Miller Electric DS-2 User manual

Visit our website at
www.MillerWelds.com
Processes
Description
Wire Feeder
OM-197 509B
July 2002
DS-2
MIG (GMAW) Welding
Flux Cored (FCAW) Welding

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 orindividual 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.
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 figure out what the problem is. The
parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You
Milleroffers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.

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 3. . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – DEFINITIONS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Site Selection 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Equipment Connection Diagrams 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Installing Wire Guides And Drive Rolls 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. 10-Pin Plug PLG8 Information 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. 7-Pin Plug PLG1 Information 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. 10-Pin Plug And Shielding Gas Connections 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Connecting Weld Cable 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Connecting Welding Gun 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10.Changing Nameplates 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11.Installing Wire Spool And Adjusting Hub Tension 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12.Threading Welding Wire 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – OPERATION 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Pendant Controls 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – MAINTENANCE & TROUBLESHOOTING 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – ELECTRICAL DIAGRAM 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – PARTS LIST 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)

OM-197 509 Page 1
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.
YMarks a special safety message.
.Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary
actions to avoid the hazards.
1-2. Arc Welding Hazards
YThe symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-4. Read and
follow all Safety Standards.
YOnly qualified persons should install, operate, maintain, and
repair this unit.
YDuring operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is on.
The input power circuit and machine internal
circuits are also live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll housing, and all
metal parts touching the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is a hazard.
DDo not touch live electrical parts.
DWear dry, hole-free insulating gloves and body protection.
DInsulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
DDo not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
DUse AC output ONLY if required for the welding process.
DIf AC output is required, use remote output control if present on
unit.
DDisconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according
to OSHA 29 CFR 1910.147 (see Safety Standards).
DProperly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
DAlways verify the supply ground –check and be sure that input
power cord ground wire is properly connected to ground terminal
in disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
DWhen making input connections, attach proper grounding
conductor first –double-check connections.
DFrequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged –bare wiring can kill.
DTurn off all equipment when not in use.
DDo not use worn, damaged, undersized, or poorly spliced cables.
DDo not drape cables over your body.
DIf earth grounding of the workpiece is required, ground it directly
with a separate cable.
DDo not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
DUse only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
DWear a safety harness if working above floor level.
DKeep all panels and covers securely in place.
DClamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
DInsulate work clamp when not connected to workpiece to prevent
contact with any metal object.
DDo not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
DTurn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
FUMES AND GASES can be hazardous.
DKeep your head out of the fumes. Do not breathe the fumes.
DIf inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
DIf ventilation is poor, use an approved air-supplied respirator.
DRead the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
DWork in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
DDo not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
DDo not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.

OM-197 509 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 RAYS can burn eyes and skin.
DWear awelding 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 listed in Safety Standards).
DWear approved safety glasses with side shields under your
helmet.
DUse protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
DWear protective clothing made from durable, flame-resistant
material (leather and wool) and foot protection.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks,
hot workpiece, and hot equipment can cause fires
and burns. Accidental contact of electrode to metal objects can
cause sparks, explosion, overheating, or fire. Check and be sure the
area is safe before doing any welding.
WELDING can cause fire or explosion.
DProtect yourself and others from flying sparks and hot metal.
DDo not weld where flying sparks can strike flammable material.
DRemove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
DBe alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
DWatch for fire, and keep a fire extinguisher nearby.
DBe aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
DDo not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
DConnect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
DDo not use welder to thaw frozen pipes.
DRemove stick electrode from holder or cut off welding wire at
contact tip when not in use.
DWear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
DRemove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
DWelding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
DWear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
DShut off shielding gas supply when not in use.
DAlways ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
DDo not touch hot parts bare handed.
DAllow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
DPacemaker wearers keep away.
DWearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
DWear approved ear protection if noise level is
high.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding
process, be sure to treat them carefully.
CYLINDERS can explode if damaged.
DProtect compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flames, sparks, and arcs.
DInstall cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
DKeep cylinders away from any welding or other electrical circuits.
DNever drape a welding torch over a gas cylinder.
DNever allow a welding electrode to touch any cylinder.
DNever weld on a pressurized cylinder –explosion will result.
DUse only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
DTurn face away from valve outlet when opening cylinder valve.
DKeep protective cap in place over valve except when cylinder is in
use or connected for use.
DRead and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.

OM-197 509 Page 3
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
DDo not install or place unit on, over, or near
combustible surfaces.
DDo not install unit near flammables.
DDo not overload building wiring –be sure power supply system
is properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
DUse lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
DUse equipment of adequate capacity to lift and
support unit.
DIf using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
OVERUSE can cause OVERHEATING
DAllow cooling period; follow rated duty cycle.
DReduce current or reduce duty cycle before
starting to weld again.
DDo not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
DPut on grounded wrist strap BEFORE
handling boards or parts.
DUse proper static-proof bags and boxes to
store, move, or ship PC boards.
MOVING PARTS can cause injury.
DKeep away from moving parts.
DKeep away from pinch points such as drive
rolls.
WELDING WIRE can cause injury.
DDo not press gun trigger until instructed to do
so.
DDo not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
MOVING PARTS can cause injury.
DKeep away from moving parts such as fans.
DKeep all doors, panels, covers, and guards
closed and securely in place.
H.F. RADIATION can cause interference.
DHigh-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
DHave only qualified persons familiar with
electronic equipment perform this installation.
DThe user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
DIf notified by the FCC about interference, stop using the
equipment at once.
DHave the installation regularly checked and maintained.
DKeep high-frequency source doors and panels tightly shut,
keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.
ARC WELDING can cause interference.
DElectromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
DBe sure all equipment in the welding area is
electromagnetically compatible.
DTo reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
DLocate welding operation 100 meters from any sensitive elec-
tronic equipment.
DBe sure this welding machine is installed and grounded
according to this manual.
DIf interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances,
American Welding Society Standard AWS F4.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-197 509 Page 4
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
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
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.

OM-197 509 Page 5
SECTION 2 –DEFINITIONS
A. Warning! Watch Out! There
are possible hazards as
shown by the symbols.
B. Drive rolls can injure fingers.
C. Welding wire and drive parts
are at welding voltage during
operation –keep hands and
metal objects clear.
1 Electric shock can kill.
1.1 Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet
or damaged gloves.
1.2 Protect yourself from electric
shock by insulating yourself
from work and ground.
1.3 Disconnect input plug or
power before working on
machine.
2 Breathing welding fumes can
be hazardous to your health.
2.1 Keep your head out of the
fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove
fumes.
3 Welding sparks can cause
explosion or fire.
3.1 Keep flammables away from
welding. Don’t weld near
flammables.
3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby and have a watch
person ready to use it.
3.3 Do not weld on drums or any
closed containers.
4 Arc rays can burn eyes and
injure skin.
4.1 Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
5 Become trained and read the
instructions before working
on the machine or welding.
6 Do not remove or paint over
(cover) the label.
2-1. Warning Label Definitions
A
BC

OM-197 509 Page 6
SECTION 3 –INSTALLATION
3-1. Specifications
Welding Power
Source Type Type of Input Power Wire Feed Speed Range
Wire
Diameter
Range
Welding Circuit
Rating Overall Dimensions Weight
Deltaship
Constant Voltage
(CV) DC With
10-Pin Receptacle
24 Volts DC (5
Amp) For Wire
Feed Motor
24 Volts AC (0.5
Amp) For Gas
Valve
0 to 780 ipm
(0 To 20 mpm)
Solid Wire
.045 To 1/16 in
(1.2 To 1.6 mm)
Flux Cored Wire
.045 To .068 in
(1.2 To 1.7 mm)
Max Spool
Weight:
44 lb (20 kg)
38 Volts,
350 Amperes,
100% Duty Cycle
Length: 20-7/8 in
(530 mm)
Width: 9 in (229
mm)
Height: 13-3/4 in
(286 mm)
17.5 lb (8 kg)
3-2. Site Selection
Ref. ST-802 483-A
1 Wire Feeder
2 Gas Cylinder (Customer
Supplied)
YDo not put feeder where
welding wire hits cylinder.
YDo not move or operate
equipment when it could tip.
2
1

OM-197 509 Page 7
3-3. Equipment Connection Diagrams
1 Deltaship 502 Welding Power
Source With 24 VAC Power
2 10-Pin Control Cord
3 Positive Weld Cable
(Customer Supplied)
4 Work Cable (Customer
Supplied)
5 Work
6 Wire Feeder
7 Welding Gun
8 Gas Hose (Customer
Supplied)
5
3
2
167
4
8
3-4. Installing Wire Guides And Drive Rolls
Ref. ST-802 483-A / ST-802 481
1 Pressure Assembly Knob
2 Pressure Assembly Arm
Move Knob to the right, and pres-
sure arm pops up.
3 Inlet Wire Guide
4 Inlet Wire Guide Securing
Screw
To change inlet wire guide, loosen
screw and remove guide.
5 Outlet Wire Guide
6 Outlet Wire Guide Securing
Screw
To change outlet wire guide, loos-
en screw and remove guide out
front of gun block.
7 Lower Drive Roll
8 Coned Spacer Washer
9 Thumb Screw
To change drive roll, remove thumb
screw and coned spacer washer,
and slide drive roll off shaft. Be sure
holes in drive roll line up with pins
on gear.
10 Retaining Clip
11 Upper Drive Roll
12 Gear
13 Pin
To change upper drive roll, remove
retaining clip from pin. Slide pin
out, and lift drive roll and gear out
of pressure arm. When installing
upper drive roll, be sure holes in
drive roll line up with pins on gear.
14 Drive Roll Size
When installing a drive roll, either
into the pressure arm or onto the
lower gear adapter, install drive roll
with the wire size stamp of the wire
being used (i.e. 1.2 mm) facing the
operator, even though the corre-
sponding wire groove is on the op-
posite side of the drive roll.
Tools Needed:
4
35
7
11
12
13
10
2
1
6
9
8
1.2 mm
Corresponding 1.2 mm
Wire Groove
1.2 mm Wire
Size Stamp
14

OM-197 509 Page 8
3-5. 10-Pin Plug PLG8 Information
Pin Pin Information
A24 volts ac for gas valve control when triggered or purging gas.
B+15 volts dc with gun trigger open; 0 volts dc with gun trigger closed.
CCircuit common.
D0 to +10 volts dc output from min to max of Output Command control R1.
E+10 volts dc input.
F0 to +10 volts dc output from min to max of Wire Speed control R2
G+15 volts dc with Jog switch S3 open; 0 volts dc with switch closed.
HMotor positive (+), (0 to +24 volts dc input to wire drive motor M1 with respect to pin I.)
IMotor negative (–).
JNot used
3-6. 7-Pin Plug PLG1 Information
Pin Pin Information
1Not used.
2Not used.
3Circuit common.
40 to +10 volts dc output from min to max of Output Command control R1.
5+10 volts dc input.
60 to +10 volts dc output from min to max of Wire Speed control R2
197 504 7+15 volts dc with Jog switch S3 open; 0 volts dc with switch closed.
1 Gas Hose (Customer
Supplied)
Connect to gas supply.
2 10 Pin Plug PLG8
Use plug to make connection to
welding power source.
3 Weld Cable w/Quick Connect
3-7. 10-Pin Plug And Shielding Gas Connections
Ref. St–802 483-A
Tools Needed:
1
11/16 in
2
3

OM-197 509 Page 9
1 Female Weld Cable Connec-
tor (Supplied)
2 Weld Cable (Customer Sup-
plied)
Select weld cable according to
welding power source Owner’s
manual.
Install female weld cable connec-
tor as shown.
3 Male Weld Cable Connector
Connect male and female weld
cable connectors.
3-8. Connecting Weld Cable
Ref. ST-802 483-A
2
3
A. Push weld cable through insulator as shown.
B. Remove 1 in. (25 mm) of insulation from end of cable.
C. Install supplied sleeve on stripped end of cable.
D. Insert cable with sleeve into connector body so that cable is
snug and against bottom of connector body.
E. Install and tighten setscrew with supplied hex wrench to se-
cure connector body onto cable.
F. Push insulator onto connector body to cover setscrew.
1
1
Insulator
Weld Cable
Sleeve
Setscrew
Connector Body
(Male Or Female)
2

OM-197 509 Page 10
1 Gun Securing Knob
Loosen knob.
2 Gun Block
3 Gun End
Slide gun end as far as possible
into gun block and tighten gun se-
curing knob.
4 Gun Trigger Plug
Connect gun trigger plug to match-
ing receptacle on wire feeder.
3-9. Connecting Welding Gun
Ref. ST-802 483-A
12
3
4
1 Pendant
2 Nameplates
Pendant has three nameplates
stacked one on top of the other.
Each nameplate contains the volt-
age and amperage ranges for a dif-
ferent size flux cored welding wire
(for reference only).
Unit is shipped with 1.2 mm wire
nameplate on top. To change to 1.4
mm or 1.6 mm wire nameplate, re-
move the four screws and bring the
desired nameplate to the front.
Install the four (4) screws back in
place to hold the nameplates.
3-10. Changing Nameplates
Ref. ST-802 483-A
1
2
Tools Needed:
5/16 in

OM-197 509 Page 11
3-11. Installing Wire Spool And Adjusting Hub Tension
Ref. ST-802 483-A / Ref. ST-072 573-B
When a slight force is needed
to turn spool, tension is set.
15/16 in
Tools Needed:
1 Hub Support Arm
2 Spool Hub
3 Retaining Ring
4 Hub Pin
Remove retaining ring. Slide wire
spool onto spool hub so wire feeds
off bottom of spool . Install spool so
hub pin fits spool hole. Reinstall re-
taining ring.
5 Tension Nut
Adjust tension nut so a slight force
is needed to turn spool.
1
2
3
5
2
4

OM-197 509 Page 12
3-12. Threading Welding Wire
Tools Needed:
1 Pressure Assembly
2 Pressure Assembly
Adjustment Knob
Lay gun cable out straight.
A Open pressure assembly,
hold wire tightly, and cut off
end. Push wire through guides
into gun.
B Close and tighten pressure
assembly, and let go of wire.
C To adjust drive roll pressure,
press gun trigger to feed wire
against wood surface. Tighten
knob so wire does not slip.
Cut off wire.
Ref. ST-802 483-A
WOOD
Tighten
12
A
C
B

OM-197 509 Page 13
SECTION 4 –OPERATION
4-1. Pendant Controls
Controls are pendant mounted. An optional
remote pendant extension cord is available.
1 Nameplate
Pendant has three nameplates stacked one
on top of the other. Each nameplate contains
the voltage and amperage range for a differ-
ent size flux cored welding wire (for reference
only).
Unit is shipped with 1.2 mm wire nameplate
on top. See Section 3-10 to change to 1.4 mm
or 1.6 mm flux cored welding wire nameplate.
2 Voltage Control
Use control to set welding power source volt-
age at the wire feeder. Numbers are for refer-
ence only.
3 Wire Speed Control
Use control to adjust wire feed speed from 0
to 20 meters per minute.
.Match colored bands on voltage and wire
speed controls to get an acceptable
welding condition.
4 Jog Switch
Use Jog switch to momentarily feed welding
wire at speed set on Wire Speed control with-
out energizing welding circuit or shielding gas
valve.
Ref. ST-802 483-A / ST-199 348 / ST-199 350 / 199 343
2
4
3
1
Use Nameplates As A Voltage And Amperage Reference Only.

OM-197 509 Page 14
SECTION 5 –MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance
YDisconnect power before maintaining.
3 Months
Replace
Unreadable
Labels
Clean And
Tighten
Weld
Terminals
Repair Or
Replace
Cracked
Weld Cable
10-Pin Cord Gas HoseGun Cable
Replace
Cracked
Parts
6 Months
Blow Out Or Vacuum
Inside,
During Heavy Service,
Clean Monthly
OR
Clean
Drive
Rolls
5-2. Troubleshooting
Trouble Remedy
No weld output; unit completely
inoperative. Place line disconnect switch in On position (see welding power source owner’s manual).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see welding power source
owner’s manual).
Check for proper input power connections (see welding power source owner’s manual).
Check for proper jumper link position (see welding power source owner’s manual).
No weld output; Power switch pilot
light on. Check, repair, or replace feeder (see welding power source owner’s manual).
Unit overheated. Allow unit to cool with fan On (see welding power source owner’s manual).
Have Factory Authorized Service Agent check control board PC1 and/or motor drive board PC2.
Unit provides only maximum or
minimum weld output. Have Factory Authorized Service Agent check control board PC1, motor drive board PC2 and Hall Device HD1.
Erratic or improper weld output. Use proper size and type of weld cable (see welding power source owner’s manual).
Clean and tighten all weld connections.
Check wire feeder installation (see Section 3-3
Use proper tap on stabilizer (see welding power source owner’s manual).
Have Factory Authorized Service Agent check control board PC1, motor drive board PC2 and/or
SCR in main rectifier.
No 115 volts ac output at duplex re-
ceptacle. Reset circuit breaker CB1 (see welding power source owner’s manual).

OM-197 509 Page 15
Trouble Remedy
Fan in welding power source not oper-
ating. Note: fan runs only when cool-
ing is necessary.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
Wire does not feed, unit completely
inoperative. Check 10–pin plug PLG8 connections (see Section 3-7).
Check input power.
Wire does not feed. Check circuit breaker CB2 on welding power source, and reset if necessary (see welding power source
owner’s manual).
Check gun trigger connection at wire feeder (see Section 3-9). Check gun trigger leads and trigger
switch.
Have Factory Authorized Service Agent check drive motor, control board PC1, and motor board PC2.
Wire feeds erratically. Readjust hub tension and drive roll pressure (see Section 3-11 and 3-12).
Use correct size drive roll (see Parts List).
Clean or replace dirty or worn drive roll (see 3-4 Section).
Remove weld spatter around nozzle opening.
Replace contact tip or liner.
Have Factory Authorized Service Agent check drive motor and control board PC1.
Wire feeds when Jog switch is pressed
but not when gun trigger is pressed. Check gun trigger connection at wire feeder (see Section 3-9). Check gun trigger leads and trigger switch.
Wire feeds as soon as power is applied. Check gun trigger.
Wire does not feed until trigger is
pressed, but continues to feed after
trigger is released.
Check position of Mode switch on welding power source. This is normal operation when switch is in
Crater Fill On or Trigger Hold On positions (see welding power source owner’s manual).
Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads.
Gas valve rattles loudly and wire feeds
slowly or erratically. Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads.
Gas does not flow; wire feeds. Check gas valve and flowmeter.

OM-197 509 Page 16
SECTION 6 –ELECTRICAL DIAGRAM
203 365
Figure 6-1. Circuit Diagram For Wire Feeder