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November1996 Form: TM-1571
Effective With Serial No. JJ507797
MiIIe~
TECHNICAL MANUAL
Service And Parts
S-21E
Wire Feed Equipment
Use MILLER Testing Booklet (Part No.
A WARNING
150 853) when servicing this unit.
SERVICING can be hazardous.
Use only genuine MILLER replacement
• Have all service procedures performed only by
parts.
qualified persons following standard safety
practices.
U For help, call Factory ~U~r FAX: U Or write to:
Service Department: 14-735-4136 MILLER Electric Mfg. Co.
414-735
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OM-1571B — 3/91 TABLE OF CONTENTS Section No. Page No. SECTION 1 - SAFETY PRECAUTIONS AND SIGNAL WORDS 1-1. General Information And Safety 1 1-2. Safety Alert Symbol And Signal Words 1 1-3. Safety Precautions 1 SECTION 2- SHIPPING AND STORAGE 2-1. Preparation For Reshipment 2 2-2. Storage 2 SECTION 3— SPECIFICATIONS 3-1. Description 3 SECTION 4- INSTALLATION OR RELOCATION 4-1. Location 3 4-2. Drive Roll Installation 3 4-3. Welding Gun Connections 5 4-4. Shielding Gas Installation 5 4-5. 14-Pin P
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Section No. Page No. SECTION 8- TROUBLESHOOTING 8-1. Testing Instruments And Information 14 8-2. Circuit Board Handling Precautions 14 8-3. Troubleshooting 14 Diagram 8-1. Troubleshooting Circuit Diagram For Wire Feeder 16 8-4. Motor Board PCi Testing Information 17 Diagram 8-2. Troubleshooting Circuit Diagram For Motor Control Board PCi 18 8-5. Optional SpotlBurnback Board PC2 Testing Information 20 Diagram 8-3. Troubleshooting Circuit Diagram For Optional Spot/Burnback 22 Board PC2 SECTION 9-
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SECTION 1 - SAFETY PRECAUTIONS AND SIGNAL WORDS 1-1. GENERAL INFORMATION AND SAFETY • Shut down unit and disconnect input power when servicing unless the procedure specifi- This manual provides theory of operation along with cally requires an energized unit. specific operating, testing, and troubleshooting proce- • Do notleave live unit unattended. dures. It also includes precautionary information rele- vant to these procedures. This manual can be an effec- ARC RAYS, SPARKS, AND HOT SURFACES tiv
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SECTION 2- SHIPPING AND STORAGE PREPARATION FOR RESHIPMENT STORAGE WARNING: ELECTRIC SHOCK can kill. WARNING: ELECTRIC SHOCK can kill. • Do not touch live electrical parts. • Do not touch live electricalparts. A A • Shut down wire feeder and welding power • Shut down wire feeder and welding power source, and disconnect input poweremploy- source, and disconnect inputpower employ- ing lockout/tagging procedures before ing lockout/taggingprocedures before storing preparing unit for shipping. unit.
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SECTION 3- SPECIFICATIONS Table 3-1. Specifications Input Power Electrode Wire Wire Spool Electrode Wire Weight Requirements Diameter Capacity Capacity Feed Speed Net Ship 10 to 20 lb. 24 VAC (4.5 to 9 kg) 75-600 ipm 30 lbs. 33 lbs. 3.5 Amps .O23thru .045 in. 8 in. (203mm) spools (1.9-15.2 mom) 50/60 Hz (0.6 thru 1.1 mm) up to 60 lb. at 24 VA~ (13.6 kg) (15 kg) (27.2 kg)_coils 22-1(2 in. (572 mm) 10-112 In. (267 mm) SB-124 467 Figure 3-1. Overall Dimensions 3-1. DESCRIPTION only poweravailablefo
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Pressure Roll Assembly (Shown In Open PosItion) Hub Wire • Spring 9 Retaining Ring GunlFeeder connector Securing Knob • OPTIONAL Ret. 50497 Ref. SB-125 923 Figure 4-1. Wire Feeder Components It is necessary to install the required drive rolls when set- Loose metal objects in this compartment may create an electrical path between the weld out- ting up this unit and also when changing wire sizes. put circuit and any metal surfaces or compo- IMPORTANT: Base drive rollselection on the following nent
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5. For 50 Series style one-piece drive rolls: B. Gun Trigger (Figure 5-1) a. Slide drive roll onto drive roll mounting hub. b. Align drive roll with holes. ‘9= c. Insert securing screws, and tighten. TRIGGER RECEPTACLE 6. For 50 Series style split drive rolls: Connect gun trigger plug to trigger receptacle on the a. Align holes on pair of split drive rolls. front panel as follows: align keyways, insert gun plug into trigger receptacle, and rotate threaded collar fully b. Insert securing screw. c
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Flow Adjustment Gas cylinder Valve Argon or Argon CO Mix cylinder 2 Washer CO2 cylinder SB-109 492 CO2 Installation Argon Installation Figure 4-2. Typical RegulatorlFlowmeter Installation 4-5. 14-PIN PLUG CONNECTION (Figures 4-3And 4-4) The 14-pin plug PLG1 00, on the end of the interconnect- ing cord, provides a junction point for connecting the wire feeder to a welding powersource. This connection provides 24 volt ac power, and contactor control when used with a constant voltage (CV) power sou
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A. Installation Of Spool-Type Wire (Figure 4-1) 4-7. WELDING WIRE THREADING 1. Remove retaining ring from hub. WARNING: ELECTRIC SHOCK can kill; MOVING PARTS can cause injury. A 2. Slide wire spool on hub so that wire feeds off the • Do not touch live electrical parts. bottom of the spool. • Keep clear of pinch points. 3. Rotate wire spool until hole in spool slides over • Do notenergize weldingpowersource orwirE pin in hub and seats against back flange of the feeder until instructed to do so. h
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be made when the wire feeder is put into WELDING WIRE can cause puncture Wounds; HOT SURFACES can burn skin. operation. • Do not depress gun trigger until instructed to do 4-8. ADJUST THE HUB TENSION (Figure 4-1) so. • Do not point gun toward any part of the body CAUTION: LOOSE WELDING WIRE can any conductive surface, or other personnel A when threading welding wire. :ause Injury. Keep a firm hold on the wire during installa- • Allow gun to cool before touching. tion, removal, and threading oper
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SECTION 5- OPERATOR CONTROLS 5-1. POWER SWITCH (Figure 5-1) POWER Access Hole For Gun/Feeder Connector The POWER switch functions as the ON/OFF switch for the wire feeder. 5-2. WIRE SPEED CONTROL (Figure 5-1) WIRE SPEED Gun Trigger ojo Receptacle Wire Speed The WIRE SPEED control adjusts the wire feed speed Control 88-124 467 in inches per minute within thewire speed range. Rotat- ing the WIRE SPEED control clockwise increases wire Figure 5-1. Control Panel View feed speed. The scale is calibrat
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WARNING: ELECTRIC SHOCK can kill; 6-2. SHUTTING DOWN TANGLED WELDING WIRE can touch case A causing welding power source open-circuit 1. Stop welding. voltage to be presenton case if gun trigger is 2. Place POWER switch in the OFF position. pressed. • Do nottouch wire feeder case ifgun trigger is 3. Shut down welding power source or generator. pressed and wire does not feed. • If wire stops feeding, turn off welding power 4. Turn off shielding gas at source, if applicable. source, and determine t
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0 4- 0. 0 •1~ 0 4- 1~ 4) 4) LI- 4) I- 0 U- E (U I- 0) (U 0 0 1~ E (U 0) (U 0 -A c~.~ ~(i) .~Q) tb~. ~3O c~o I—0 ZQ) S-21E TM-1571 Page 11
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B. SpotlBurnback Time Control Option (Diagram 3. Spot time potentiometer R25 allows adjustment of spot time from 0.12 to 2.5 seconds or 0.25 to 5 7-2) seconds depending on the setting of Spot Time DIP Switch Sl. 1. Optional Spot/Burnback Board PC2 provides control of spot weld time and adjustment of burn- 4. Spot/Continuous switch S51 allows either a nor- back time. mal untimed weld cycle or a timed spot weld cycle. 2. Burnback potentiometer R26 allows adjustment 5. Spot time DIP switch 51 provi
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Notes S-21E TM-1571 Page 13
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SECTION 8— TROUBLESHOOTING 8-1. TESTING INSTRUMENTS AND INFORMA- 8-3. TROUBLESHOOTING (Table 8-1 And Dia- TION gram 8-1) The service procedures in this manual require proper WARNING: ELECTRIC SHOCK can kill. testing instruments. Use a good quality digital volt- ohmmeter (DVM) with one megohm input impedanceor • Do not touch live electrical parts. A greater and diode check capability (use an analog VOM • Shut down wire feeder and welding power for variable resistor testing). If an oscilloscope is
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Table 8-1. Troubleshooting TROUBLE CAUSE REMEDY Wire does not feed. Circuit breaker CB1. Check gun liner, hub tension, and drive roll pressure (see Section 4). Reset CBl (see Sec tion 10-5). Loose or improperly made gun Check gun trigger connection (see Section trigger connection. 4-3). Gun trigger. See gun Owner’s Manual. Welding gun shorted. Repair or replace welding gun. Motor Ml. Check connections for continuity to Ml. Check motor brushes (see Section 10-4). Replace Ml if necessary. Motor Co
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