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OM-1546 090 004M
August 2000
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Wire Feeder
S-32S And S-32SL
Visit our website at
www.MillerWelds.com
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From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that bu
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TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . .
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Welding
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. 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 li
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cau
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1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body. years of resea
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SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Identifie un message de sécurité particulier. risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous au
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LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation. (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées Veiller toujours à bien aérer les espaces
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1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou à proxi- Rester à l’écart des organes mobiles comme le mité de surfaces infllammables. ventilateur. Maintenir fermés et fixement en place les portes, Ne pas installer l’appareil à proximité de produits inflammables panneaux, recouvrements et dispositifs de Ne pa
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1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. Règles de sécurité en soudage, coupage et procédés conne
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SECTION 2 – INSTALLATION 2-1. Specifications Input Welding Wire Feed Wire Max. Wire Type Of Welding Overall Power Speed Diameter Spool Weight Input Power Circuit Dimensions Source Type Range Range Capacity Rating Standard: 50 To 700 ipm Length: 22-1/2 (1.3 To 18 Standard: Constant in (572 mm) 500 Amperes mpm) .023 To 5/64 in Open-Circuit/ Voltage (CV) 10 Thru 60 lb At 100% Low Speed: (0.6 To 2 mm) Width: 10-3/4 in Arc Voltage, Or Constant (4.5 Thru 27 33 lb (15 kg) Duty Cycle 15 To 100 25 To 325
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2-2. Installing And Aligning Wire Guide And Drive Roll When changing wire size or type, check drive roll and wire guide size (see Parts List). Installing Wire Guide And Drive Rolls: 1 Drive Roll Nut 2 Drive Roll Carrier Turn nut one click until lobes of nut 5 line up with lobes of drive roll carrier. 3 Drive Roll Slide drive roll onto drive roll carrier. Turn nut one click. Repeat procedure for top drive roll. 4 Inlet Wire Guide Screw 3 5 Inlet Wire Guide Loosen screw. Install inlet guide so scr
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2-3. Typical Connections 1 CV Welding Power Source With 24 VAC Power 2 CC Welding Power Source Without Contactor 3 External Secondary Contactor 4 Remote Contactor Cord 5 Weld Cable 6 Work 1 6 5 3 2 4 6 5 2-4. Connecting Welding Gun, Volt Sense Lead, And Weld Cable 1 Gun Securing Knob 1 2 Gun Block 3 Gun Outlet Wire Guide 2 Loosen knob, insert gun into block. 3 Position outlet wire guide as close as possible to drive rolls without touching. Tighten knob. 4 Gun Trigger Plug 5 Gun Trigger Receptacl
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2-5. Connecting Shielding Gas (Optional) 1 Gas Hose With 5/8-18 Right- hand Thread Fittings (Cus- tomer Supplied) 1 Tools Needed: 5/8 in Ref. ST-158 789 2-6. Installing Welding Wire And Adjusting Hub Tension 1 Retaining Ring 2 Wire Spool 3 Hub 4 4 Spool Support 3 2 If necessary, move hub on support for use of different size wire spool. Remove retaining ring, and install spool so hub pin fits spool hole. Re- install retaining ring. 1 5 5 Hub Tension Adjustment Nut Adjust tension nut so only a sli
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2-7. Threading Welding Wire 1 Pressure Assembly Adjust- ment Knob Lay gun cable out straight. A Open pressure assembly, hold wire tightly, and cut off end. Push wire through guides into gun. 1 B Close and tighten pressure assembly. Press gun trig- ger until wire comes out gun. C To adjust wire pressure, feed wire against wooden surface and tighten knob so wire does not slip. D Cut off wire, and close door. A B C D Tighten WOOD Tools Needed: 9/16 in Ref. ST-158 897 / S-0627-A OM-1546 Page 13
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SECTION 3 – OPERATION 3-1. Controls 1 Wire Speed Control (See Sec- tion 3-2) 2 Power Control Switch 3 Circuit Breaker CB1 1 CB1 protects wire feeder from over- load. 3 Correct problem and manually re- set breaker. 4 CV/CC Switch 2 Selector Switch for 4 Type of Power Source Constant Voltage CV Constant Current (drooper) CC S-090 438-D Ref. ST-091 547-D / ST-176 214 OM-1546 Page 14
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3-2. Wire Speed Control Settings S-32S Models Arc Wire Speed Setting Wire Speed Setting Voltage CC Mode CV Mode 100 90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 100 222 205 188 170 153 136 119 102 84 67 50 15 50 76 102 127 153 179 205 231 256 282 308 254 234 213 193 172 152 132 111 91 70 50 16 50 78 106 133 161 189 217 247 272 300 328 268 246 224 203 181 159 137 115 94 72 50 17 50 81 112 143 174 205 235 266 297 328 359 295 271 246 222 197 173 148 124 99 75 50 18 50 84 118 152 186 22
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SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance Disconnect power before maintaining. 3 Months Repair Or Clean And Replace Replace Tighten Unreadable Cracked Weld Labels Weld Cable Terminals Replace Cracked Parts Gun Cable Gas Hose 6 Months Blow Out Or Vacuum Clean Inside, Drive OR During Heavy Service, Rolls Clean Monthly 4-2. Troubleshooting Trouble Remedy Wire does not feed; open-circuit voltage Check circuit breaker CB1 and reset (see Section 3-1). available. Check sensin
