Miller VCI-1 User manual

May

1982

FORM:

OM-868A

~LE

CCO~t

i~1URN

OWN

ERS

MANUAL

MILLER

ELECTRIC

MFG.

CO.

718

BOUNDS

ST.

P.O.

Box

1079

APPLETON

54912

USA

ADDITIONAL COPY

PRICE

CENTS

NWSA

CODE

NO.

4579

PRINTED

U.S.A.

MODEL

vcI-1

$~W

~~P L~P

L

~-.

LIMITED

WARRANTY

EFFECTIVE:

JUNE

1979

This

warranty

supersedes

all

MILLER

warranties

and

clusive

with

other

guarantees

warranties

expressed

implied.

LIMITED

WARRANTY-Subject

the

terms

and

conditions

matter

general

policy

only,

Miller

may

honor

claims

hereof,

Miller

Electric

Mfg.

Co.

Appleton,

Wisconsin

warrants

submitted

the

original

user

within

the

foregoing

periods.

its

Distributor/Dealer

that

all

new

and

unused

Equipment

(

furnished

Miller

free

from

defect

workmanship

and

the

case

Millers

breach

warranty

any

other

duty

material

the

time

and

place

delivery

Miller.

war-

with

respect

the

quality

any

goods,

the

exclusive

remedies

ranty

made

Miller

with

respect

engines,

trade

ac-

therefore

shall

be,

Millers

option

Ill

repair

(21

replacement

cessorues

other

items

manufactured

others.

Such

or,

where

authorized

writing

Miller

appropriate

cases,

(3)

engines,

trade

accessories

and

other

items

are

sold

subject

the

reasonable

cost

repair

replacement

authorized

the

warranties

their

respective

manufacturers,

any

All

Miller

service

station

(41

paymentof

credit

for

the

purchase

engines

are

warranted

their

manufacturer

for

one

year

from

price

hess

reasonable

depreciation

based

upon

actual

use)

upon

date

original

purchase.

return

the

goods

Customers

risk

and

expense.

Upon

receipt

notice

apparent

defect

failure,

Miller

shall

instruct

the

clai-

Except

specified

below,

Millers

warranty

does

not

apply

mant

the

warranty

claim

procedures

followed.

components

having

normal

useful

life

less

than

one

Ill

year,

such

spot

welder

tips,

relay

and

contactor

points,

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

MILLERMATIC

parts

that

come

contact

with

the

welding

ANY

IMPLIED

WARRANTY,

GUARANTY

REPRESENTA

wire

including

nozzles

and

nozzle

insulators

where

failure

does TION

PERFORMANCE,

AND

ANY

REMEDY

FOR

not

result

from

defect

workmanship

material.

BREACH

CONTRACT

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

IMPLICATION,

OPERATION

LAW,

Miller

shall

required

honor

warranty

claims

war-

CUSTOM

TRADE

COURSE

DEALING,

INCLUDING

ranted

Equipment

the

event

failure

resulting

from

defect

ANY

IMPLIED

WARRANTY

MERCHANTABILITY

within

the

following

periods

from

the

date

delivery

Equip-

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

ment

the

original

user:

ANY

AND

ALL

EQUIPMENT

FURNISHED

MILLER

CLUDED

AND

DISCLAIMED

MILLER.

Arc

welders,

power

sources

and

components

year

Original

main

power

rectifiers

years

EXCEPT

EXPRESSLY

PROVIDED

MILLER

(labor

year

onlyl

WRITING,

MILLER

PRODUCTS

ARE

INTENDED

FOR

Allweldinggunsandfeeder/guns

90days

ULTIMATE

PURCHASE

COMMERCIAL/INDUSTRIAL

1

All

other

Millermatic

Feeders

year

USERS

AND

FOR

OPERATION

PERSONS

TRAINED

AND

Replacement

repair

parts,

exclusive

labor

days

EXPERIENCED

THE

USE

AND

MAINTENANCE

Batteries

months

WELDING

EQUIPMENT

AND

NOT

FOR

CONSUMERS

CONSUMER

USE.

MILLER

WARRANTIES

NOT

EXTEND

provided

that

Miller

notified

writing

within

thirty

1301

days

TO,

AND

RESELLER

AUTHORIZED

EXTEND

the

date

such

failure.

MILLERS

WARRANTIES

TO,

ANY

CONSUMER.

~1,

j?

...Yt,

ERRATA

SHEET

After

this

manual

was

printed,

refinements

equipment

design

occurred.

This

sheet

lists

exceptions

data

appearing

later

this

manual.

AMENDMENT

SECTION

INTRODUCTION

Amend

Section

1-3.

DESCRIPTION

C~-~f

Delete

the

reference

750E

welding

power

source

AMENDMENT

SECTION

MAINTENANCE

TROUBLESHOOTING

Amend

Figure

3-1.

Circuit

Diagram

~LG

Figure

3.1.

Circuit

Diagram

Effective

With

Style

No.

JC.49

Dia.

Part

Mkgs.

No.

Description

Quantity

C53

035

834

CAPACITOR,

metalized

film

1.5

100

volts

R70

035 885

RESISTOR,

carbon

film

0.25

watt

68K

ohm

SURE

PROVIDE

MODEL

AND

SERIAL

NUMBERS

WHEN

ORDERING

REPLACEMENT

PARTS.

February

15,

1983

FORM:

OM-868A

~D8K

GPN

Circuit

Diagram

No.

A-088

175-B

PRONG

VIEW

SECTION

INTRODUCTION

carefully

followed

could

result

serious

personal

injury

loss

life.

t~~Ikls]~I

statements

include

installation,

operating,

and

maintenance

procedures

practices

which

not

carefully

followed could

result

minor

personal

injury

damage

this

equipment.

IMPORTANT

third

signal

word,

highlights

instruc

tions

which

need

special

emphasis

obtain

the

most

efficient

operation

this

equipment.

1-2.

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

will

furnished

the

manufacturer

quest

occasion

file

claim

arises.

When

requesting

information

concerning

this

equip

ment,

essential

that

Model

Description

and

Serial

(or

Style)

Number

the

equipment

supplied.

1-3.

DESCRIPTION

The

Voltage

Interface

Control

allows

Automatic

weld

control

interface

with

series

and

CP-750E

welding

power

source.

The

Interface

Control

also

provides

circuitry

which

com

pensates

for

line

load

variations.

SECTION

INSTALLATION

Affix

the

supplied

15

AMP

FUSE

label

over

the

10

AMP

designation

directly

under

the

fuse

holder.

I~:l~II~e~

ELECTRIC

SHOCK

can

kill.



not

touch

live

electrical

parts.



Shut

down

the

welding

power

source

and

sure

cannot

accidentally

energized.

2-1.

VOLTAGE

INTERFACE

CONTROL

INTER

CONNECTIONS

(Figure

2-1)

Connect

the

4-socket

plug

PLG2

from

the

Inter

face

Control

the

4-pin

receptacle

RC1

the

Automatic

right

side

panel.

Insert

the

3-pole

twistlock

plug

PLG1

from

the

Interface

Control

into

the

Voltage

Control

recep

tacle

the

welding

power

source

and

rotate

clockwise.

Connect

terminal

black

feedback

lead

welding

power

source

Negative

output

terminal.

Connect

terminal

white

feedback

lead

welding

power

source

Positive

output

terminal.

2-2.

VOLTS

CONTROL

CIRCUIT

FUSE

REPLACEMENT

AND

SERIES

WELDING

POWER

SOURCES

Replace

the

volts

control

cir

cuit

fuse,

the

650

and

750 ampere

models;

the

350

and

450

ampere

models,

with

the

supplied

ampere

fuse.

See

the

Owners

Manual

for

fuse

location.

IMPORTANT

1-1.

GENERAL

INFORMATION

AND

SAFETY

General

Information

prØsehted

this

manual

and

various

labels,

tags,

and

plates

provided

the

unit

pertains

equipment

design,

installation,

operation,

maintenance,

and

troubleshooting

which

should

read,

understood,

and

followed

for

the

safe

and

effective

use

this

equip

ment.

Safety

The

installation,

operation,

maintenance,

and

troubleshooting

arc

welding

equipment

requires

practices

and

procedures

which

ensure

personal

safety

and

the

safety

others.

Therefore,

this

equipment

installed,

operated,

and

maintained

only

qualified

persons

accordance

with

this

manual

and

all

plicable

codes

such

as,

but

not

limited

to,

those

listed

the

end

Section

Safety

Rules

For

Operation

Arc

Welding

Power

Source

the

welding

power

source

Owners

Manual.

Safety

instructions

specifically

pertaining

this

unit

pear

throughout

this

manual

highlighted

the

signal

words

____________

and

___________

which

identify

different

levels

hazard.

ITLTL~

~h~I

kIcI

statements

include

installation,

operating,

and

maintenance

procedures

practices

which

not

WARNING

CAUTION

Place

the

Voltage

Control

switch

the

welding

power

source

the

REMOTE

position.

we/ding

power

source

with

voltage

range

switch,

place

the

switch

the

single

wide

range

position.

PLG1

Feedback

Terminals

TB-047

489

Figure

2-1.

Voltage

Interface

Control

OM-868

Page

SECTION

MAINTENANCE

TROUBLESHOOTING

WARNING

_________

ELECTRIC

SHOCK

can

kill.



not

touch

live

electrical

parts.



Disconnect

unit

from

input

power

before

internal

inspecting

servicing.

Troubleshooting

internal parts

performed

only

qualified

persons.

IMPORTANT

______________

Periodically

inspect

the

labels

this

unit

for

legibility.

All

labels

must

maintained

clearly

readable

state

and

rep/aced

where

necessary.

See

the

Parts

List

for

part

number

labels.

Periodically

inspect

all

interconnecting

cords

for

damage

breaks

the

insulating

jacket,

particularly

the

plug.

Repair

replace

the

cord(s)

necessary.

Figure

3-1.

Circuit

Diagram

,WH

5-ORN~~GRN

Circuit

Diagram

No.

A-084

801

PLC~

PRONG

VIEW

Page

May

1982

FORM:

OM-868A

PARTS

LIST

MODEL

vcI-1

Figure

Complete

Assembly

TD-047

550

~~-1

I

OM-868

Page

Item

Dia.

Part

No.

Mkgs.

No.

Description

Quantity

Figure

Complete

Assembly

006

535

RECTIFIER,

silicon

diode

(consisting

of)

050

037 952

DIODE,

rectifierl5amp200

voltsstraight

polarity

006

428

BRACKET,

mounting

heat

sink

006

534

AMPLIFIER,

power

(consisting

of)

Q53

007 716

TRANSISTOR,

amp

100

volts

PNP

Q54

007

715

.TRANSISTOR,3Oamp9OvoItsNPN

006

425

HEAT

SINK,

diode

D53

037

952

DIODE,

rectifier

amp

200

volts

straight

polarity

R69

006

429

RESISTOR,

5watt0.1

ohm

D52

037

451

DIODE,

rectifier

amp

200

volts

reverse

polarity

073

756

STAND-OFF,

No.

6-32

5/8

long

1/4 hex

601

242

INSULATOR,

washer-heatsink

019

677

HANDLE,

door-

pull

t021

475

WRAPPER

047

497

LABEL,

general

precautionary

006 427

BRACKET,

mounting-circuit

card

007

156

CIRCUITCARD(consistingof)

A50

008

971

.INTEG

RATED

CIRCUIT,

operational

amplifier

C51

031

721

CAPACITOR,

mylar

0.22

200

volts

C52

031

693

CAPACITOR,

mylar0.33uf75voltsdc

051 037

449

DIODE,

zener

volts

watt

straight

polarity

Q50,52

039 353

TRANSISTOR,

amp

volts

NPN

Q51

039

354

TRANSISTOR,

amp

volts

PNP

R51

000 039

RESISTOR,

carbon 2

watt

680

ohm

R52,58

605

979

RESISTOR,

metal

film

0.25

watt

15K

ohm

R53,55

006

424

POTENTIOMETER,

cermet

turn

watt

ohm

R56

035

825

RESISTOR,

carbon

film

0.25

watt

ohm

R57,60

605 978

RESISTOR,

metal

film

0.25

watt2.74K

ohm

R59

000 035

RESISTOR,

metal

film

0.5

watt

6.8K

ohm

R61

035

884

RESISTOR,

carbon

film

0.25

watt

lOOK

ohm

R62

030

033

RESISTOR,

carbon

0.5

watt

470

ohm

R63

030 038

RESISTOR,

carbon

0.5

watt

220

ohm

R64,65

030

024

RESISTOR,

carbon

0.5

watt

1000

ohm

R66,67

030 839

RESISTOR,

fixed

watt

220

ohm

R68.

030

937

RESISTOR,

carbon0.Swattl0ohm

,2T

000

059

BLOCK,

terminal

amp

pole

R50

006

532

RESISTOR,

WWadj50watt5ohmw/Ieads

084

804

CORD,

voltage

control

(consisting

of)

007

826

CORD,

No.

3/c

(order

ft)

lift

039 828

CLAMP,

cable

047

544

PLUG,4socketMS-3106A-14S-2SX

048

298

CASE

SECTION,

base/front/rear

010 610

CONNECTOR,

clamp-cable

010

659

CONNECTOR,

clamp

cable

3/8

inch

deg

006

530

CABLE,

power

(consisting

of)

006

531

CABLE,

power

PLG1

605

797

CAP,

twistlock3P3W20

amp

125

volts

600340

.CORD,

No.

2/c(orderbyft)

6ft

006

426

BRACKET,

mounting

capacitor

C50

031

728

CAPACITOR,

electrolytic

9000

volts

*027

419

FUSE,

ceramic

amp

250

volts

(loose

item)

013312

LABEL,

usei5ampfuse

*Recommended

Spare

Parts.

tWhen

ordering

component

originally

displaying

precautionary

label,

the

label

should

also

ordered.

SURE

PROVIDE

MODEL

AND

SERIAL

NUMBERS

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-868

Page

Table of contents

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