Miller PSA-2 User manual

OWNER’S MANUAL

OM‐542 122 218E

2009−01

Model: PSA-2

1. Specifications

Ref. ST-143 353-C

115 To 24 Volts AC Power Supply Adapter (PSA)

For Connecting GMAW Wire Feeder To Welding Power Source

24 Volts AC, 8 Amperes Output; Nominal 110 Volts AC Input Power

Overload Protection; 14-Socket Wire Feeder Receptacle

Includes Mounting Bracket And 115 Volts AC/Remote Contactor Cord

2. Safety Symbol Definitions

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in

the adjoining symbols.

Have only trained and qualified persons install, operate,

or service this unit. Call your distributor if you do not un-

derstand the directions. For WELDING SAFETY and

EMF information, read wire feeder and welding power

source manuals.

Beware of electric shock from welding electrode or wiring.

Touching the electrode while in contact with the work or

ground can cause electric shock. Always wear dry

gloves. Keep all panels and covers closed.

Wear safety glasses with side shields.

3. Installation Onto Wire Feeder

!Disconnect power before in-

stalling.

1 Side Brackets

2 Spool Support

Remove side brackets. Install

adapter into spool support using

hardware removed from side

brackets.

ST-143 460-C

Tools Needed:

3/8 in

OM-542 Page 2

4. Installation Onto Welding Power Source

ST-159 574-A / ST-159 573-A

!Disconnect power before in-

stalling.

Mount adapter so it does not cover

labels or air louvers on welding

power source.

1 Screws From Welding Power

Source

2 Supplied Grommets

3 Bracket

4 Locking Nut

5 Supplied Screws

Top Mount:

Insert grommets into bracket, and

install adapter using one or two

screws as shown.

Side Mount:

Install bracket and insert grommets

into bracket. Install adapter as

shown.

Top Mount

Side Mount

Tools Needed:

3/8 in

OM-542 Page 3

5. Connections And Circuit Breaker CB1

Ref. ST-143 353-C / ST-159 932 / Ref. ST-143 353-C

!Disconnect power before in-

stalling.

Standard Connections

1 115 Volts AC/Remote Contac-

tor Plug

Use to make 115 volts AC/remote

contactor connections.

2 Remote 14 Receptacle

Use to make 24 volts AC input pow-

er connection to wire feeder.

Pin Information:

A 24 volts AC with respect to

socket G.

B Contact closure to A com-

pletes 24 volts AC contac-

tor control circuit.

G Circuit common for 24

volts AC circuit.

The remaining pins are not used.

3 Circuit Breaker CB1

If CB1 opens, the wire feeder does

not work. Reset breaker.

4 Remote Contactor Plug

5 115 Volts AC Plug

Connect plugs to matching remote

contactor and 115 volts AC recep-

tacles on welding power source.

If 115 volts AC plug does not match

welding power source receptacle,

replace plug as shown.

Replacing 115 Volts AC Plug

Obtain plug to match 115 volts AC

receptacle.

Connect leads to new 115 volts AC

plug as follows:

Green: Ground.

White: 115 volts AC common.

Black: 115 volts AC hot.

Connect plug to 115 volts AC

receptacle.

Contactor Control Connections

!Do not apply 115 volts AC to

welding power source re-

quiring only a contact clo-

sure for contactor operation.

Disconnect power before in-

stalling.

If welding power source only needs

contact closure to activate contac-

tor, replace existing plug with a suit-

able plug as follows:

Cut off plug, and strip cord jacket

enough to separate leads.

Strip insulation and connect leads

to new plug according to table

below.

Connect plug to matching recep-

tacle on welding power source.

Tools Needed:

Replacing 115

Volts AC Plug

Connections For 115 Volts AC/Remote Contactor Plug And Cord

Connections For Contact Closure-Type Contactor Control

Leads

White

Orange And Green

Black

Red

Connect To

115 volts AC common.

Continuity closure for power source contactor closure.

115 volts AC hot.

Not used. Tape end to insulate from other connections.

OM-542 Page 4

6. Troubleshooting

Trouble

No weld output.

Remedy

Be sure welding power source Power switch is On.

Check cord connections or replace cords, if necessary.

Reset circuit breaker CB1 (see Section 5).

Check welding gun and/or wire feeder.

SA-143 280-C

7. Parts List

15161718

25 24 23 22 21 20

ST-148 377-C

1 +143 283 Wrapper (1). . . . . . .

2 131 515 Label, Warning (1). . . . . . . . .

3 Nameplate, (Order By Model And. . . . . . . . . . . . . . . . . Serial Number) (1)

4 143 282 Angle, Foot (2). . . . . . . . .

5 604 311 Grommet, .250 Id X .375Mtg Hole (4). . . . . . . . .

089 799 Screw, .250-20 X .500 (4). . . . . . . . . . .

152 461 Nut, .250-20 (4). . . . . . . . . . .

6 143 976 Connector W/Sockets (1). . . . . . . . .

7 011 244 Circuit Breaker, 2A 240VAC (1). . . . . . . . .

8 143 278 Insulator (1). . . . . . . . .

9 143 485 Transformer (1). . . . . . . . .

10 059 712 Clip, Component (1). . . . . . .

11 136 190 Nut, 10-32 (1). . . . . . . .

12 143 281 Enclosure (1). . . . . . .

13 006 393 Relay, 24VAC Dpdt (1). . . . . . .

14 123 741 Bracket (1). . . . . . .

15 010 325 Bushing, .840 Id X .875Mtg Hole (1). . . . . . .

16 600 343 Cable, No. 16 5/C (Order By Ft) (2ft). . . . . . .

17 079 531 Connector, Clamp Str Rlf (1). . . . . . .

18 046 958 Connector W/Pins (1). . . . . . .

19 081 964 Cable, Interconnecting (Consisting Of) (1). . . . . . .

20 048 284 Connector & Sockets (1). . . . . . . . .

21 079 531 Connector, Clamp Str Rlf (1). . . . . . . . .

22 604 571 Cable, No. 18 4/C (Order By Ft) (10ft). . . . . . . . .

23 039 687 Plug, Grd 2P3W 15A 277V (1). . . . . . . . .

24 049 455 Cable, No. 18 2/C (Order By Ft) (2ft). . . . . . . . .

25 039 635 Connector Body, 2P2W 20A 250V (1). . . . . . . . .

+When ordering a component originally displaying a precautionary la-

bel, the label should also be ordered.

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN

ORDERING REPLACEMENT PARTS.

Part

No.

Item

No. Description (Qty) Part

No.

Item

No. Description (Qty)

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