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Miller Electric S-32S manual

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Table of contents for the manual

  • Page 1

    Visit our website at www.MillerWelds.com OM-1546 090 004M August 2000 Processes Description MIG (GMA W) W elding Flux Cored (FCA W) W elding Wire Feeder S-32S And S-32SL[...]

  • Page 2

    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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 4

    [...]

  • Page 5

    OM-1546 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means W arning! W atch[...]

  • Page 6

    OM-1546 Page 2 Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D 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 Z8[...]

  • Page 7

    OM-1546 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. F [...]

  • Page 8

    OM-1546 Page 4 1-5. EMF Information Considerations About W elding And The Effects Of Low Frequency Electric A n d M a g netic Fields W elding 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 years [...]

  • Page 9

    OM-1546 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives. Y Identifie un message de s é curit é particulier .[...]

  • Page 10

    OM-1546 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage. LES RA YONS DE L ’ ARC peuvent pro- voquer des br û lures dans l[...]

  • Page 11

    OM-1546 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance Risque D ’ INCENDIE OU D ’ EXPLOSION. D Ne pas placer l ’ appareil sur , au-dessus ou à proxi- mit é de surfaces infllammables. D Ne pas installer l ’ appareil à proximit é de produits inflammables D Ne pas surcharger [...]

  • Page 12

    OM-1546 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American Wel- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Of fice, Washington, D.C. 20402. Recommended Safe Practice for the[...]

  • Page 13

    OM-1546 Page 9 SECTION 2 – INST ALLA TION 2-1. Specifications T ype Of Input Power W elding Power Source T ype Wire Feed Speed Range Wire Diameter Range Input W elding Circuit Rating Max. Wire Spool Capacity Overall Dimensions W eight Open-Circuit/ Arc V oltage, 15 T o 100 V olts DC Constant V oltage (CV) Or Constant Current (CC) DC Standard: 50 [...]

  • Page 14

    OM-1546 Page 10 2-2. Installing And Aligning Wire Guide And Drive Roll 3/16 in Ref. ST-091 547-D / Ref. ST -1 12 370-C / S-0856 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 line u p with lobes[...]

  • Page 15

    OM-1546 Page 1 1 1 CV Welding Power Source With 24 V AC Power 2 CC Welding Power Source Without Contactor 3 External Secondary Contactor 4 Remote Contactor Cord 5 Weld Cable 6 W ork 2-3. T ypical Connections 1 6 5 6 5 3 2 4 1 Gun Securing Knob 2 Gun Block 3 Gun Outlet Wire Guide Loosen knob, insert gun into block. Position outlet wire guide as clos[...]

  • Page 16

    OM-1546 Page 12 1 Gas Hose With 5/8-18 Right- hand Thread Fittings (Cus- tomer Supplied) 2-5. Connecting Shielding Gas (Optional) Ref. ST-158 789 T ools Nee d e d : 1 5/8 in 2-6. Installing W elding Wire And Adjusting Hub T ension Ref. ST-158 788 / ST -091 601-A 1 Retaining Ring 2 Wire Spool 3 Hub 4 Spool Support If necessary , move hub on support [...]

  • Page 17

    OM-1546 Page 13 1 Pressure Assembly Adjust- ment Knob Lay gun cable out straight. A Open pressure assembly , hold wire tightly , and cut of f end. Push wire through guides into gun. B Close and tighten pressure assembly . Press gun trig- ger until wire comes out gun. C T o adjust wire pressure, feed wire against wooden surface and tighten knob so w[...]

  • Page 18

    OM-1546 Page 14 SECTION 3 – OPERA TION 3-1. Controls Ref. ST-091 547-D / ST -176 214 2 4 Selector Switch for T ype of Power Source Constant V oltage CV Constant Current (drooper) CC S-090 438-D 1 Wire Speed Control (See Sec- tion 3-2) 2 Power Control Switch 3 Circuit Breaker CB1 CB 1 protects wire feeder from over- load. Correct problem and manua[...]

  • Page 19

    OM-1546 Page 15 Wire Speed Setting CC Mode 100 90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 100 222 254 268 295 314 342 365 388 406 429 452 480 498 526 549 572 595 623 205 234 246 271 288 313 334 354 370 391 412 437 453 478 499 520 541 566 188 213 224 246 261 284 302 320 335 353 372 394 408 430 449 468 486 508 170 193 203 222 235 254 2[...]

  • Page 20

    OM-1546 Page 16 SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace Unreadable Labels Clean And T ighten W eld T erminals Repair Or Replace Cracked W eld Cable Gas Hose Gun Cable Replace Cracked Parts 6 Months Blow Out Or V acuum Inside, During Heavy Service, Clean Monthly[...]

  • Page 21

    OM-1546 Page 17 SECTION 5 – ELECTRICAL DIAGRAM SB-176 227 Figure 5-1. Circuit Diagram For Wire Feeder[...]

  • Page 22

    OM-1546 Page 18 SECTION 6 – P ARTS LIST Figure 6-1. Main Assembly ST-091 506-K . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 15 14 17 18 19 22 21 20 12 23 24 25 26 27 28 29 30 – FIG. 6 – 2 31 33 34 35 36 32 37 38 39 40 41 42[...]

  • Page 23

    OM-1546 Page 19 Figure 6-1. Main Assembly Description Quantity Part No. Dia. Mkgs. Item No. 1 097 770 LABEL, warning electric shock can kill 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 +089 818 WRAPPER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 24

    OM-1546 Page 20 Figure 6-2. Motor & Wire Drive Assembly (Fig 6-1 Item 30) Description Quantity Part No. Dia. Mkgs. Item No. 1 166 338 LEVER, mtg pressure gear 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 166 072 SP ACER, gear 1 . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 25

    OM-1546 Page 21 T able 6-1. Drive Roll & Wire Guide Kits Base selection of drive rolls upon the following recommended usages: 1. V -Grooved rolls for hard wire. 2. U-Grooved rolls for soft and soft shelled cored wires. 3. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). 4. V -Knurled rolls for hard shelled cored w[...]

  • Page 26

    OM-1546 Page 22 Notes[...]

  • Page 27

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 Y o ur distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expertise [...]

  • Page 28

    PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Com pany 1635 W est S pencer St reet Applet on, WI 54914 USA International He adquarters – USA USA Phone: 920-735-4505 Auto-A t t ended USA & Canada F AX : 920-735-4134 Int ernati onal FAX: 920-735-4125 European Headqua rters – United[...]