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Miller Electric wire feeder manual

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Table of contents for the manual

  • Page 1

    cover 1/94 – ST-108 014-A PRINTED IN USA  1995 MILLER Electric Mfg. Co. Read and follow these instructions and all safety blocks carefully . Have only trained and qualified persons install, operate, or service this unit. Call your distributor if you do not understand the directions. Give this manual to the operator . For help, call your distri[...]

  • Page 2

    Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. T o locate your near est distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW el[...]

  • Page 3

    OM-877 – 1 1/95 T ABLE OF CONTENTS SECTION 1 – SAFETY RULES FOR OPERA TION OF ARC WELDING POWER SOURCE 1 . . . . . . . 1-1. Introduction 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. General Precautions 1 . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-877 Page 1 SECTION 1 – SAFETY RULES FOR OPERA TION OF ARC WELDING POWER SOURCE 1-1. INTRODUCTION We learn by experience. Learning safety through per- sonal experience, like a child touching a hot stove is harmful, wasteful, and unwise. Let the experience of others teach you. Safe practices developed from experience in the use of welding and cu[...]

  • Page 6

    OM-877 Page 2 atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichloroethylene or perchloroethylene. C. Fire and Explosion Prevention Causes of fire and explosion are: combustibles reached by the arc, flame, flying sparks, hot slag or heated mate- rial; misuse of compressed gases and cylinders;[...]

  • Page 7

    OM-877 Page 3 Locate or secure cylinders so they cannot be knocked over . Passageways and work areas. Keep cylinders clear of areas where they may be struck. T ransporting cylinders. With a crane, use a secure sup- port such as a platform or cradle. Do NOT lift cylinders off the ground by their valves or caps, or by chains, slings, or magnets. Do N[...]

  • Page 8

    OM-877 Page 4 1-3. ARC WELDING Comply with precautions in 1-1, 1-2, and this section. Arc Welding, properly done, is a safe process, but a careless operator invites trouble. The equipment carries high currents at significant voltages. The arc is very bright and hot. Sparks fly , fumes rise, ultraviolet and in- frared energy radiates, weldments are [...]

  • Page 9

    OM-877 Page 5 quate to carry ground currents safely . Equipment made electrically HOT by stray current may shock, possibly fatally . Do NOT GROUND to electrical conduit, or to a pipe carrying ANY gas or flammable liquid such as oil or fuel. Three-phase connection. Check phase requirements of equipment before installing. If only 3-phase power is ava[...]

  • Page 10

    OM-877 Page 6 5. ANSI Standard Z41.1, ST ANDARD FOR MEN ’ S SAFETY -TOE FOOTWEAR obtainable from th e American National Standards Institute, 1430 Broadway , New Y ork, NY 10018. 6. ANSI Standard Z49.2, FIRE PREVENTION IN TH E USE OF CUTTING AND WELDING PROC- ESSES obtainable from the American National Standards Institute, 1430 Broadway , New Y or[...]

  • Page 11

    OM-877 Page 7 SECTION 3 – SPECIFICA TIONS Rated Load For Single- Phase AC Input 50/60 Hertz 100% Duty Cycle Weight Net Ship 10 kW At 120 V olts, 83 Amperes 240 V olts, 42 Amperes 125 lb (57 kg) 145 lb (66 kg) Figure 3-1. Specifications 22 in (559 mm) 37-3/4 in (959 mm) 30 in (762 mm) ST-108 014 Figure 3-2. Dimensional View 3-1. DESCRIPTION This u[...]

  • Page 12

    OM-877 Page 8 T able 4-1. Cord Size By Ampacity Rating Cord Size – A WG* Ampacity Of Cord 18 10 14 18 12 25 10 30 8 40 6 50 4 70 2 95 *Cord sizes are based on National Electrical Code (1984 Edition) specifications for allowable ampacity for not more than two ther- moset or thermoplastic insulated current-carrying copper conduc- tors in a cord (se[...]

  • Page 13

    OM-877 Page 9 SECTION 5 – OPERA TOR CONTROLS ST-108 014-A Cord Storage Area Amperage Load Switches Load Selector Switch 120/240V AC Pilot Light For 120V AC Load AC V oltmeter Hertz Meter Front Access Panel Pilot Light For 240V AC Load Dual Scale AC Ammeter Figure 5-1. Front Panel Controls And Component Locations 5-1. 120 VOL T LOAD/240 VOL T LOAD[...]

  • Page 14

    OM-877 Page 10 T able 5-1. Power Requirements For Load Amperage At Input V oltage AMPERES A T 120V KW 1 8 1.5 12 2 17 2.5 21 3 25 4 33 5 42 6 50 7 58 7.5 62 8 67 9 75 10 83 AMPERES A T 240V 4 6 8 1 01 21 72 1 2 5 2 93 1 3 3 3 74 2 Power requirements up to 10kw at 120 or 240 vac input for various ampere load values are shown in T able 5-1 and on the[...]

  • Page 15

    OM-877 Page 1 1 3. Connect Load Bank cord to the ac power source. Be sure to use appropriate cord when Load Bank has both 120 and 240 volt cords installed. 4. Place 120 VOL T LOAD/240 VOL T LOAD selector switch in proper position (see Section 5-1). 5. T urn on or start the ac power source. 6. Check pilot lights for proper input voltage load selecti[...]

  • Page 16

    OM-877 Page 12 SECTION 8 – P ARTS LIST Figure 8-1. Main Assembly ST-108 016 1 2 Fig 8-2 3 Fig 8-3 4 5 6 7 8 9 10 11 12 13 14[...]

  • Page 17

    OM-877 Page 13 Description Part No. Item No. Figure 8-1. Main Assembly Quantity 1 106 661 P ANEL, LH side 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Figure 8-2 P ANEL, front-w/components 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 18

    OM-877 Page 14 Description Part No. Dia. Mkgs. Item No. Figure 8-2. Panel, Front w/Components (Fig 1 Item 2) Quantity 1 NAMEPLA TE, (order by model and serial number) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 106 673 P ANEL, front 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 19

    OM-877 Page 15 Description Part No. Item No. Figure 8-3. Resistor Assembly (Fig 1 Item 3) Quantity 1 106 667 BUS BAR, connecting resistors 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 059 800 RESISTOR, 25A 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 20

    OM-877 Page 16 Notes[...]

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    OM-877 Page 17 Notes[...]

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    OM-877 Page 18 Notes[...]

  • Page 23

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expertise o[...]

  • Page 24

    PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Company 1635 West Spenc er St reet Applet on, W I 54914 US A International He adquarte rs – USA USA Phone: 920-735-4505 Aut o-A t t ended USA & C anada F A X : 9 20-735-4134 Int ernati onal F AX : 920-735-4125 European Headqua rters –[...]