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Miller Electric
Welding System
S-21E
Miller Electric S-21E User Manual
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MiIIe~
November1996
Form:
TM-1571
Effective
With
Serial
No.
JJ507797
TECHNICAL
MANUAL
Service
And
Parts
Wire
Feed
Equipment
A
WARNING
SERVICING
can
be
hazardous.
•
Have
all
service
procedures
performed
only
by
qualified
persons
following
standard
safety
practices.
Use
MILLER
Testing
Booklet
(Part
No.
150
853)
when
servicing
this
unit.
Use
only
genuine
MILLER
replacement
parts.
S-21E
U
For
help,
call
Factory
~U~r
FAX:
U
Or
write
to:
Service
Department:
14-735-4136
MILLER
Electric
Mfg.
Co.
414-735-4505
L................J
RO.
Box
1079
Appleton,
WI
54912
USA
coverjml
—
SB-124
467
©
1996
MILLER
Electric
Mfg.
Co.
PRINTED
IN
USA
2
Table of Contents
Default Chapter
3
Table of Contents
3
Section no
4
Safety Precautions and Signal Words
5
General Information and Safety
5
Safety Alert Symbol and Signal Words
5
Safety Precautions
5
Section 2- Shipping and Storage
6
Preparation for Reshipment
6
Storage
6
Section 3- Specifications
7
Description
7
Section 4- Installation or Relocation
7
Location
7
Drive Roll Installation
7
Welding Gun Connections
9
Shielding Gas Installation
9
14-Pin Plug Connection
10
Welding Wire Installation
10
Welding Wire Threading
11
Adjust the Hub Tension
12
Welding Cable Connection
12
Feeding Welding Wire
12
Section 5-Operator Controls
13
Power Switch
13
Wire Speed Control
13
Section 6- Sequence of Operation
13
Gas Metal Arc (GMAW) and Flux Cored Arc (FCAW) Welding
13
Shutting down
14
Section 7- Theory of Operation
14
Theory of Operation
14
Diagram 7-1. Block Diagram for Wire Feeder
15
Diagram 7-2. Block Diagram for Spotlburnback Time Control Option
16
Section 8- Troubleshooting
18
Testing Instruments and Information
18
Circuit Board Handling Precautions
18
Troubleshooting
18
Diagram 8-1. Troubleshooting Circuit Diagram for Wire Feeder
20
Motor Board Pci Testing Information
21
Diagram 8-2. Troubleshooting Circuit Diagram for Motor Control Board Pci
22
Optional Spotlburnback Board PC2 Testing Information
24
Diagram 8-3. Troubleshooting Circuit Diagram for Optional Spot/Burnback Board PC2
26
Section 9- Component Identification and Location
28
Section 10- Maintenance
29
Routine Maintenance
29
10-2. Aligning Drive Roll and Wire Guide
30
Reinstallation of Hub Assembly
30
10-4. Brush Inspection and Replacement
30
10-5. Overload Protection
31
Electrical Diagrams
32
Section 11 Electrical Diagrams
32
Diagram 11-2. Wiring Diagram for S-21 E Effective with Serial no
33
Diagram 11-1. Circuit Diagram for S-21E Effective with Serial No. JJ507797 and Following
33
Effective with Serial No. JJ507797 Thru JK742028
35
Effective with Serial No. JK742029 and Following
36
JJ507797 and Following
33
Section 12- Parts List
37
4
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Miller Electric S-21E Specifications
General
Input Frequency
50/60 Hz
Output Current Range
30-90A
Wire Size Capacity
0.023 - 0.045 in (0.6 - 1.2 mm)
Wire Feed Speed
50-450 ipm
Input Phase
Single Phase
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