOR
PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL
USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING
EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at manufacturers option: (1)
repair; or (2) replacement; or, where authorized in writing by
manufacturer in appropriate cases, (3) the reasonable cost
of repair or replacement at an authorized 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 customer’s risk and expense. manufacturer’s
option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at an authorized service
facility as determined by manufacturer. Therefore no
compensation or reimbursement for transportation costs of
any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MANUFACTURER BE
LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL
OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MANUFACTURER IS
EXCLUDED AND DISCLAIMED BY MANUFACTURER.
4.
6 Months — Batteries
5.
90 Days — Parts and Labor
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
*
*
*
*
*
*
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated
herein, and to the extent that they may not be waived, the
limitations and exclusions set out above may not apply. This
Limited Warranty provides specific legal rights, and other
rights may be available, but may vary from province to
province.
MIG Guns/TIG Torches
Plasma Cutting Torches
Remote Controls
Accessory Kits
Replacement Parts
Spoolmate 185
brand_warr 3/99
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
Resources Available
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Owner’s Manuals
Circuit Diagrams
Contact the Delivering Carrier for:
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
PRINTED IN USA
File a claim for loss or damage during
shipment.