Table of Contents
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Read and follow these instructions and all
safety blocks carefully.
Have only trained and qualified persons
install, operate, or service this unit.
Call your distributor if you do not understand
the directions.
cover 7/93 – ST-155 507-A
OWNER'S
MANUAL
Gold Seal
CV/DC Welding Power Source/Wire Feeder
For FCAW And GMAW Welding
90 Amperes, 18 Volts At 20% Duty Cycle
Uses 115 Volts AC, Single-Phase Input Power
Overheating, Short-Circuit, And Motor Overload Protection
Usable Range Of 30 To 130 Amperes
Includes Gun, Welding Wire, And Gas Valve
1997 MILLER Electric Mfg. Co.
October 1997
Form: OM-174 470B
Effective With Serial No. KH531011
Model 420
Give this manual to the operator.
For help, call your distributor
or: MILLER ELECTRIC Mfg. Co., P.O. Box
1079, Appleton, WI 54912
414-734-9821
PRINTED IN USA
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Table of Contents
Troubleshooting
Related Manuals for Miller Gold Seal Model 420
Summary of Contents for Miller Gold Seal Model 420
- Page 1 Have only trained and qualified persons For help, call your distributor install, operate, or service this unit. Call your distributor if you do not understand or: MILLER ELECTRIC Mfg. Co., P.O. Box the directions. 1079, Appleton, WI 54912 414-734-9821 1997 MILLER Electric Mfg. Co.
- Page 3 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 instructions. WARNING WARNING statements identify procedures or practices which must be followed to avoid serious personal injury or loss of life.
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Page 4: Table Of Contents
5. Watch for fire, and keep a fire extinguisher nearby. WELDING can cause fire or explosion. Sparks and spatter fly off from the welding arc. The 6. Be aware that welding on a ceiling, floor, bulkhead, or partition flying sparks and hot metal, weld spatter, hot can cause fire on the hidden side. -
Page 5: Section 1 - Specifications
SECTION 1 – SPECIFICATIONS Table 1-1. Welding Power Source Specifications Description Type Of Output Direct Current/Constant Voltage (DC/CV) Rated Weld Output 90 Amperes, 18 Volts DC, 20% Duty Cycle Type Of Input Power Single-Phase; 60 Hz; At 115 Volts AC Input Amperes At Rated Output 20 A At 115 V KVA/KW Used At Rated Output... -
Page 6: Section 2 - Installation
SECTION 2 – INSTALLATION 2-1. Installing Work Clamp Insulator Bolt Smaller Hole Work Clamp Tabs Bend tabs around work cable. Work Cable From Unit Tools Needed: 3/8, 7/16 in Ref. ST-025 190-D Figure 2-1. Installing Work Clamp 2-2. Installing Gas Supply WARNING CYLINDERS can explode if damaged. -
Page 7: Connecting Input Power
2-3. Connecting Input Power Connect unit to a properly grounded receptacle of a 20 ampere individual branch circuit protected by time-delay fuses or circuit breakers. Select an extension cord of 12 AWG for up to 75 ft (23 m) or 10 AWG for up to 140 ft (46 m). 2-4. -
Page 8: Threading And Feeding Welding Wire
2-6. Threading And Feeding Welding Wire WARNING CYLINDERS can explode if damaged. WELDING WIRE can cause puncture wounds. Keep cylinders away from welding and other electrical circuits. Do not press gun trigger until instructed to do so. Never touch cylinder with welding electrode. Do not point gun toward any part of the body, other people, or any metal when threading welding wire. -
Page 9: Section 3 - Operation
SECTION 3 – OPERATION READ SAFETY BLOCKS at beginning WARNING of manual before proceeding. MOVING PARTS can cause injury. ARCING can damage switch. Keep away from pinch points such as drive rolls. Do not change Voltage switch position while welding. Keep all doors, panels, covers, and guards closed and securely in place. -
Page 10: Section 4 - Maintenance & Troubleshooting
SECTION 4 – MAINTENANCE & TROUBLESHOOTING WARNING ELECTRIC SHOCK can kill. MOVING PARTS can cause injury. Do not touch live electrical parts. Keep away from moving parts. Turn Off welding power source, and disconnect Keep away from pinch points such as drive rolls. input power before inspecting, maintaining, or servicing. -
Page 11: Drive Assembly Maintenance
C. Short Circuit Shutdown If contact tip is shorted and sticks to workpiece, the unit shuts down, but fan runs. To resume operation, release gun trigger, turn Off unit, and remove contact tip from workpiece. Check contact tip and replace if damaged. Turn On unit to continue operation. -
Page 12: Gun Maintenance
4-3. Gun Maintenance READ SAFETY BLOCKS at start of WARNING Section 4 before proceeding. FLYING METAL CHIPS AND DIRT can cause injury and damage equipment. Point gun away from people and in a safe direction when blowing out with compressed air. swarn10.1 10/91 Turn Off and unplug unit. -
Page 13: Section 5 - Electrical Diagram
Wire Drive/Gun Trouble Remedy Section Electrode wire feeding stops during Straighten gun cable and/or replace damaged parts. welding. Adjust drive roll pressure. Readjust hub tension. Replace contact tip if blocked. Clean or replace wire inlet guide or liner if dirty or plugged. 4-2, 4-3 Replace drive roll or pressure bearing if worn or slipping. - Page 14 NOTES OM-174 470 Page 10...
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Page 15: Section 6 - Parts List
SECTION 6 – PARTS LIST ST-155 532-A Figure 6-1. Main Assembly OM-174 470 Page 11... - Page 16 Parts For Main Assembly NOTE: All items indented by a dot(s) are included with the item listed directly above. Item Part Item Part Item Part Description Description Description 149 332 Hose Clamp *073 426 · Fuse, slo-blo 5A 155 530 ·...
- Page 17 Suggested Welding Settings Wire Type, Metal Thickness Wire Operator Shielding Gas, Diameter Control 1/8 in. 22 ga. And 12 ga. 14 ga. 16 ga. 18 ga. 20 ga. And Flow Rate (inch) Settings* (3.2 mm) Thinner Voltage – 0.030 Wire Speed –...
- Page 19 LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT & PLAZCUT Model Plasma Cutting below, Miller Electric Mfg. Co., Appleton, Wisconsin, Torches warrants to its original retail purchaser that new Miller Remote Controls...