Miller PSA-2 User manual

OWNER’S MANUAL
©2009 MILLER Electric Mfg. Co.
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.
1
2
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
2
1
3
2
5
41
1
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.
4
5
Tools Needed:
Replacing 115
Volts AC Plug
3
2
1
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
12
3
4
5
67
8
9
14
15161718
25 24 23 22 21 20
19
ST-148 377-C
10
11
12
13
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)