Miller Electric wire feeder User Manual
OM-877 Form: 108 026
November 1995
OWNER’S
MANUAL
10KW AUXILIARY POWER BANK
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.
cover 1/94 – ST-108 014-A PRINTED IN USA
1995 MILLER Electric Mfg. Co.
Give this manual to the operator.
For help, call your distributor
or: MILLER Electric Mfg. Co., P.O. Box 1079,
Appleton, WI 54912 414-734-9821
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 build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy.
With Miller you can count on years of reliable
service with proper maintenance. And if for
some reason the unit needs repair, there’s a
Troubleshooting section that will help you
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
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. To locate your nearest
distributor or service agency call 1-800-4-A-Miller,
or visit us at www.MillerWelds.com on the web.
figure out what the problem is. The parts list
will then help you to decide which exact part
you may need to fix the problem. Warranty and
service information for your particular model
are also provided.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. T o obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMA W-P.
TABLE OF CONTENTS
SECTION 1 – SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1. . . . . . .
1-1. Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. General Precautions 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Arc Welding 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Standards Booklet Index 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – SAFETY PRECAUTIONS AND SIGNAL WORDS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. General Information And Safety 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Safety Alert Symbol And Signal Words 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – SPECIFICATIONS 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Description 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Location 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Interconnecting Cord Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – OPERATOR CONTROLS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. 120 Volt Load/240 Volt Load Selector Switch 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Pilot Lights 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Amperage Load Switches 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Voltmeter 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Hertz Meter 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Dual-Scale AC Ammeter 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – SEQUENCE OF OPERATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Loading Procedure 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Shutting Down 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – MAINTENANCE 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Inspection And Upkeep 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Internal Cleaning 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 – PARTS LIST 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-1. Main Assembly 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-2. Panel, Front w/Components 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-3. Resistor Assembly 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-877 – 11/95
SECTION 1 – SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1. INTRODUCTION
We learn by experience. Learning safety through personal 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 cutting are described in this manual. Research, development, and field experience have
evolved reliable equipment and safe installation, operation, and servicing practices. Accidents occur when
equipment is improperly used or maintained. The reason for the safe practices may not always be given.
Some are based on common sense, others may require
technical volumes to explain. It is wiser to follow the
rules.
Read and understand these safe practices before attempting to install, operate, or service the equipment.
Comply with these procedures as applicable to the particular equipment used and their instruction manuals,
for personal safety and for the safety of others.
Failure to observe these safe practices may cause serious injury or death. When safety becomes a habit, the
equipment can be used with confidence.
These safe practices are divided into two Sections:
1-General Precautions, common to arc welding and cutting; and 2-Arc Welding (and Cutting) (only).
Reference standards: Published Standards on safety
are also available for additional and more complete procedures than those given in this manual. They are listed
in the Standards Index in this manual. ANSI Z49.1 is the
most complete.
The National Electrical Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements also provide a basis for equipment installation, use, and service.
1-2. GENERAL PRECAUTIONS
Different arc welding processes, electrode alloys,
and fluxes can produce different fumes, gases, and
radiation levels. In addition to the information in
this manual, be sure to consult flux and electrode
manufacturers Material Safety Data Sheets
(MSDSs) for specific technical data and precautionary measures concerning their material.
A. Burn Prevention
Wear protective clothing-gauntlet gloves designed for
use in welding, hat, and high safety-toe shoes. Button
shirt collar and pocket flaps, and wear cuffless trousers
to avoid entry of sparks and slag.
Wear helmet with safety goggles and glasses with side
shields underneath, appropriate filter lenses or plates
(protected by clear cover glass). This is a MUST for
welding or cutting, (and chipping) to protect the eyes
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
Avoid oily or greasy clothing. A spark may ignite them.
Hot metal such as electrode stubs and workpieces
should never be handled without gloves.
Medical first aid and eye treatment. First aid facilities
and a qualified first aid person should be available for
each shift unless medical facilities are close by for immediate treatment of flash burns of the eyes and skin
burns.
Ear plugs should be worn when working on overhead or
in a confined space. A hard hat should be worn when
others work overhead.
Flammable hair preparations should not be used by persons intending to weld or cut.
B. Toxic Fume Prevention
Severe discomfort, illness or death can result from
fumes, vapors, heat, or oxygen enrichment or depletion
that welding (or cutting) may produce. Prevent them
with adequate ventilation as described in ANSI Standard Z49.1 listed in Standards Index. NEVER ventilate
with oxygen.
Lead -, cadmium -, zinc -, mercury -, and beryllium-bearing and similar materials, when welded (or cut) may produce harmful concentrations of toxic fumes. Adequate
local exhaust ventilation must be used, or each person
in the area as well as the operator must wear an air-supplied respirator. For beryllium, both must be used.
Metals coated with or containing materials that emit
toxic fumes should not be heated unless coating is removed from the work surface, the area is well ventilated
and, if necessary , while wearing an air-supplied respirator.
Work in a confined space only while it is being ventilated
and, if necessary , while wearing an air-supplied respirator.
Gas leaks in a confined space should be avoided.
Leaked gas in large quantities can change oxygen concentration dangerously . Do not bring gas cylinders into a
confined space.
Leaving confined space, shut OFF gas supply at source
to prevent possible accumulation of gases in the space if
downstream valves have been accidentally opened or
left open. Check to be sure that the space is safe before
re-entering it.
Vapors from chlorinated solvents can be decomposed
by the heat of the arc (or flame) to form PHOSGENE, a
highly toxic gas, and other lung and eye irritating products. The ultraviolet (radiant) energy of the arc can also
decompose trichloroethylene and perchloroethylene
vapors to form phosgene. DO NOT WELD or cut where
solvent vapors can be drawn into the welding or cutting
OM-877 Page 1
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 material; misuse of compressed gases and cylinders; and
short circuits.
BE AWARE THAT flying sparks or falling slag can pass
through cracks, along pipes, through windows or doors,
and through wall or floor openings, out of sight of the
goggled operator. Sparks and slag can fly 35 feet.
To prevent fires and explosion:
Keep equipment clean and operable, free of oil, grease,
and (in electrical parts) of metallic particles that can
cause short circuits.
If combustibles are in area, do NOT weld or cut. Move
the work if practicable, to an area free of combustibles.
Avoid paint spray rooms, dip tanks, storage areas, ventilators. If the work cannot be moved, move combustibles at least 35 feet away out of reach of sparks and
heat; or protect against ignition with suitable and snugfitting, fire-resistant covers or shields.
Walls touching combustibles on opposite sides should
not be welded on (or cut). Walls, ceilings, and floor near
work should be protected by heat-resistant covers or
shields.
Fire watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if:
a. appreciable combustibles (including building
construction) are within 35 feet
b. appreciable combustibles are further than 35
feet but can be ignited by sparks
c. openings (concealed or visible) in floors or walls
within 35 feet may expose combustibles to
sparks
d. combustibles adjacent to walls, ceilings, roofs,
or metal partitions can be ignited by radiant or
conducted heat.
Hot work permit should be obtained before operation to
ensure supervisor’s approval that adequate precautions have been taken.
After work is done, check that area is free of sparks,
glowing embers, and flames.
An empty container that held combustibles, or that can
produce flammable or toxic vapors when heated, must
never be welded on or cut, unless container has first
been cleaned as described in AWS Standard A6.0,
listed 7 in Standards Index.
This includes: a thorough steam or caustic cleaning (or
a solvent or water washing, depending on the combustible’s solubility) followed by purging and inerting with nitrogen or carbon dioxide, and using protective equip-
OM-877 Page 2
ment as recommended in A6.0. Waterfilling just below
working level may substitute for inerting.
A container with unknown contents should be cleaned
(see preceding paragraph). Do NOT depend on sense
of smell or sight to determine if it is safe to weld or cut.
Hollow castings or containers must be vented before
welding or cutting. They can explode.
Explosive atmospheres. Never weld or cut where the air
may contain flammable dust, gas, or liquid vapors (such
as gasoline).
D. Compressed Gas Equipment
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-1, SAFE
HANDLING OF COMPRESSED GASES IN CYLINDERS, listed 11 in Standards Index.
1. Pressure Regulators
Regulator relief valve is designed to protect only the
regulator from overpressure; it is not intended to protect
any downstream equipment. Provide such protection
with one or more relief devices.
Never connect a regulator to a cylinder containing gas
other than that for which the regulator was designed.
Remove faulty regulator from service immediately for
repair (first close cylinder valve). The following symptoms indicate a faulty regulator:
Leaks-if gas leaks externally.
Excessive Creep-if delivery pressure continues to rise
with downstream valve closed.
Faulty Gauge-if gauge pointer does not move off stop
pin when pressurized, nor returns to stop pin after pressure release.
Repair. Do NOT attempt to repair. Send faulty regulators for repair to manufacturer’s designated repair cen-
ter, where special techniques and tools are used by
trained personnel.
2. Cylinders
Cylinders must be handled carefully to prevent leaks
and damage to their walls, valves, or safety devices:
Avoid electrical circuit contact with cylinders including
third rails, electrical wires, or welding circuits. They can
produce short circuit arcs that may lead to a serious accident. (See 1-3C.)
ICC or DOT marking must be on each cylinder. It is an
assurance of safety when the cylinder is properly handled.
Identifying gas content. Use only cylinders with name of
gas marked on them; do not rely on color to identify gas
content. Notify supplier if unmarked. NEVER DEFACE
or alter name, number, or other markings on a cylinder. It
is illegal and hazardous.
Empties: Keep valves closed, replace caps securely;
mark MT; keep them separate from FULLS and return
promptly.
Prohibited use. Never use a cylinder or its contents for
other than its intended use, NEVER as a support or
roller.
Locate or secure cylinders so they cannot be knocked
over.
outlet away from people and sources of ignition. Wipe
with a clean lintless cloth.
Passageways and work areas. Keep cylinders clear of
areas where they may be struck.
Transporting cylinders. With a crane, use a secure support 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 NOT expose cylinders to excessive heat, sparks,
slag, and flame, etc. that may cause rupture. Do not allow contents to exceed 130°F. Cool with water spray
where such exposure exists.
Protect cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when moving cylinders.
Stuck valve. Do NOT use a hammer or wrench to open a
cylinder valve that can not be opened by hand. Notify
your supplier.
Mixing gases. Never try to mix any gases in a cylinder.
Never refill any cylinder.
Cylinder fittings should never be modified or ex-
changed.
3. Hose
Prohibited use. Never use hose other than that designed for the specified gas. A general hose identification rule is: red for fuel gas, green for oxygen, and black
for inert gases.
Use ferrules or clamps designed for the hose (not ordinary wire or other substitute) as a binding to connect
hoses to fittings.
No copper tubing splices. Use only standard brass fittings to splice hose.
Match regulator to cylinder. Before connecting, check
that the regulator label and cylinder marking area, and
that the regulator inlet and cylinder outlet match.
NEVER CONNECT a regulator designed for a particular
gas or gases to a cylinder containing any other gas.
Tighten connections. When assembling threaded connections, clean and smooth seats where necessary.
Tighten. If connection leaks, disassemble, clean, and
retighten using properly fitting wrench.
Adapters. Use a CGA adapter (available from your supplier) between cylinder and regulator, if one is required.
use two wrenches to tighten adapter marked RIGHT
and LEFT HAND threads.
Regulator outlet (or hose) connections may be identified
by right hand threads for oxygen and left hand threads
(with grooved hex on nut or shank) for fuel gas.
5. Pressurizing Steps:
Drain regulator of residual gas through suitable vent before opening cylinder (or manifold valve) by turning adjusting screw in (clockwise). Draining prevents excessive compression heat at high pressure seat by allowing
seat to open on pressurization. Leave adjusting screw
engaged slightly on single-stage regulators.
Stand to side of regulator while opening cylinder valve.
Open cylinder valve slowly so that regulator pressure in-
creases slowly. When gauge is pressurized (gauge
reaches regulator maximum) leave cylinder valve in following position: For oxygen, and inert gases, open fully
to seal stem against possible leak. For fuel gas, open to
less than one turn to permit quick emergency shutoff.
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on
regulators.
Avoid long runs to prevent kinks and abuse. Suspend
hose off ground to keep it from being run over, stepped
on, or otherwise damaged.
Coil excess hose to prevent kinks and tangles.
Protect hose from damage by sharp edges, and by
sparks, slag, and open flame.
Examine hose regularly for leaks, wear, and loose con-
nections. Immerse pressured hose in water; bubbles indicate leaks.
Repair leaky or worn hose by cutting area out and splicing (1-2D3). Do NOT tape.
4. Proper Connections
Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing
Check for leaks on first pressurization and regularly
there-after. Brush with soap solution (capfull of Ivory
Liquid* or equivalent per gallon of water). Bubbles indicate leak. Clean off soapy water after test; dried soap is
combustible.
E. User Responsibilities
Remove leaky or defective equipment from service immediately for repair. See User Responsibility statement
in equipment manual.
F. Leaving Equipment Unattended
Close gas supply at source and drain gas.
G. Rope Staging-Support
Rope staging-support should not be used for welding or
cutting operation; rope may burn.
*Trademark of Proctor & Gamble.
OM-877 Page 3
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 infrared energy radiates, weldments are hot, and compressed gases may be used. The wise operator avoids
unnecessary risks and protects himself and others from
accidents. Precautions are described here and in standards referenced in index.
A. Burn Protection
Comply with precautions in 1-2.
The welding arc is intense and visibly bright. Its radiation
can damage eyes, penetrate lightweight clothing, reflect
from light-colored surfaces, and burn the skin and eyes.
Skin burns resemble acute sunburn, those from gasshielded arcs are more severe and painful. DON’T GET
BURNED; COMPLY WITH PRECAUTIONS.
1. Protective Clothing
Wear long-sleeve clothing (particularly for gas-shielded
arc) in addition to gloves, hat, and shoes (1-2A). As necessary, use additional protective clothing such as
leather jacket or sleeves, flame-proof apron, and fire-resistant leggings. Avoid outer garments of untreated cotton.
Bare skin protection. Wear dark, substantial clothing.
Button collar to protect chest and neck and button pockets to prevent entry of sparks.
2. Eye and Head Protection
Protect eyes from exposure to arc. NEVER look at an
electric arc without protection.
Welding helmet or shield containing a filter plate shade
no. 12 or denser must be used when welding. Place over
face before striking arc.
Protect filter plate with a clear cover plate.
Cracked or broken helmet or shield should NOT be
worn; radiation can pass through to cause burns.
Cracked, broken, or loose filter plates must be replaced
IMMEDIATELY. Replace clear cover plate when broken,
pitted, or spattered.
Flash goggles with side shields MUST be worn under
the helmet to give some protection to the eyes should
the helmet not be lowered over the face before an arc is
struck. Looking at an arc momentarily with unprotected
eyes (particularly a high intensity gas-shielded arc) can
cause a retinal burn that may leave a permanent dark
area in the field of vision.
3. Protection of Nearby Personnel
Enclosed welding area. For production welding, a separate room or enclosed bay is best. In open areas, surround the operation with low-reflective, non-combustible screens or panels. Allow for free air circulation, particularly at floor level.
OM-877 Page 4
Viewing the weld. Provide face shields for all persons
who will be looking directly at the weld.
Others working in area. See that all persons are wearing
flash goggles.
Before starting to weld, make sure that screen flaps or
bay doors are closed.
B. Toxic Fume Prevention
Comply with precautions in 1-2B.
Generator engine exhaust must be vented to the out-
side air. Carbon monoxide can kill.
C. Fire and Explosion Prevention
Comply with precautions in 1-2C.
Equipment’s rated capacity. Do not overload arc weld-
ing equipment. It may overheat cables and cause a fire.
Loose cable connections may overheat or flash and
cause a fire.
Never strike an arc on a cylinder or other pressure ves-
sel. It creates a brittle area that can cause a violent rupture or lead to such a rupture under rough handling.
D. Compressed Gas Equipment
Comply with precautions in 1-2D.
E. Shock Prevention
Exposed hot conductors or other bare metal in the welding circuit, or in ungrounded, electrically-HOT equipment can fatally shock a person whose body becomes a
conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR
TOUCH a wet surface when welding, without suitable
protection.
To protect against shock:
Wear dry insulating gloves and body protection. Keep
body and clothing dry. Never work in damp area without
adequate insulation against electrical shock. Stay on a
dry duckboard, or rubber mat when dampness or sweat
can not be avoided. Sweat, sea water, or moisture between body and an electrically HOT part or grounded
metal reduces the electrical resistance, and could enable dangerous and possibly lethal currents to flow
through the body.
A voltage will exist between the electrode and any conducting object in the work circuit. Examples of conducting objects include, but are not limited to, buildings, electrical tools, work benches, welding power source cases,
workpieces, etc. Never touch the electrode and any
metal object unless the welding power source is
off.
1. Grounding the Equipment
Arc welding equipment must be grounded according to
the National Electrical Code, and the work must be
grounded according to ANSI Z49.1 “Safety In Welding
And Cutting.”
When installing, connect the frames of each unit such a s
welding power source, control, work table, and water circulator to the building ground. Conductors must be ade-
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