Miller Electric MS Weld Control User manual

February
1976
FORM:
OM-1510
Effective
with
serial
No.
HE787389
MODEL
MS
Weld
Control
STOCK
NO.
079
065
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
ADDITIONAL
COPY
PRICE
80
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
to
be
free from
defects
in
material
and
factory
workmanship
for the
periods
indicated
below,
provided
the
equipment
is
installed and
operated
according
to
manufacturers
Instructions.
MILLER
Electric
Mfg.
Cos
obligation,
under
this
warranty,
is
expressly
limited
to
replacing
or
repairing
any
defective
part
or
correcting
any
manufacturing
defect
without
charge during
the
warranty
period
if
MILLERS
inspection
confirms
the existence of
such
defects.
MILLERs
option
of
repair
or
replacement
will
be
f.o.b.
factory
at
Appleton,
Wisconsin
or
f.o.b. a
MILLER
authorized service
facility,
and
therefore
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
The
warranty
period,
beginning
on
the date
of
sale
to
the
original
purchaser.user
of
the
equipment,
will
be
as
follows:
-~
C
1.
Arc
welders,
power
sources,
and
components

1
year
2.
Original
main
power
rectifiers

3
years
(unconditionally)
3.
MHG-20E,
20K
and all
guns

90
days
4.
All other
Millermatic Feeders

1
year
5.
Mag-Diesel
engine
on
DEL-200

6
months
6.
All
other
engines
1
year
The
labor
expense
on
installing
original
main
power
rectifiers
after
being
in
service
one
year
will
be the
owners
responsibility.
C
Engine
Warranties
are
covered
by
the
engine
manufacturers,
subject
to their procedures
and
to
be
handled
through
their
C
S
authorized
local
Service
Stations
or
agencies.
No
warranty
will be
made
in
respect
to
trade
accessories,
such
being
subject
to
the
warranties for
their
respective
manufacturers.
c
MILLER
Electric
Mfg.
Co. will
not be
liable for
any
loss
or
consequential
damage
or
expense
accruing
directly
or
indirectly
from
s
the
use
of
equipment
covered
in
this
warranty.
c
C)
C
This
warranty
supersedes
all
previous
MILLER
warranties and
is
exclusive with
no
other
guarantees
or
warranties
expressed
or
C

implied.
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ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this manual.
AMENDMENT
TO
SECTION
3
FUNCTION
OF
CONTROLS
~NOTE~
The
circuit
1manual.
diagram(s)
on
this
supplement
replace
any
other
circuit
diagram(s)
appearing
later in
this
i
Circuit
Diagram
No.
C-003
161-B
Amend
Figure
3-2
as
follows:
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For
Models
Effective With Serial
No.
HE787389
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OM-1510
Page
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OM-1510
Page
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Figure
3-2. Circuit
Diagram
For
Models
Effective
With
Serial
No.
HH023190
Thru
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Figure
3-2.
Circuit
Diagram
For Models
Effective
With Serial
No.
HH050890 And
Following
circuit Diagram
No.
C-053
192
OM-1510
Page
C

Item
or Dia.
Part
No.
Listed
Replaced
With
ftem3l
079281
Item5O
073211
Item
53
~R
1
030
131
Jtem56
073722
Item57 073719
2
ftem72
073642

Item
C
602
071
14
Page
4
06
073
535
Page4
RB
605919

Page
4
R9
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Page4
R15
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CR4
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C6,9.14,18
073739
4
C7,8,11,17
073738
4
C10,13,19
073732
3
C16
073737
1
C20
073547
1
01,4-18,20-
23,27,29,
32.36
27
D19
1
01,4,9,11
13,15
6
02,3,10
3
05,7,8,
12,14
037289
5
016
073710
1
Al
078426
1
R2
605909
1
R3,20
605910
2
R4
030853
1
R5,21
605916
2
R6
078434
1
R7
,14,17,
24,27,29,
37
7
R
10,
12,
19,
25
605
908
4
R13,16,28
605911 3
R15
035830
1
R18,26
-
078428 2
R22
078431
1
R23
030091
1
R30
078433
1
R34,35,36
605919 3
R38
030016
1
SR1,2
074453
2
T1,2,4
073
682 3
T3,5,6
000 350 3
Item
4
075
318
-=
Page
No.
Mkgs.
-,
In
Parts List
-
Part
No.
Description
Quantity
PB3
PB3,4
R
2,4,5,6.
1
2
1
1
052
841
-
CIRCUIT
CARD
ASSEMBLY,
program
(Eff
with
S/N
HH050890) (See
NOTE
below
for
components
of 052
841)
075
077
SCREW,
cap
-
brass
hex
hd
5/8-1
1
x
3
052 602
BEZEL,
meter
.
double
079
361
POTENTIOMETER,
carbon
1
turn
2
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
1
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
ac
3PDT
1
1
NOTE

Components
for 052
841
CAPACITOR,
tantalum
0.15
uf
50
volts
CAPACITOR,
electrolytic
100
uf
35
volts
dc
CAPACITOR,
tantalum
0.22
uf
35
volts
CAPACITOR,
tantalum
0.1
uf
50
volts
CAPACITOR,
ceramic 0.01
uf
50
volts
CAPACITOR,
ceramic
0.1
uf
50
volts
CAPACITOR,
ceramic
0.68
uf
50
volts
CAPACITOR, electrolytic
10
uf
50
volts
dc
CAPACITOR,
electrolytic
25
uf
50
volts
dc
CAPACITOR,
mylar
0.33
uf 200
volts
073
540
DIODE,
signal
0.15
amp
75
volts
reverse
polarity
037
386
DIODE,
zener
11
volts
1
watt
straight
polarity
.
073533
THYRISTOR,SCR 6amp200volts
073
790
DIODE,
rectifier
10
amp
14 volts
straight
polarity
-
TRANSISTOR,
UJT 50
MA
35
volts
THYRISTOR,
SCR
6
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
1K
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
1
meg
ohm
IRESISTOR,
carbon
0.25
watt
47 ohm
RESISTOR,
carbon
0.5
watt
3300
ohm
RECTIFIER,
integrated
1
amp
600
volts
TRANSFORMER,
pulse
TRANSFORMER,
pulse
700
volts
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
BE SURE
TO
PROVIDE
STOCK.
MODEL,
AND SERIAL
OM-t5lOPzigeD

TABLE
OF CONTENTS
Paragraph
No.
Page
No.
SECTION
1

INTRODUCTION
1- 1.
General
1
1
-
2.
Receiving-Handling
1
1
-
3.
Description
1
1-4.
Safety
1
SECTION
2INSTALLATION
2-1.
Location
1
2-
2.
Electrical
Input,
Contactor
Control
And
Voltmeter
Connections
2
2
-
3.
Shielding
Gas
Connections
2
2
-
4.
Secondary
Connections
2
2-
5.
Weld Head
Connections
2
2
-
6. Remote Gas Control
&
Remote Fixture
Start Connections
2
2- 7.
Remote
Start,
Stop,
And
Emergency
Stop
Connections
3
SECTION 3
FUNCTION
OF
CONTROLS
3-1. Weld
Start Switch
3
3-
2.
Weld
Current
Control
3
3-
3.
Stop
Switch
3
3
-
4.
Emergency
Stop
Switch
3
3- 5. Inch
Up
And Inch Down
Switches
3
3
-
6.
Purge
Switch
3
3-7.
PowerOn
Light
3
3-8. Circuit Breaker
3
3-9. Meters
3
3-10.
Burnback Control
3
3-11. Run
In
Control
4
3-12. Pre Flow Control
4
3-13.
Post
Flow
Control
4
3-14. Weld Time Control
4
A.
Spot
Weld Mode
Of
Operation
4
B.
Full
Automatic
Mode Of
Operation
4
C. Semi-Automatic Mode Of
Operation
4
3-1
5.
Operational
Mode
Connections
4
A.
Full
Automatic
Operation
4
B.
Spot
Weld
Operation
4
C.
Semi-Automatic
Operation
4
PARTS
LIST

Circuit
Breaker
Shielding
Gas
Output
~Receptac1e
Shielding
Gas
Input
Receptacle
Remote
Gas Control
&
Remote
Fixture Start
Receptacle
RC
1
\
Figure
2-2. Front
Panel
and
Bottom
View
CAUTION
Ensure that the 115
volts
ac
power
Su~nd
welding
power
source are
deenergized
before
electrical
con
nections
are
made.
Do
not connect
the
conductors
to
the
115 volts
ac
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)
A.
Weld
Control Connections
Insert
plug
PLG3
into
the weld control
receptacle
RC3.
Ro
tate
the
plug
threaded
outer
ring
clockwise
Onto
the
recep
tacle
threaded
body
as
far
as
possible.
This
action will
secure
the
plug
in the
receptacle.
B. Electrical
Input
Connections
Connect
the
supplied
electrical
input
cord,
labeled
115,
to
the
115 volts
ac, single
phase,
60
hertz
power
supply.
It
is
recommended
that the
welding
power
source
115
vac
recep
tacle
be
used
as
the
115
vac
power
supply.
Connect
the
two
input
conductors,
colored
white and
black,
to
the
115
volts
ac
power
supply
and
connect
the
ground
conductor,
colored
green,
to
a
proper
ground.
Use
whatever
grounding
method
that is
acceptacle
to
the
local electrical
inspection
authority.
The
green
ground
conductor
is
connected
to
the
weld
control
chassis
and
is
for
grounding
purposes
only.
Do
not
connect
the
green
ground
conductor
to
any
one
of
the
115
volts
ac
power
supply
terminals
as
this
will
result
in
an
electrically
hot
weld
control
chassis.
C.
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,
to
the
welding
power
source
contactor Control
circuitry.
Connect
the voltmeter
conductor,
colored
green,
to
the
welding
power
source
negative
(-)
secondary
terminal.
2-
3.
SHIELDING GAS
CONNECTIONS
(Figure
2-2)
Connect
a
hose of
suitable
length
and
construction
from
the
shielding
gas
supply
to the
weld
control
GAS
-
FROM
SUP-
PLY
gas
receptacle.
Connect
the
supplied
hose
from
the weld
control
GAS
-
TO
WELD HEAD
gas
receptacle
to
the
gun gas
receptacle.
Both
of the weld control
gas
receptacles
have
5/8-lB
right-handed
threading.
2.4.
SECONDARY
CONNECTIONS
(Figure
2.2)
Connect cables
of suitable
length,
size,
and construction
between
the
following
points:
A.
Welding
power
source
positive
(+)
secondary
terminal to
weld
control
positive
(+)
secondary
terminal.
B.
Weld
control
negative
(-)
secondary
terminal
to
gun
secondary
terminal.
C.
Welding
power
source
negative
(-)
secondary
terminal
to
weidment
(workpiece).
Refer
to
the
welding
power
source
Owners
Manual for
suitable cable
size
and Construction. The weld control
secondary
terminals
are
112
in
diameter
so
corresponding
size cable
connectors
should
be
used
at
these
points.
2-
5.
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
as
far
as
possible.
This
action will
secure
the
plug
in the
receptacle.
Insert
PLG
from
the weld head into
receptacle
AC. Rotate
the
plug
threaded
Outer
ring
clockwise
Onto
the
receptacle
threaded
body
as
far
as
possible.
This
action will
secure
the
plug
in the
receptacle.
2-6.
REMOTE
GAS CONTROL
&
REMOTE
FIXTURE
START CONNECTIONS
(Figure
2.2)
If
remote
control of
a
shielding
gas
valve
or
relay
is
desired,
connect
the
leads
from
the
gas
valve
or
relay
to
pins
C and D
of
plug
PLG1.
This
valve
or
relay
must be able
to
operate
with
.25
amp
or
less
@
115
volts
ac.
This
valve
or
relay
will
be
energized
and
deenergized
in
unison
with the
gas
valve
GS1
within the
weld
control.
If
remote control of
a
fixture
relay
is
desired
connect
the
leads from
the
relay
to
pins
A
and B of
plug
PLG1.
This
relay
must
be able
to
operate
with
.5
amp
or
less
@
115
volts
ac.
This
relay
will
be
energized
and
deenergized
in
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
in
the
receptacle.
Remote
Start,
Stop,
&
Emergency
Stop
Receptacle
RC2
________
115
VAC
Input,
________________
Voltmeter,
&
-o
c~
'~
Contactor
Control
~
11
Receptacle
Rc3
Negative
Secondary
Terminal
Emergency
Stop
Switch
Positive
Secondary
Terminal
Weld
H~a d
Receptacle
RC4
TB-079
064-1
U
Page
2

SECTION
1
-
INTRODUCTION
Electrical
Input
To
Weld
Control
Max.
Voltage
Applied
To
Weld
Head
Overall
Dimensions
(Inches)
Weight
(Pounds)
Net
I
Ship
I
35
I
37
j
115 Volts
AC
Single
Phase
60
Hertz
100
Volts
DC
Height
-
15-3/8
Width
-
11-3/4
Depth
-
5-1/4
Figure
I-i.
Specifications
1
-
1.
GENERAL
This
manual
has
been
prepared
especially
for
use
in
familiar
izing personnel
with the
design,
installation,
operation,
main
tenance,
and
troubleshooting
of this
equipment.
All
informa
tion
presented
herein
should
be
given
careful
consideration
to
assure
optimum
performance
of
this
equipment.
1 -2.
RECEIVING-HANDLING
Prior
to
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
or
damage
that
may
have
occurred
in transit
must
be
filed
by
the
purchaser
with
the carrier. A
copy
of
the
bill of
lading
and
freight
bill will
be
furnished
by
the carrier
on
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equipment,
it
is
essential that
Model
Description
and/or
Stock Number and
Serial
(or
Style)
Numbers
of
the
equipment
be
supplied.
1
-
3.
DESCRIPTION
This
weld
control
has
silicon
control
rectifiers,
diodes,
and
transistors
in
the
timing,
speed,
and
brake
circuits
for
pre
cision
control
and
dependable
service.
The
printed
Circuit
board
can
be
easily
replaced
as
a
unit
if
required.
This
weld
control
is
designed
for
use
with
a
constant
potential
welding
power
source.
This
weld
control
includes
controls
for
gas
metal-arc
spot
welding.
A
simple
jumper
relocation
Converts
control from
one
process
to
the
other.
Ten-foot
interconnecting
cords and
gas
hose
are included.
The
following
definitions
apply
to
CAUTION,
IMPORTANT,
and
NOTE
blocks
found
throughout
this
manual:

Under
this
heading,
installation,
operating,
and main
tenance
procedures
or
practices
will
be
found that if
not
carefully
followed
may
create
a
safety
hazard
to
personnel.
I
I
11rTA;~I
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will be
found
that
if
not
carefully
followed
may
result
in
damage
to
equip
ment.
NOTE
Under
this
heading,
explanatory
statements
will be
found
that
need
special emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
A
proper
installation site should
be
selected
for
the weld
control
if
the unit
is
to
provide
dependable
service,
and
re
main
relatively
maintenance free.
A
proper
installation site
permits
freedom of
air
movement
into
and out
of the weld
control,
and
also
least
subjects
the
I

~
TB-079
064-1
unit
to
dust, dirt,
moisture,
and corrosive
vapors.
The
instal
lation
Site should also
permit
easy
access
to
the
weld control
for
Operational
and
maintenance
functions.
Lead
lengths
must
be considered
when
locating
the
control.
Holes
are
provided
in
the weld
control
back
panel
for
mount
ing
purposes.
Figure
2-1
gives
overall
dimensions
and
mount
ing
hole
layout.
1
-4.
SAFETY
I
I I
U
I
SECTION
2
-
INSTALLATION
I
I
2-
1. LOCATION
(Figure
2-1)
Figure
2-1. Overall
Dimensions
and
Mounting
Hole
Layout
OM-1510
Page
1