Miller VCI-1 User manual

May
1982
FORM: OM-868A
~LE
CCO~t
i~1URN
~w
~
OWN
ERS
MANUAL
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST. P.O.
Box
1079
APPLETON WI
54912
USA
ADDITIONAL COPY
PRICE
20 CENTS
NWSA
CODE
NO. 4579
PRINTED IN U.S.A.
MODEL
vcI-1
ER
~
$~W
~

~~P L~P L
~
~-.
~
LIMITED
WARRANTY
EFFECTIVE:
JUNE
1.
1979
This
warranty
supersedes
all
previous
MILLER warranties and is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY-Subject
to
the
terms
and
conditions
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
hereof,
Miller
Electric
Mfg.
Co.
Appleton,
Wisconsin
warrants
submitted
by
the
original
user
within
the
foregoing
periods.
to
its
Distributor/Dealer that
all
new
and
unused
Equipment
(
furnished
by
Miller is
free
from
defect
in
workmanship
and
In
the
case
of
Millers
breach of
warranty
or
any
other
duty
material
as
of
the
time
and
place
of
delivery
by
Miller. No
war-
with
respect
to
the
quality
of
any
goods,
the exclusive
remedies
ranty
is
made
by
Miller with
respect
to
engines,
trade
ac-
therefore shall
be,
at
Millers
option
Ill
repair
or
(21
replacement
cessorues
or
other
items
manufactured
by
others.
Such
or,
where
authorized in
writing
by
Miller
in
appropriate
cases,
(3)
engines,
trade
accessories
and other items
are
sold
subject
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of their
respective manufacturers,
if
any
.
All
Miller
service station
or
(41
paymentof
or
credit for the
purchase
engines
are
warranted
by
their
manufacturer for
one
year
from
price
hess
reasonable
depreciation
based
upon
actual
use)
upon
date
of
original
purchase.
return
of the
goods
at
Customers risk
and
expense.
Upon receipt
of notice
of
apparent
defect
or
failure,
Miller
shall instruct the clai-
Except
as
specified
below,
Millers
warranty
does not
apply
mant
on
the
warranty
claim
procedures
to
be followed.
to
components
having
normal
useful life of
less than
one Ill
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
ANY EXPRESS WARRANTY
NOT
PROVIDED
HEREIN
AND
MILLERMATIC
parts
that
come
in
contact
with
the
welding
ANY
IMPLIED
WARRANTY,
GUARANTY
OR REPRESENTA
wire
including
nozzles
and
nozzle
insulators
where
failure
does TION
AS TO
PERFORMANCE,
AND ANY REMEDY
FOR
not
result from
defect
in
workmanship
or
material.
BREACH
OF CONTRACT
WHICH,
BUT
FOR THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
Miller
shall
be
required
to
honor
warranty
claims
on war-
CUSTOM
OF
TRADE
OR COURSE
OF
DEALING,
INCLUDING
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
ANY IMPLIED WARRANTY
OF MERCHANTABILITY
OR
OF
within
the
following periods
from
the date of
delivery
of
Equip-
FITNESS
FOR PARTICULAR
PURPOSE,
WITH
RESPECT TO
t
ment to
the
original
user:
ANY
AND ALL EQUIPMENT
FURNISHED
BY MILLER IS EX
CLUDED
AND
DISCLAIMED
BY
MILLER.
1.
Arc
welders,
power
sources
and
components
..
1
year
2.
Original
main
power
rectifiers
3
years
EXCEPT
AS EXPRESSLY PROVIDED
BY MILLER IN
(labor
-
1
year
onlyl
WRITING,
MILLER
PRODUCTS
ARE
INTENDED FOR
3.
Allweldinggunsandfeeder/guns
90days
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
1
4.
All other Millermatic
Feeders
1
year
USERS AND FOR OPERATION
BY
PERSONS TRAINED AND
5.
Replacement
or
repair
parts,
exclusive of labor
.
60
days
EXPERIENCED IN THE USE AND MAINTENANCE OF
6,
Batteries
6
months
WELDING EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER USE.
MILLER
WARRANTIES DO NOT
EXTEND
provided
that
Miller is notified
in
writing
within
thirty
1301
days
TO,
AND NO RESELLER IS
AUTHORIZED
TO
EXTEND
of the
date
of
such
failure.
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
~1, j?
~
...Yt,
j~

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
1
-
INTRODUCTION
Amend
Section
1-3.
DESCRIPTION
~
C~-~f
Delete the reference
to
CP 750E
welding
power
source
AMENDMENT TO SECTION
3
-
MAINTENANCE ~
TROUBLESHOOTING
Amend
Figure
3-1. Circuit
Diagram
~LG
i
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 uf 100
volts
1
R70
035 885
RESISTOR,
carbon
film
0.25
watt
68K
ohm
1
BE
SURE TO
PROVIDE
MODEL
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
February
15,
1983
FORM:
OM-868A
~D8K
A
~0 C
GPN
Circuit
Diagram
No.
A-088 175-B
PRONG
VIEW

SECTION
1
-
INTRODUCTION
carefully
followed
could
result
in serious
personal
injury
or
loss of life.
t~~Ikls]~I
statements
include
installation,
operating,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed could
result
in
minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
A
third
signal
word,
,
highlights
instruc
tions
which
need
special
emphasis
to
obtain
the
most
efficient
operation
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
will
be
furnished
by
the
manufacturer
on re
quest
if occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
it
is essential
that
Model
Description
and
Serial
(or
Style)
Number
of
the
equipment
be
supplied.
1-3.
DESCRIPTION
-
The
Voltage
Interface
Control
allows
an
Automatic
2
weld
control
to
interface with
MP
&
FC
series
and CP-750E
welding
power
source.
The
Interface
Control
also
provides
circuitry
which
com
pensates
for
line
or
load
variations.
SECTION
2
-
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.

Do
not
touch live electrical
parts.

Shut
down
the
welding
power
source
and
be
sure
it
cannot
be
accidentally
energized.
2-1.
VOLTAGE
INTERFACE
CONTROL
INTER
CONNECTIONS
(Figure
2-1)
1.
Connect
the
4-socket
plug
PLG2
from
the
Inter
face
Control
to
the
4-pin receptacle
RC1
1
on
the
Automatic
2
right
side
panel.
2. Insert the
3-pole
twistlock
plug
PLG1 from the
Interface
Control
into
the
Voltage
Control
recep
tacle
on
the
welding
power
source
and
rotate
clockwise.
3.
Connect terminal
on
black
feedback
lead
to
welding
power
source
Negative
output
terminal.
4.
Connect
terminal
on
white
feedback
lead
to
welding
power
source
Positive
output
terminal.
2-2.
30
VOLTS
CONTROL
CIRCUIT
FUSE
REPLACEMENT
IN
MP
AND FC
SERIES
WELDING
POWER
SOURCES
-
Replace
the
30 volts control cir
cuit
fuse,
Fl
in
the
650
and
750 ampere
models;
F2
in
the
350
and 450
ampere
models,
with the
supplied
15
ampere
fuse.
See
the
Owners Manual for
fuse
location.
IMPORTANT
1-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
prØsehted
in this
manual
and
on
various
labels,
tags,
and
plates
provided
on
the
unit
pertains
to
equipment
design,
installation,
operation,
maintenance,
and
troubleshooting
which should be
read, understood,
and followed for the
safe
and effective
use
of
this
equip
ment.
B.
Safety
The
installation,
operation,
maintenance,
and
troubleshooting
of
arc
welding equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of others.
Therefore,
this
equipment
is
to
be
installed,
operated,
and
maintained
only by qualified
persons
in
accordance with
this
manual
and
all
ap
plicable
codes
such
as,
but not
limited
to,
those
listed
at
the
end
of
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power Source
in the
welding
power
source
Owners
Manual.
Safety
instructions
specifically pertaining
to
this unit
ap
pear
throughout
this
manual
highlighted
by
the
signal
words
____________
and
___________
which
identify
different levels of hazard.
ITLTL~
~h~I
kIcI
statements
include
installation,
operating,
and
maintenance
procedures
or
practices
which
if
not
WARNING CAUTION
Place
the
Voltage
Control
switch
on
the
welding power
source
in
the
REMOTE
position.
On
we/ding
power
source
with
a
voltage
range
switch,
place
the
switch
in
the
single
wide
range
position.
PLG1
Feedback
Terminals
TB-047 489
Figure
2-1.
Voltage
Interface Control
OM-868
Page
1

SECTION
3
-
MAINTENANCE
&
TROUBLESHOOTING
WARNING
_________
ELECTRIC SHOCK
can
kill.

Do
not
touch
live
electrical
parts.

Disconnect
unit from
input
power
before
internal
ly
inspecting
or
servicing.
Troubleshooting
of internal parts
to
be
performed
only
by
qualified
persons.
IMPORTANT
______________
Periodically
inspect
the
labels
on
this
unit for
legibility.
All
labels
must
be
maintained
in
a
clearly
readable
state
and
rep/aced
where
necessary.
See the
Parts
List for
part
number
of
labels.
Periodically
inspect
all
interconnecting
cords
for
damage
to
or
breaks
in
the
insulating
jacket,
particularly
at
the
plug.
Repair
or
replace
the
cord(s) as
necessary.
Figure
3-1.
Circuit
Diagram
,WH
T
5-ORN~~GRN
Circuit
Diagram
No.
A-084
801
PLC~
PRONG VIEW
Page
2

May
1982
FORM:
OM-868A
PARTS
LIST
MODEL
vcI-1

4
S
30
29
Figure
A
-
Complete
Assembly
TD-047
550
I
14
~~-1
I
25
23
22
OM-868
Page
1

Item
Dia.
Part
No.
Mkgs.
No.
Description
Quantity
Figure
A
Complete
Assembly
1
006
535
RECTIFIER,
silicon
diode
(consisting
of)
1
2 050 037 952
.
DIODE,
rectifierl5amp200
voltsstraight
polarity
1
3 006
428
.
BRACKET,
mounting
-
heat
sink
1
4
006 534
AMPLIFIER,
power
(consisting
of)
1
5
Q53
007 716
.
TRANSISTOR,
30
amp
100
volts
PNP
1
6 Q54
007
715
.TRANSISTOR,3Oamp9OvoItsNPN
1
7
006
425
.
HEAT
SINK,
diode
1
8
D53
037
952
.
DIODE,
rectifier 15
amp
200
volts
straight
polarity
1
9
R69 006
429
.
RESISTOR,
5watt0.1
ohm 1
10
D52 037 451
.
DIODE,
rectifier
12
amp
200
volts
reverse
polarity
1
11
073
756
.
STAND-OFF,
No.
6-32
x
5/8
long
1/4 hex
4
12
601
242
.
INSULATOR,
washer-heatsink
1
13
019 677
HANDLE,
door-
pull
1
14
t021
475
WRAPPER
1
047
497
LABEL,
general
precautionary
1
15
006 427
BRACKET,
mounting-circuit
card
1
16
007
156
CIRCUITCARD(consistingof)
1
A50
008 971 .INTEG
RATED
CIRCUIT,
operational
amplifier
1
C51
031
721
.
CAPACITOR,
mylar
0.22 uf
200
volts
dc
1
C52
031
693
.
CAPACITOR, mylar0.33uf75voltsdc
1
051 037
449
.
DIODE,
zener
15
volts
1
watt
straight
polarity
1
Q50,52
039 353
.
TRANSISTOR,
4
amp
40
volts
NPN
2
Q51
039
354
.
TRANSISTOR,
4
amp
40
volts
PNP
1
R51
000 039
.
RESISTOR,
carbon 2
watt
680
ohm
1
R52,58
605
979
.
RESISTOR,
metal film 0.25
watt
15K
ohm
2
R53,55
006
424
.
POTENTIOMETER,
cermet
1
turn
5 watt
2K
ohm
2
R56
035
825
.
RESISTOR,
carbon
film
0.25 watt
1K
ohm
1
R57,60
605 978
.
RESISTOR,
metal
film
0.25
watt2.74K
ohm
2
R59 000 035
.
RESISTOR,
metal film
0.5 watt
6.8K
ohm
1
R61
035
884
.
RESISTOR,
carbon
film
0.25 watt
lOOK
ohm
1
R62
030
033
.
RESISTOR,
carbon
0.5 watt
470
ohm
1
R63
030 038
.
RESISTOR,
carbon
0.5
watt
220
ohm
1
R64,65
030
024
.
RESISTOR,
carbon
0.5
watt
1000
ohm
1
R66,67
030 839
.
RESISTOR,
WW fixed
5
watt
220
ohm
2
R68.
030
937
.
RESISTOR,
carbon0.Swattl0ohm
1
1
,2T
000
059
.
BLOCK,
terminal
5
amp
6
pole
2
17
R50
006
532
RESISTOR,
WWadj50watt5ohmw/Ieads
1
18
084
804
CORD,
voltage
-
control
(consisting
of)
1
19
007
826
.
CORD,
No. 18
3/c
(order
by
ft)
lift
20
039 828
.
CLAMP,
cable
1
21
047
544
.
PLUG,4socketMS-3106A-14S-2SX
1
22
048
298 CASE
SECTION,
base/front/rear
1
23
010 610
CONNECTOR,
clamp-cable
1
24
010
659
CONNECTOR,
clamp
-
cable
3/8
inch 90
deg
1
25
006
530
CABLE,
power
(consisting
of)
1
26
006
531
.
CABLE,
power
1
27
PLG1
605
797
.
CAP,
twistlock3P3W20
amp
125
volts
1
28
600340
.CORD,
No.
16
2/c(orderbyft)
6ft
29
006
426
BRACKET,
mounting
-
capacitor
1
30 C50
031 728
CAPACITOR,
electrolytic
9000
uf
35
volts
dc
1
*027
419
FUSE,
ceramic
15
amp
250
volts
(loose
item)
1
013312
LABEL,
usei5ampfuse
1
*Recommended
Spare
Parts.
tWhen
ordering
a
component
originally
displaying
a
precautionary
label,
the
label should
also
be
ordered.
BE
SURE
TO PROVIDE
MODEL
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-868
Page
2