Miller Electric S-21E User manual

MiIIe~

November1996

Form:

TM-1571

Effective

With Serial

No.

JJ507797

TECHNICAL

MANUAL

Service

And

Parts

Wire

Feed

Equipment

WARNING

SERVICING

can

hazardous.

•

Have

all

service

procedures

performed only

qualified

persons

following

standard

safety

practices.

Use

MILLER

Testing Booklet

(Part

No.

150

853)

when

servicing

this

unit.

Use

only genuine

MILLER

replacement

parts.

S-21E

For

help,

call

Factory

~U~r

FAX:

write

to:

Service

Department:

14-735-4136

MILLER

Electric

Mfg.

Co.

414-735-4505

L................J

RO.

Box

1079

Appleton,

54912

USA

coverjml

—

SB-124

467

1996

MILLER Electric

Mfg.

Co.

PRINTED

USA

OM-1571B

—

3/91

TABLE

CONTENTS

Section

No.

Page

No.

SECTION

SAFETY

PRECAUTIONS AND

SIGNAL

WORDS

1-1.

General

Information And

Safety

1-2.

Safety

Alert

Symbol And

Signal

Words

1-3.

Safety

Precautions

SECTION

SHIPPING

AND

STORAGE

2-1. Preparation

For

Reshipment

2-2. Storage

SECTION

3—

SPECIFICATIONS

3-1.

Description

SECTION

INSTALLATION

RELOCATION

4-1.

Location

4-2.

Drive

Roll

Installation

4-3.

Welding Gun Connections

4-4. Shielding

Gas

Installation

4-5.

14-Pin

Plug

Connection

4-6.

Welding

Wire

Installation

4-7.

Welding

Wire

Threading

4-8.

Adjust

The

Hub

Tension

4-9.

Welding

Cable

Connection

4-10.

Feeding Welding

Wire

SECTION

5-OPERATOR

CONTROLS

5-1.

Power

Switch

5-2.

Wire

Speed

Control

SECTION

6—

SEQUENCE

OPERATION

6-1.

Gas

Metal Arc (GMAW)

And

Flux Cored

Arc

(FCAW) Welding

6-2.

Shutting

Down

SECTION

THEORY

OPERATION

7-1.

Theory Of

Operation

Diagram

7-1.

Block

Diagram

For

Wire Feeder

Diagram

7-2.

Block

Diagram

For

SpotlBurnback

Time

Control

Option

Section

No.

Page

No.

SECTION

TROUBLESHOOTING

8-1.

Testing

Instruments And Information

8-2.

Circuit

Board

Handling

Precautions

8-3.

Troubleshooting

Diagram

8-1.

Troubleshooting

Circuit

Diagram For

Wire Feeder

8-4. Motor

Board

PCi

Testing

Information

Diagram

8-2.

Troubleshooting

Circuit

Diagram For

Motor Control

Board

PCi

8-5.

Optional

SpotlBurnback

Board PC2 Testing

Information

Diagram

8-3.

Troubleshooting

Circuit

Diagram For

Optional Spot/Burnback

Board PC2

SECTION

COMPONENT

IDENTIFICATION

AND

LOCATION

Figure

9-1.

Component

Identification And

Location

SECTION

10—

MAINTENANCE

10-1.

Routine

Maintenance

10-2.

Aligning

Drive

Roll And

Wire

Guide

10-3.

Reinstallation

Hub

Assembly

10-4.

Brush

Inspection

And

Replacement

10-5.

Overload

Protection

SECTION

ELECTRICAL

DIAGRAMS

Diagram

11-1.

Diagram

11-2.

Diagram

11-3.

Diagram

11-4.

Diagram

11-5.

Circuit

Diagram For

S-21

Effective

With Serial

No.

JJ507797

And Following

Wiring

Diagram

For

S-21

Effective

With

Serial

No.

JJ507797

And Following

Circuit

Diagram For

Motor Control

Board

PCi

Effective

With Serial

No.

JJ507797 And Following

Circuit

Diagram

For

Optional

SpotlBurnback

Board PC2

Effective

With Serial

No.

JJ507797

Thru

JK742028

Circuit

Diagram For

Optional Spot/Burnback

Board PC2

Effective

With Serial

No.

JK742029

And Following

SECTION

12—

PARTS

LIST

CHARTS AND

TABLES

Table 3-1.

Specifications

Table 8-1.

Troubleshooting

Table

10-1.

Maintenance

Schedule

Table

11-1.

List

Circuit Diagrams

And

Wiring

Diagrams

SECTION

SAFETY

PRECAUTIONS

AND

SIGNAL WORDS

1-1.

GENERAL

INFORMATION

AND SAFETY

This

manual

provides

theory

operation

along

with

specific

operating,

testing, and

troubleshooting

proce-

dures.

also includes

precautionary information

rele-

vant

these

procedures.

This

manual

can

be an

effec

tive tool

the

hands

trained

serviceperson.

How-

ever,

does

not

and

cannot

take

the

place

training

nor

safety-conscious service

work.

any

doubt

arises

about

the

specific

application

of procedures

pre

sented,

problems

arise

which

are

not

covered

in this

manual,

contact

the

factory

Service Department

before

proceeding

further.

1-2.

SAFETY

ALERT

SYMBOL AND

SIGNAL

WORDS

The

following safety alert

symbol

and signal

words

are

used

throughout

this

manual to

call

attention

to and

identify

different

levels of

hazard

and

special

instruc

tions.

This safety alert

symbol

used

with

the

signal

words

WARNING and

CAUTION

call

atten

tio

the

safety

statements.

WARNING statements identify

procedures

practices which

must

followed

avoid

seri

ous personal injury

or loss of

life.

CAUTION

statements identify procedures

practices which

must

followed

avoid

minor

personal injury

damage

this

equipment.

IMPORTANT

statements identify special

instructions

necessary

for

the

most efficient

operation

this

equip

ment.

1-3.

SAFETY

PRECAUTIONS

ARNING: ELECTRIC

SHOCK

can kill.

not

touch

live

electrical

parts.

•

Protect

yourself

with

dry

insulating

gloves

and

clothing.

•

Insulate

yourself

from

ground

using

rubber9loves

and

insulating

floormats

when

power is

applied

the

unit.

•

Shut

down

unit

and

disconnect

input

power

when

servicing

unless

the

procedure

specifi

cally

requires

energized

unit.

•

not

leave

live

unit

unattended.

ARC

RAYS,

SPARKS,

AND HOT

SURFACES

can

burn eyes

and

skin; NOISE

can

damage

hearing.

•

Wear

correct

eye,

ear,

and body

protection.

FUMES

AND

GASES can

seriously

harm

your

health.

•

Keep

your

head out

the

fumes.

•

Ventilate to

keep

from

breathing

fumes

and

gases.

•

ventilation

inadequate,

use

approved

breathing

device.

•

Read Material

Safety

Data

Sheets

(MSDSs)

and

manufacturer’s

instructions

for

any

materials

used.

WELDING

WIRE

can

cause

puncture

wounds.

•

not

point

gun towa

any

part of

the

body,

any

conductive

surface,

other

personnel.

HOT

METAL,

SPATrER,

AND

SLAG

can

cause

fire

and

burns.

•

Watch

for

fire.

•

Have

fire

extinguisher

nearby

and

know

how

use

it.

•

not

use

near

flammable

material.

•

Allow

work

and

equipment

cool

before

handling.

MOVING

PARTS

can

cause

serious

injury.

•

Keep

away

from

moving

parts.

HOT

SURFACES

can

cause

severe

burns.

•

Allow

cooling

period

before

servicing.

MAGNETIC

FIELDS

FROM

HIGH CURRENTS

can

affect

pacemaker

operation.

•

Wearers

should

consult

their

doctor

before

going near

the

servicing

arc

welding

equip

ment

any

arc

welding

operations.

5-21E

TM-1571

Page

SECTION

SHIPPING

AND

STORAGE

PREPARATION

FOR

RESHIPMENT

WARNING:

ELECTRIC

SHOCK

can

kill.

•

not

touch

live

electrical

parts.

•

Shut

down wire

feeder

and

welding

power

source,

and

disconnect

input

power

employ

ing

lockout/tagging

procedures

before

preparing unit

for

shipping.

Lockout/tagging

procedures

forwire

feedercon

sist

disconnecting

interconnecting

cord,

and

for

welding

power

source

consist

padlocking

line

disconnect switch

in open

position,

remov-

ing

fuses

from

fuse

box,

or shutting

off

and red-

tagging circuit breaker or

other

disconnecting

device.

Stop

engine, and

disconnect

negative

(—)

battery

cable

from

battery

welding

gen

erators.

Disconnect

interconnecting

cord

from

rear

wire

feeder.

Disconnect

weld

cable

from drive

assembly.

Disconnect and remove

any

remote

controls

devices.

Disconnect

shielding

gas

(and

water

applica

ble)

hoses from

wire

feeder.

Disconnect gun

from

wire

feeder.

Secure

welding

wire

spool/reel,

and

remove

wire

spool

reel

from

wire

feeder.

Tape

plastic

around

top

and

sides

unit.

Securely

tie

and/or tape cardboard over

top

and

around

sides

unit.

Use

original

shipping carton

available.

IMPORTANT:

not

ship without

a cardboard

carton.

Not

only

costs increase

dramatically

but

the

unit

subject

loss

damage

without

carton.

sending

unit

factory,

ship

unit

directed

factory

Service

Department

Transportation

Department.

STORAGE

WARNING:

ELECTRIC

SHOCK

can

kill.

•

not

touch

live

electrical

parts.

•

Shut

down

wire

feeder

and

welding

power

source,

and

disconnect

put power

employ

ing

lockout/tagging

procedures

before

storing

unit.

Lockout/tagging

procedures

forwirefeedercon

sist

disconnecting

interconnecting

cord,

and

for

welding

power

source consist

padlocking

line

disconnect switch

in open

position,

remov-

ing

fuses

from

fuse box,

or shutting

off and

red-

tagging circuit

breaker

other

disconnecting

device. Stop

engine, and

disconnect negative

(—)

battery

cable

from

battery

welding

gen

erators.

Disconnect

interconnecting

cord

from

rear

wire

feeder.

Disconnect weld

cable

from drive

assembly.

Disconnect and remove

any

remote

controls

devices.

Disconnect

shielding

gas

(and

water

applica-

ble)

hoses

from

wire

feeder.

Disconnect gun

from

wire

feeder.

Secure

welding

wire

spool/reel,

and remove

wire

spool

reel

from

wire

feeder.

Clean outside of

unit.

Remove

wrapper.

Using

dry

compressed

air,

clean

inside of

unit.

10.

Reinstall wrapper.

11.

Select

storage

location that

least

subjects

the

unit

wide

temperature

variation,

dust,

dirt,

and

corrosive

vapors.

12.

Carry

unit

to storage

location.

13.

Cover

unit

with

plastic

or suitable

tarp.

TM-1571

Page

5-21E

SECTION

SPECIFICATIONS

Table 3-1.

Specifications

Input

Power

Requirements Electrode

Wire

Diameter

Capacity Wire

Spool

Capacity

Electrode

Wire

Feed Speed

Weight

Net

Ship

lb.

VAC

3.5

Amps

50/60

.O23thru

.045

in.

(0.6 thru

1.1

mm)

(4.5 to

kg)

in.

(203mm)

spools

lb.

(27.2

kg)_coils

75-600 ipm

(1.9-15.2

mom)

VA~

lbs.

(13.6

kg)

lbs.

(15 kg)

SB-124

467

Figure

3-1. Overall Dimensions

3-1. DESCRIPTION

This

unit

semiautomatic

constant speed wire feeder

which

operates

on 24

volts

ac.

The

feeder

designed

for

connection to

constant

voltage (CV)

type

power

source

through

14-pin

connector.

115

volts ac

the

only

power

available

for

use

with

the

feeder,

the

optional

power supply

adapter

Model

PSA-2

115/24 should

used

to convert

the

power

volts

ac.

The

case

can

tightly

latched to

help

keep

out

dust

and

dirt.

SECTION

INSTALLATION OR

RELOCATION

4-1.

LOCATION

(Figure 3-1)

The

service

life

and

efficiency

this unit

and

associated

components

are

reduced

when

they

are

subjected to

high

levels of

dust,

dirt, moisture,

corrosive

vapors, and

extreme

heat.

proper installation

site should

selected

for

the

wire

feeder

the

unit

to provide

dependable

service.

Lead

lengths

must

considered

when

installing

the

unit.

slot

provided in

the

base

the

unit

fit

over

the

lifting

eye

welding

power

sources

equipped. Suitable

space

should

maintained

around

the

unit

for

making

necessary

connections

and

for

maintenance

functions.

4-2.

DRIVE

ROLL

INSTALLATION (Figure 4-1)

WARNING: ELECTRIC

SHOCK

can kill.

•

not

touch

live

electrical

parts.

•

Shut

down

wire

feeder and

welding

power

source,

and

disconnect

input

power

employ

ing

lockout/tagging

procedures

before

specting

installing.

Lockout/tagging

procedures

for

wire feeder

con

sist

disconnecting

interconnecting

cord,

and

for

welding

power

source consist

padlocking

line

disconnect switch

in open

position,

remov-

ing

fuses

from

fuse

box,

or shutting

off

and

red-

tagging

circuit

breaker

other

disconnecting

device.

Stop

engine, and

disconnect negative

(—)

battery

cable

from

battery

welding

gen

erators.

TM-1571

Page

10-112

In.

(267

mm)

22-1(2

in.

(572

mm)

S-21E

•

OPTIONAL

Pressure

Roll

Assembly

(Shown

Open

PosItion)

necessary

install

the

required

drive

rolls

when

set

ting

this unit

and

also

when

changing

wire

sizes.

IMPORTANT:

Base drive

roll

selection

the

following

recommendations:

The

dual-grooved drive

roll

provided

with

the

feeder

commodates

.023

through

.045

in.

(0.6 through

1.1

mm)

wire.

This

drive

roll

has

both

“‘I”

groove

and

“‘I”

knurled

groove.

Use

the “V”

groove

for

feeding

.023

and

.030

in.

(0.6 and

0.76

mm)

wire.

Use

the

“V”

knurled

groove

for

feeding

.035

and

.045

in.

(0.89

and

1.1

mm)

wire.

The

wire

size

for

each

groove

stamped

the

side

the

drive

roll.

When

the

drive

roll is

installed

the

feeder,

the

wire

size

stamp

for

the

unused

groove

will

visible.

The

Series wire feeder

style

drive

rolls

may

used

with

this feeder,

but,

due to

the flat

idler pressure

roll

used,

knurled

drive

roll is

recommended

when

feeding

.035

and

.045

(.089

and

1.1

mm)

wire.

ARNING:

ELECTRIC

SHOCK

can

kill.

not

store metallic

objects

this

compart

ment. The

motor

drive

assembly

electri

cally

hot

whenever

the

welding

circuit

ener

gized.

Loose

metal

objects

in this

compartment

may

create

electrical

path

between

the

weld

out

put

circuit and

any

metal

surfaces

compo-

nents

resulting in

electric

shock.

IMPORTANT:

Both

types

Series

style

drive

rolls

can

be reversed

for

reuse

when

they

become

worn.

verse

rolls

position

unused

groove(s)

feed

wire.

The

dual-grooved

drive

roll

pro

vided

with

this

feedercan

reversed,

but

only

feed a

different

size

wire.

Unlatch

and

open

left

case

access

door.

Loosen

pressure

adjustment

knob,

and

pivot

knob

free of

pressure

arm.

Pivot

pressure

arm

away

to expose

drive

roll

carrier.

For

dual-grooved

roll

supplied

with

feeder:

Choose

the

proper

groove.

Slide

drive

roll onto

drive

roll

mounting hub with

chosen

groove

toward

inside of machine.

The

wire

size

for

the

unused

groove

will

visible

after

installation.

Align

the

drive

roll

with

holes.

Insert

securing

screws, and tighten.

Hub

Wire

•

Spring

Retaining

Ring

Ret.

50497

Figure

4-1.

Wire

Feeder

Components

GunlFeeder

connector

Securing

Knob

Ref.

SB-125

923

TM-1571

Page

5-21E

For

Series

style

one-piece

drive

rolls:

Gun

Trigger (Figure 5-1)

Slide

drive

roll

onto

drive

roll

mounting

hub.

Align

drive

roll

with

holes.

Insert

securing

screws, and tighten.

For

Series

style

split

drive

rolls:

Align holes

pair of split

drive

rolls.

Insert

securing

screw.

Slide

drive

rolls

onto

drive

roll

mounting

hub.

Align

drive

rolls

with

holes.

Insert

securing

screws, and tighten.

IMPORTANT:

Horizontal

alignment

the drive

roll

the drive

roll

mounting

hub

with

the

wire

guide

factory

set

and

should

not

require

readjustment.

readjustment

becomes

necessary,

see

Section 10-2.

and

secure

left

case

access

door.

4-3.

WELDING

GUN

CONNECTIONS

(Figures

4-1

And

5-1)

WARNING:

ELECTRIC

SHOCK

can kill.

•

not

touch

live

electrical

parts.

•

Shut

down

wire

feeder

and

welding

power

source,

and

disconnect

input

power

employ

ing

lockout/tagging

procedures

before

work

ing

feeder.

Lockout/tagging

procedures

for

wire feeder

con

sist

disconnecting

interconnecting

cord,

and

for

welding

power

source consist

padlocking

line

disconnect switch

in open

position,

remov-

ing

fuses

from

fuse box,

or shutting

off

and red-

tagging circuit

breaker

other

disconnecting

device.

Stop

engine, and

disconnect

negative

(—)

battery

cable

from

battery

welding

gen

erators.

IMPORTANT:

hole

ispro

vided

the

nameplate

form-

stallation

gun

requiring an

opening

for

external

gas

line.

Remove snap-in

blank

before

installation.

Gun

Connector

Drive

Assembly

(Figure 4-1)

Unlatch and

open

left

case

access

door.

Loosen

gun/feeder

connector securing

knob

the

wire

drive

housing.

Insert

gun/feeder connector

through

the

access

hole

the

front

panel.

Insert

gun/feeder

connector

into

drive

housing

with

the

outlet

wire

guide

the

drive

rolls

possible

without touching,

and

tighten

the

curing

knob.

S-21E

Close and

secure

left

case

access

door.

‘9=

TRIGGER

RECEPTACLE

Connect

gun

trigger plug

trigger receptacle

the

front

panel

follows:

align

keyways,

insert

gun

plug

into

trigger

receptacle,

and

rotate

threaded

collar

fully

clockwise.

4-4.

SHIELDING

GAS

INSTALLATION

(Figures

4-2

And

4-3)

WARNING:

PRESSURIZED

CYLINDERS can

rupture

causing serious

personal

injury

and

loss

life;

FALLING

CYLINDERS

can

cause

serious

injury

and

equipment

damage.

•

Keep

cylinders

away

from

welding

other

electrical circuits.

•

Never

allow

a welding

electrode

touch

any

cylinder.

•

Always fasten

cylinder

securely

running

gear

bracket,

wall,

other

stationary

sup-

port.

Gas

Cylinder (Customer

Supplied)

Chain

the

cylinder

wall or

other

stationary

support

prevent

the

cylinder

from

falling

over

and

breaking

off

the

valve.

optional

power

source

running

gear is

used,

secure gas

cylinder

to running

gear

with

supplied

chain.

Regulator/Flowmeter

(Customer

Supplied)

With

the

cylinder

securely

installed,

remove

the

cylinder

cap,

stand

to one

side

cylinder

valve,

and

open

valve

slightly.

When

gas

flows

from

cyl

inder,

valve.

This procedure

blows

out

dust

dirt

that

may

have

accumulated

around

the

valve

seat.

IMPORTANT:

gasket should

installed

prevent

leaks.

not

use

lubricants

sealing

agents.

The

regulator/flowmeter

must

properly

equipped with

stem,

nut

connectors,

and

gas

ket

for

use

with

either

CO2

cylinders

inert

gas

type

cylinders.

Install

gas

regulator/flowmeter onto

gas

cylinder

valve;

keep

the

face

the

regulator/flowmeter

gauge

vertical

position,

and

tighten

stem

nut

securely

gas

cylinder

valve.

shielding

gas fitting

provided

the

rear of

the

wire

feeder.

Obtain

suitable

hose

with

5/8-18

right- hand

fitting.

Attach

one end of

the

gas

hose

this

fitting.

Attach the

other

end of

the

gas

hose

the

regulator/flowmeter.

TM-1571

Page

Figure

4-2. Typical

RegulatorlFlowmeter

Installation

4-5.

14-PIN

PLUG CONNECTION

(Figures

4-3

And

4-4)

The

14-pin

plug

PLG1

00,

the

end of

the

interconnect

ing

cord,

provides

junction

point

for

connecting

the

wire

feeder

welding

power

source.

This

connection

provides

volt

power,

and

contactor

control when

used

with

constant

voltage

(CV)

power

source

with

14-pin

receptacle.

make

connections,

align

keyway,

insert

plug,

and

rotate

threaded

collar

fully

clockwise.

The

pins

plug

PLG

100

are

defined

relation

both

the

power

source

and

wire

feeder.

The

welding

power

source

provides

six

functions

the

wire

feeder.

The

pins

are

designated as

follows:

amperes

volts

ac,

Hz,

with

spect

socket

G (circuit

common);

protected by

fuse

welding

power

source.

volts ac

input

power

energize

the

weld

con

tactor.

The

feeder

sends

back

volts ac by

means

contact closure

from pin A

volts ac

circuit common;

also connected

welding

power

source

chassis.

IMPORTANT:

The

remaining

pins

the

receptacle are

not

used

the

feeder.

Shielding

Gas

valve

Fitting,

14-Pin

Plug

Gas

cylinder

Valve

Argon

Mix

cylinder

SB-109

492

Ref.

S-0004

Figure

4-4. Front

View

14-Pin

Plug

With

Locations

4-6.

WELDING

WIRE

INSTALLATION

(Figure

4-5)

WARNING: ELECTRIC

SHOCK

can kill.

•

not

touch

live

electrical

parts.

•

Shut

down

wire

feeder and

welding

power

source,

and

disconnect

input

power

ploy

ing

lockout/tagging

procedures

before

work

ing

feeder.

Lockout/tagging

procedures

forwire

feeder

con

sist

disconnecting

interconnecting

cord,

and

for

welding

power

source consist

padlocking

line

disconnect

switch

in open

position,

remov-

ing

fuses

from

fuse

box,

or shutting

off and

red-

tagging

circuit

breaker

other

disconnecting

device.

Stop

engine, and

disconnect

negative

(—)

battery cable

from battery

welding

gen

erators.

CAUTION: LOOSE

WELDING

WIRE can

cause

Injury.

•

Keep

firm

hold

the

wire

during

installa

tion,

removal,

and

threading

operations.

Spooled wire

has

tendency

unravel

rapidly

when

loosened

from

the

spool.

SA-125

924

IMPORTANT:

it should become

necessary

replace

any

part of

the

hub

assembly

see

hub

assembly

rein

stallation instruction

Section

10-3.

Flow

Adjustment

CO2

Washer

CO2

cylinder

CO2

Installation

Argon

Installation

Wire

Feed

Weld

Cable

Connection

Opening

Figure

4-3.

Rear

Panel

View

TM-1571

Page

5-21E

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