Miller Electric MS Weld Control User manual

February

1976

FORM:

OM-1510

Effective

with

serial

No.

HE787389

MODEL

Weld

Control

STOCK

NO.

079

065

MODEL/STOCK

NO.

SERIAL/STYLE

NO.

DATE

PURCHASED

ADDITIONAL

COPY

PRICE

CENTS

OWNERS

MANUAL

MILLER

ELECTRIC

MFG.

CO.

APPLETON,

WISCONSIN,

USA

54911

NWSA

CODE

NO.

4579

LIMITED

WARRANTY

MILLER

Electric

Mfg.

Co.,

Appleton.

Wisconsin,

warrants

all

new

equipment

free

from

defects

material

and

factory

workmanship

for

the

periods

indicated

below,

provided

the

equipment

installed

and

operated

according

manufacturers

Instructions.

MILLER

Electric

Mfg.

Cos

obligation,

under

this

warranty,

expressly

limited

replacing

repairing

any

defective

part

correcting

any

manufacturing

defect

without

charge

during

the

warranty

period

MILLERS

inspection

confirms

the

existence

such

defects.

MILLERs

option

repair

replacement

will

f.o.b.

factory

Appleton,

Wisconsin

f.o.b.

MILLER

authorized

service

facility,

and

therefore

compensation

for

transportation

costs

any

kind

will

allowed.

The

warranty

period,

beginning

the

date

sale

the

original

purchaser.user

the

equipment,

will

follows:

Arc

welders,

power

sources,

and

components



year

Original

main

power

rectifiers



years

(unconditionally)

MHG-20E,

20K

and

all

guns



days

All

other

Millermatic

Feeders



year

Mag-Diesel

engine

DEL-200



months

All

other

engines

year

The

labor

expense

installing

original

main

power

rectifiers

after

being

service

one

year

will

the

owners

responsibility.

Engine

Warranties

are

covered

the

engine

manufacturers,

subject

their procedures

and

handled

through

their

authorized

local

Service

Stations

agencies.

warranty

will

made

respect

trade

accessories,

such

being

subject

the

warranties

for

their

respective

manufacturers.

MILLER

Electric

Mfg.

Co.

will

not

liable

for

any

loss

consequential

damage

expense

accruing

directly

indirectly

from

the

use

equipment

covered

this

warranty.

This

warranty

supersedes

all

MILLER

warranties

and

exclusive

with

other

guarantees

warranties

expressed



implied.

~tQtQW1~LQfiLQOJ~QJWJ1P.flfiJJ

ttOJQ

QWtQ~L



c.I

OTO~OT1O

OT~1O~OTO~TOOTbTOOTWOTQo

OTO

OTbTOTOTOThTO0

bTbb

CTC

ERRATA

SHEET

After

this

manual

was

printed,

refinements

equipment

design

occurred.

This

sheet

lists

exceptions

data

appearing

later

this

manual.

AMENDMENT

SECTION

3

FUNCTION

CONTROLS

~NOTE~

The

circuit

1manual.

diagram(s)

this

supplement

replace

any

other

circuit

diagram(s)

appearing

later

this

Circuit

Diagram

No.

C-003

161-B

Amend

Figure

3-2

follows:

I..

___________________________________________________________________________

;flcff~

A.~.

r~r

I

at

~a~~

aoo

Figure

3-2.

Circuit

Diagram

For

Models

Effective

With

Serial

No.

HE787389

Thru

HH023189

c-tn

POWIR

WORIC

----LW

r~,

.a,()a.

___

_____

______

~E~i~_:~J

~I1~J

a

OM-1510

Page

OM-1510

Page

Figure

3-2.

Circuit

Diagram

For

Models

Effective

With

Serial

No.

HH023190

Thru

HH050888

HIS

~,.

1~2

APLO,

IL,

R1000E

GXS

FI.U0

ROPOPS

i

IRMOTE

FIXTURE

.SA~W

MAO.

55-

____________

5000900O~

1J2

AILGS

z:::i:~~~

_______

PLR4

C5C5

r-i



11CR

CR,

X(I

~?~~~L?}S



_i::~~i

z.~



SAC



jjl_

MOTOR

bARD

Ill

I3I~

121

2.1

1~–j2

Dy

lAO

AS??

REMOTE

START

STOP

V

14?

4lP~~2

C~~El~~T

_________



________________

~j

,26–~L__

~lcfi

TCj~~~i2A

fIX

_________T~AJ

~DT

912

915

~O,3

~l1U,.

~99o

09;

iI;

~~ES

STOPS

UREA

~T3UW:~S~012I

-_.~E~

~Z1~

)C~~,__4

)o.~

DjjI

;iv

IMERGETICT

CS1

___

I~

C;,1

U3R~

PROGRAM

ERAS.

033

Circuit

Diagram

No.

C-039

428

III-

115W

JAA

WER

WORK

~WT

P51802

A A

r~i

IL1

I~5Wj

REMOTE

CR5

FLUX

HOPPER

I

REMOTE

FIXTURE

115

.5AMP

MAX.

ISV.

5000

000,

25.

PAN

SUKNS~5

BEll?

C~UC5

9(1

D.~1

W1TD

15111121

RFCR

~

~R,EzC*I

kn.os~J

T4C~

_________

P1.04

RC4

_________________

–If:

~0E~

+4RE~~

sd?1

RECS

REC.

.~O3



0v1R~

i~~

H-

lOAN



a;

0

REMOTE

START

STOP

?~?PLG2

CURRETIT

~y

RC2

CR2

RELAY

~

~i1I~

_______



______

________________

t~~se

j~.

.T5~)

~rT

,,~

BAN

.L1 j 1

..~

~60

o_,

~LOIRI..J

LJRI~5T

PR.

IP(O



TIMEISF

lRIFLOW

START

PRE.

SIN

JUMPER

L.~

I I

FLOW

SEE

M,O

CW$

IANSUAL

57 2



22t

_____

~ZR.

~~TAR

____

~~?ZA

C19

TIA~





TIP

~?I

014

0.5

0fl3

HIS

D3R

402.

~O20

022

033

______________________________

032

034

TCR

_________________________

________________________

RCA1.

RESISTORS

US(D

ONLH

R(QUJIEO

,..

~~i

Cl?

REMOTE

lUMPER

FXOM~

__IL

~IE-1~

)22

DJ11

)OIS

)

)~

REMOTE

EMERGEIACP

SlOP

USED

(_3

rc~

11j

~r,R

1211

T3S~

155

PROGRAM

bARD

P5.522

_______

I___~-











035

Figure

3-2.

Circuit

Diagram

For

Models

Effective

With

Serial

No.

HH050890

And

Following

circuit Diagram

No.

C-053

192

OM-1510

Page

Item

Dia.

Part

No.

Listed

Replaced

With

ftem3l

079281

Item5O

073211

Item

030

131

Jtem56

073722

Item57

073719

ftem72

073642



Item

602

071

Page

073

535

Page4

605919



Page

074026

Page4

R15

078429

CR4

073715

039482

C3.15

073714

073716

C5,12,21

073740

C6,9.14,18

073739

C7,8,11,17

073738

C10,13,19

073732

C16

073737

C20

073547

01,4-18,20-

23,27,29,

32.36

D19

01,4,9,11

13,15

02,3,10

05,7,8,

12,14

037289

016

073710

078426

605909

R3,20

605910

030853

R5,21

605916

078434

,14,17,

24,27,29,

10,

12,

19,

605

908

R13,16,28

605911

R15

035830

R18,26

078428

R22

078431

R23

030091

R30

078433

R34,35,36

605919

R38

030016

SR1,2

074453

T1,2,4

073

682

T3,5,6

000

350

Item

075

318

Page

No.

Mkgs.

Parts

List

Part

No.

Description

Quantity

PB3

PB3,4

2,4,5,6.

052

841

CIRCUIT

CARD

ASSEMBLY,

program

(Eff

with

S/N

HH050890)

(See

NOTE

below

for

components

052

841)

075

077

SCREW,

cap

brass

hex

5/8-1

052

602

BEZEL,

meter

double

079

361

POTENTIOMETER,

carbon

turn

watt

55K

ohm

(Eff

with

S/N

HH023173)

Deleted

(Eff

with

S/N

HH050890)

073

719

SWITCH,

push

button

(qty.

change)

073 639

POTENTIOMETER,

carbon

turn

0.5

watt

50K

ohm

602

071

SCREW,

(qty.

change)

Deleted

(Eff

with

S/N

HH023190)

Deleted

(Elf

with

S/N

HH023190)

Deleted

(Eff

with

S,N

HH023190)

035

830

RESISTOR,

carbon

film

0.25

watt

6800

ohm

(Eff

with

S/N

HH023190)

039

498

RELAY,

enclosed

115

volts

3PDT

NOTE



Components

for

052

841

CAPACITOR,

tantalum

0.15

volts

CAPACITOR,

electrolytic

100

volts

CAPACITOR,

tantalum

0.22

volts

CAPACITOR,

tantalum

0.1

volts

CAPACITOR,

ceramic

0.01

volts

CAPACITOR,

ceramic

0.1

volts

CAPACITOR,

ceramic

0.68

volts

CAPACITOR,

electrolytic

volts

CAPACITOR,

electrolytic

volts

CAPACITOR,

mylar

0.33

200

volts

073

540

DIODE,

signal

0.15

amp

volts

reverse

polarity

037

386

DIODE,

zener

volts

watt

straight

polarity

073533

THYRISTOR,SCR

6amp200volts

073

790

DIODE,

rectifier

amp

volts

straight

polarity

TRANSISTOR,

UJT

volts

THYRISTOR,

SCR

amp

200

volts

RESISTOR,

carbon

0.12

watt

2200K

ohm

RESISTOR,

carbon 0.25

watt

22K

ohm

RESISTOR,

carbon

0.25

watt

15K

ohm

RESISTOR,

carbon

0.5

watt

2200

ohm

RESISTOR,

carbon

0.25

watt

ohm

RESISTOR,

carbon

0.25

watt

18K

ohm

605

918

RESISTOR,

carbon

0.25

watt

100

ohm

RESISTOR,

carbon

0.25

watt

33K

ohm

RESISTOR,

carbon

0.25

watt

10K

ohm

RESISTOR,

carbon

film

0.25

watt

6800

ohm

RESISTOR,

carbon

0.25

watt

220

ohm

RESISTOR,

carbon

0.25

watt

330

ohm

RESISTOR,

carbon

0.25

watt

1500

ohm

RESISTOR,

carbon

0.25

watt

meg

ohm

IRESISTOR,

carbon

0.25

watt

ohm

RESISTOR,

carbon

0.5

watt

3300

ohm

RECTIFIER,

integrated

amp

600

volts

TRANSFORMER,

pulse

TRANSFORMER,

pulse

700

volts

NUMBERS

WHEN

ORDERING

REPLACEMENT

PARTS.

SURE

PROVIDE

STOCK.

MODEL,

AND

SERIAL

OM-t5lOPzigeD

TABLE

CONTENTS

Paragraph

No.

Page

No.

SECTION



INTRODUCTION

General

Receiving-Handling

Description

1-4.

Safety

SECTION

2INSTALLATION

2-1.

Location

Electrical

Input,

Contactor

Control

And

Voltmeter

Connections

Shielding

Gas

Connections

Secondary

Connections

Weld

Head

Connections

Remote

Gas

Control

Remote

Fixture

Start

Connections

Remote

Start,

Stop,

And

Emergency

Stop

Connections

SECTION

3

FUNCTION

CONTROLS

3-1. Weld

Start

Switch

Weld

Current

Control

Stop

Switch

Emergency

Stop

Switch

Inch

And

Inch

Down

Switches

Purge

Switch

3-7.

PowerOn

Light

3-8.

Circuit

Breaker

3-9.

Meters

3-10.

Burnback

Control

3-11.

Run

Control

3-12.

Pre

Flow

Control

3-13.

Post

Flow

Control

3-14.

Weld

Time

Control

Spot

Weld

Mode

Operation

Full

Automatic

Mode

Operation

Semi-Automatic

Mode

Operation

3-1

Operational

Mode

Connections

Full

Automatic

Operation

Spot

Weld

Operation

Semi-Automatic

Operation

PARTS

LIST

Circuit

Breaker

Shielding

Gas

Output

~Receptac1e

Shielding

Gas

Input

Receptacle

Remote

Gas

Control

Remote

Fixture

Start

Receptacle

Figure

2-2.

Front

Panel

and

Bottom

View

CAUTION

Ensure

that

the

115

volts

power

Su~nd

welding

power

source

are

deenergized

before

electrical

con

nections

are

made.

not

connect

the

conductors

the

115

volts

power

supply

and

welding

power

source

until

all

electrical

connections

have

been

made



totheweldcontrol.

2-2.

ELECTRICAL

INPUT.

CONTACTOR

CONTROL.

AND

VOLTMETER

CONNECTIONS

(Figure

2-2)

Weld

Control

Connections

Insert

plug

PLG3

into

the

weld

control

receptacle

RC3.

tate

the

plug

threaded

outer

ring

clockwise

Onto

the

recep

tacle

threaded

body

far

possible.

This

action

will

secure

the

plug

the

receptacle.

Electrical

Input

Connections

Connect

the

supplied

electrical

input

cord,

labeled

115,

the

115

volts

ac,

single

phase,

hertz

power

supply.

recommended

that

the

welding

power

source

115

vac

recep

tacle

used

the

115

vac

power

supply.

Connect

the

two

input

conductors,

colored

white

and

black,

the

115

volts

power

supply

and

connect

the

ground

conductor,

colored

green,

proper

ground.

Use

whatever

grounding

method

that

acceptacle

the

local electrical

inspection

authority.

The

green

ground

conductor

connected

the

weld

control

chassis

and

for

grounding

purposes

only.

not

connect

the

green

ground

conductor

any

one

the

115

volts

power

supply

terminals

this

will

result

electrically

hot

weld

control

chassis.

Contactor

Control

And

Voltmeter

Connections

Locate

the

supplied

contactor

control

and

voltmeter

cord,

labeled

CONTACTOR~

Connect

the

two

contactor

control

conductors,

colored

white

and

black,

the

welding

power

source

contactor

Control

circuitry.

Connect

the

voltmeter

conductor,

colored

green,

the

welding

power

source

negative

(-)

secondary

terminal.

SHIELDING

GAS

CONNECTIONS

(Figure

2-2)

Connect

hose

suitable

length

and

construction

from

the

shielding

gas

supply

the

weld

control

GAS

FROM

SUP-

PLY

gas

receptacle.

Connect

the

supplied

hose

from

the

weld

control

GAS

WELD

HEAD

gas

receptacle

the

gun

gas

receptacle.

Both

the

weld

control

gas

receptacles

have

5/8-lB

right-handed

threading.

2.4.

SECONDARY

CONNECTIONS

(Figure

2.2)

Connect

cables

suitable

length,

size,

and

construction

between

the

following

points:

Welding

power

source

positive

(+)

secondary

terminal

weld

control

positive

(+)

secondary

terminal.

Weld

control

negative

(-)

secondary

terminal

gun

secondary

terminal.

Welding

power

source

negative

(-)

secondary

terminal

weidment

(workpiece).

Refer

the

welding

power

source

Owners

Manual

for

suitable

cable

size

and

Construction.

The

weld

control

secondary

terminals

are

112

diameter

corresponding

size

cable

connectors

should

used

these

points.

WELD

HEAD

CONNECTIONS

(Figure

2-2)

Insert

plug

PLG4

into

the

weld

control

receptacle

RC4.

Rotate

the

plug

threaded

outer

ring

clockwise

Onto

the

recep

tacle

threaded

body

far

possible.

This

action

will

secure

the

plug

the

receptacle.

Insert

PLG

from

the

weld

head

into

receptacle

AC.

Rotate

the

plug

threaded

Outer

ring

clockwise

Onto

the

receptacle

threaded

body

far

possible.

This

action

will

secure

the

plug

the

receptacle.

2-6.

REMOTE

GAS

CONTROL

REMOTE

FIXTURE

START

CONNECTIONS

(Figure

2.2)

remote

control

shielding

gas

valve

relay

desired,

connect

the

leads

from

the

gas

valve

relay

pins

and

plug

PLG1.

This

valve

relay

must

able

operate

with

.25

amp

less

115

volts

ac.

This

valve

relay

will

energized

and

deenergized

unison

with

the

gas

valve

GS1

within

the

weld

control.

remote

control

fixture

relay

desired

connect

the

leads

from

the

relay

pins

and

plug

PLG1.

This

relay

must

able

operate

with

amp

less

115

volts

ac.

This

relay

will

energized

and

deenergized

unison

with

the

weld head

motor.

Insert

plug

PLG1

into

weld

control

receptacle

RC1

and

rotate

the

plug

Outer

threaded

ring

clockwise

onto

the

recep

tacle

threaded

body.

This

action

will

secure

the

plug

the

receptacle.

Remote

Start,

Stop,

Emergency

Stop

Receptacle

RC2

________

115

VAC

Input,

________________

Voltmeter,

-o

Contactor

Control

Receptacle

Rc3

Negative

Secondary

Terminal

Emergency

Stop

Switch

Positive

Secondary

Terminal

Weld

H~a

Receptacle

RC4

TB-079

064-1

Page

SECTION

INTRODUCTION

Electrical

Input

Weld

Control

Max.

Voltage

Applied

Weld

Head

Overall

Dimensions

(Inches)

Weight

(Pounds)

Net

Ship

115

Volts

Single

Phase

Hertz

100

Volts

Height

15-3/8

Width

11-3/4

Depth

5-1/4

Figure

I-i.

Specifications

GENERAL

This

manual

has

been

prepared

especially

for

use

familiar

izing

personnel

with

the

design,

installation,

operation,

main

tenance,

and

troubleshooting

this

equipment.

All

informa

tion

presented

herein

should

given

careful

consideration

assure

optimum

performance

this

equipment.

-2.

RECEIVING-HANDLING

Prior

installing

this

equipment,

clean

all

packing

material

from

around

the

unit

and

carefully

inspect

for

any

damage

that

may

have

occurred

during

shipment.

Any

claims

for

loss

damage

that

may

have

occurred

transit

must

filed

the

purchaser

with

the

carrier.

copy

the

bill

lading

and

freight

bill

will

furnished

the

carrier

request

occasion

file

claim

arises.

When

requesting

information

concerning

this

equipment,

essential

that

Model

Description

and/or

Stock

Number

and

Serial

(or

Style)

Numbers

the

equipment

supplied.

DESCRIPTION

This

weld

control

has

silicon

control

rectifiers,

diodes,

and

transistors

the

timing,

speed,

and

brake

circuits

for

pre

cision

control

and

dependable

service.

The

printed

Circuit

board

can

easily

replaced

unit

required.

This

weld

control

designed

for

use

with

constant

potential

welding

power

source.

This

weld

control

includes

controls

for

gas

metal-arc

spot

welding.

simple

jumper

relocation

Converts

control

from

one

process

the

other.

Ten-foot

interconnecting

cords

and

gas

hose

are

included.

The

following

definitions

apply

CAUTION,

IMPORTANT,

and

NOTE

blocks

found

throughout

this

manual:



Under

this

heading,

installation,

operating,

and

main

tenance

procedures

practices

will

found

that

not

carefully

followed

may

create

safety

hazard

personnel.

11rTA;~I

Under

this

heading,

installation,

operating,

and

main

tenance

procedures

practices

will

found

that

not

carefully

followed

may

result

damage

equip

ment.

NOTE

Under

this

heading,

explanatory

statements

will

found

that

need

special

emphasis

obtain

the

most

efficient

operation

the

equipment.

proper

installation

site

should

selected

for

the

weld

control

the

unit

provide

dependable

service,

and

main

relatively

maintenance

free.

proper

installation

site

permits

freedom

air

movement

into

and

out

the

weld

control,

and

also

least

subjects

the



TB-079

064-1

unit

dust,

dirt,

moisture,

and

corrosive

vapors.

The

instal

lation

Site

should

also

permit

easy

access

the

weld

control

for

Operational

and

maintenance

functions.

Lead

lengths

must

considered

when

locating

the

control.

Holes

are

provided

the

weld

control

back

panel

for

mount

ing

purposes.

Figure

2-1

gives

overall

dimensions

and

mount

ing

hole

layout.

-4.

SAFETY

SECTION

INSTALLATION

LOCATION

(Figure

2-1)

Figure

2-1.

Overall

Dimensions

and

Mounting

Hole

Layout

OM-1510

Page

Table of contents

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