Download Miller Electric VL-M4 Specifications

OM189 580
Miller
April
1998
Eff. w/Serial Number KJ0991 10
Processes
MIG
Vie Power ~fB1ue.
(GMAW) Welding
Submerged (SAW) Welding
Description
O
Submerged Arc Controller
Welding
For
Automatic
MILLER VL-M4
0
Visit
our
website at
www.MlHerWehts.com
OWNERS
MANUAL
From Miller to You
Thank you and
you
get the
can
have time to do it any other way.
you dont
Thats
congratulations on choosing Miller. Now~
job done and get it done right. We know
why
when Niels Miller first started
building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldnt afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
people that build and sell Miller products continue the
tradition. Theyre just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
5?1~JII~LOT!
This Owners
jOWIt:1DHPCefrOrn~:Mlite~1S~:~
Today,
the
Working az hard as you do
Miller
help
Manual is
products.
you
designed help you get the most out of your
Please take time to read the Safety precautions. They will
to
protect yourself against potential hazards
every
baCked b~:the fliost kassIe~iree~
warranty in the businesa
the worksite. Weve
on
made installation and
operation quick and easy.
With Miller you can count on years of reliable
service with proper maintenance. And if for
~I iJ~J~
~
1 1
I
REGISTERED
the unit needs repair, theres a
Troubleshooting section that will help you
QUALITY SYSTEM
some reason
V
Miller is the first welding equipment
manulathwer In the U.S.A. to he
registered to Ibe ISO oooi Quality
System Standard.
figure
out
will then
what the
help
problem
is. The parts list
you to decide which exact part
you may need to fix the problem. Warranty and
service information for your particular model
are
also
provided.
Miller offers a Technical
Manual which provides
more detailed seivice and
parts information for your
urnf To obtain a Technical
Manual, contact your 1Q08!::::
distributor Your distributor
can ~lso supply ył~ With
WeldIn9 Process Manuals
such as SM.4W OTAW
GMAW and QMAWP
Miller Electric manufactures
of welders and
welding
For information
products,
to
on
other
equipment.
quality Miller
contact your local Miller distributor
catalog
\
full line
related
receive the latest full line
individual
a
catalog
or
sheets. To locate your nearest
distributor call 1-800-4-A-Miller.
O~~
TABLE OF CONTENTS
SECTION 1
1-1.
-
SAFETY PRECAUTIONS
-
READ BEFORE USING
1-4.
Symbol Usage
Arc Welding Hazards
Additional Symbols for Installation, Operation,
Principal Safety Standards
1-5.
EMF Information
1-2.
1-3.
SECTION 1
1-1.
1-2.
1-3.
-
1
1
and Maintenance
-
Signification des symboles
Dangers relatifs au soudage a arc
Dangers supplØmentaires en relation
normes
1-5.
Information
sur
SECTION 2
-
Weld Control
2-2.
Description
3-1.
3-2.
3-3.
3-4.
-
5
avec
linstallation,
le fonctionnement
7
de sØcuritØ
champs ØlectromagnØtiques
INSTALLATION
Typical Equipment Location
Mounting Hole Layout
Connection Diagram
Connecting Shunt Control
8
8
9
9
9
10
10
10
11
12
3-5.
Left Side Panel Connections
12
3-6.
Strip TEl Connections
Terminal Strip TEl Connection Information
Remote 14 Receptacle RC2 Information
Terminal Strip TE2 Connections
Terminal Strip TE2 Connection Information
Remote 17 Receptacle RC1 Information
Remote 5 Receptacle RC3 Information
Start / Stop Connections For Two (2) Units
13
3-7.
3-8.
3-9.
3-10.
3-11.
3-12.
3-13.
Terminal
SECTION 4
-
OPERATION
14
14
15
16
16
16
17
17
4-1.
Safety Equipment
17
4-2.
Front Panel Controls
18
4-3.
Inside Panel Controls
SECTION 5- MAINTENANCE & TROUBLESHOOTING
5-1.
Routine Maintenance
5-2.
Replacing
Fuses
19
20
20
20
SECTION 6- ELECTRICAL DIAGRAM
22
SECTION 7
23
-
WAR RANTY
OM-189 530
5
5
SPECIFICATIONS
2-1.
SECTION 3
les
3
LIRE AVANT UTILISATION
et Ia maintenance
Principales
3
4
CONSIGNES DE SECURITE
1-4.
1
PARTS LIST
SECTION 1
SAFETY PRECAUTIONS
-
READ BEFORE USING
-
nd5/97
som
Symbol Usage.
1-1.
Means
AA
A
Marks
a
There
not
safety
hazards
are
This group of
symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary
actions to avoid the hazards.
related.
Welding
Hazards
are used throughout this manual
identity possible hazards. When you
shown below
symbols
to call attention to and
seethe
possible
are
special safety message.
Arc
1-2.
The
Out!
Watch
procedure! The possible
adjoining symbols.
shown in the
~ Means Note~
A
Warning!
hazards with this
symbol,
watch out, and tollowthe related instructions
safety information given below is
to avoid the hazard. The
a summary of the more complete safety information
found in the Safety Standards listed in Section 1 -4. Read and
follow all Safety. Standards.
If earth
with
grounding
of the
separate cable
a
-
workpiece
is
do not
work
use
required, ground it directly
clamp or work cable.
Do not touch electrode if you are in contact with the
another electrode from a different machine.
work, ground,
or
only
A
A
Only qualified persons
repair this unit.
should
install, operate, maintain,
and
During operation, keep everybody, especially children, away.
Use
only well-maintained equipment. Repair or replace damaged
at once. Maintain unit according to manual.
parts
safety
Wear
a
Keep
all
Clamp work
or
worktable
can
kill
as near
above floor level.
securely
in
place.
metal-to-metal contact to
good
the weld
as
workpiece
practical.
clamp when not connected to workpiece to prevent
object.
contact with any metal
Do not connect
live
electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is on.
The input power circuit and machine internal
circuits are also live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll housing, and all
metal parts touching the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is a hazard.
Touching
working
and covers
cable with
Insulate work
ELECTRIC SHOCK
harness if
panels
more
than
one
electrode
or
work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before
touching any parts.
Do not touch live electrical parts.
Wear
dry,
hole-free
insulating gloves
and
body protection.
FUMES AND GASES
Insulate
yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
Do not use AC output in damp areas, if movement is confined,
there is a danger of falling.
Use AC output ONLY if
If AC
output is required,
required
use
for the
remote
or
Disconnect
output control if present
on
Properly
Owners
power or stop engine before installing or
equipment. Lockout/tagout input power according
CFR 191 0.147 (see Safety Standards).
input
this
to OSHA 29
install and
ground
this
equipment according
to its
Manual and national, state, and local codes.
Always verity the supply ground check and be sure that input
power cord ground wire is properly connected to ground terminal
in disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
-
When
making input connections,
conductor first
-
attach
proper
grounding
double-check connections.
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
-
-
Turn off all
Do not
Do not
equipment
use worn,
drape
when not in
over
If ventilation is poor,
Read
Material
the
manufacturers
your
body.
poorly spliced
cables.
and gases. Breathing
be hazardous to your
can
use an
use
exhaust at the
arc
to
approved air-supplied respirator.
Data
Safety
Sheets
instructions for metals,
(MSDSs)
and
the
consumables, coatings,
cleaners, and degreasers.
confined space
only if it is well ventilated, or while
air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
Work in
a
wearing
an
Do not weld in locations
operations.
form highly
near
degreasing, cleaning,
The heat and rays of the arc
toxic and irritating gases.
Do not weld
on
coated
plated steel,
weld area, the
or
be hazardous.
head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or
remove welding fumes and gases.
cadmium
use.
damaged, undersized,
cables
these fumes and gases
health.
Keep your
unit.
servicing
Welding produces fumes
if
welding process.
can
area
metals, such
unless the
is well
can
as
coating
or
spraying
react with vapors to
galvanized, lead,
or
is removed from the
ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
OM-189 530
Page
1
BUILDUP OF GAS
ARC RAYS can burn eyes and skin
Shut off
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
can
injure
kill
or
not in
shielding gas supply when
confined
ventilate
spaces
Always
approved air-supplied respirator.
awelding helmet fitted with a propershade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
use.
or
use
Wear
Wear
approved safety glasses
HOT PARTS
can cause severe
helmet.
Do not touch hot
protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Allow
Use
Wear
burns.
with side shields under your
parts
cooling period
bare handed.
before
working
on
gun
or
torch.
protective clothing made from durable, flame-resistant
(leather and wool) and foot protection.
material
MAGNETIC FIELDScan affect pacemakers.
WELDING can cause fire
or
explosion.
Pacemaker
keep away.
wearers
Wearers should consult their doctor before
closed containers, such as tanks,
can causethem to blow up. Sparks
can fly off from the welding arc. The flying sparks,
hot workpiece, and hot equipment can cause fires
and burns. Accidental contact of electrode to metal objects can
cause sparks, explosion, overheating, orfire. Check and besurethe
area is safe before doing any welding.
Protect
Welding
on
drums,
pipes,
yourself
or
and others from
Do not weld where
flying sparks
flying sparks
can
going near arc welding, gouging,
welding operations.
NOISE
can
or
spot
damage hearing
and hot metal.
Noise from some processes
strike flammable material.
equipment
or
can
damage hearing.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
possible, tightly cover them with approved covers.
approved
Wear
this is not
ear
protection
if noise level is
high.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for
fire, and keep
Be
that
aware
fire
can cause
Do not weld
on
welding
on
a
fire
on a
extinguisher nearby.
ceiling, floor, bulkhead,
closed containers such
tanks, drums,
as
they are properly prepared according
Safety Standards).
unless
or
as close to the welding area as
prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
Do not
to
use
can
explode if damaged
welder to thaw frozen
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding
process, be sure to treat them carefully.
pipes,
(see
to AWS F4.1
Connect work cable to the work
practical
CYLINDERS
partition
or
the hidden side.
Install
pipes.
compressed gas cylinders from excessive heat,
slag, open flames, sparks, and arcs.
Protect
mechanical shocks,
cylinders in an upright position by securing to a stationary
or cylinder rack to prevent falling or tipping.
support
Remove stick electrode from holder
contact
tip
when not in
Wear oil-free
or
cut off
welding
wire at
use.
protective garments such as leather gloves, heavy
high shoes, and a cap.
shirt, cuffless trousers,
Remove any combustibles, such as a butane
from your person before doing any welding.
FLYING METAL
can
lighter or matches,
Injure eyes
Keep cylinders away from any welding
Never
drape
Never allow
Never weld
a
a
welding
welding
on a
torch
over a
or
gas
Welding, chipping,
cause sparks and flying
they can throw off slag.
grinding
metal. As welds cool,
approved safety glasses with side
shields even under your welding helmet.
Wear
OM-189 530
Page
2
cylinder.
electrode to touch any
pressurized cylinder
-
cylinder.
explosion
will result.
Use only correct shielding gas cylinders, regulators, hoses,
fittings designed for the specific application; maintain them
associated parts in good condition.
Turn face away from valve outlet when
wire brushing, and
other electrical circuits.
Keep protective cap
use or
in
connected for
place
over valve
opening cylinder
except
when
and
and
valve.
cylinder is in
use.
Read and follow instructions on compressed gas cylinders,
equipment, and CGA publication P-i listed in Safety
associated
Standards.
1-3
Additional
~
4
For
Symbols
Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS
Do not install
place
or
unit on, over,
Keep away
or near
combustible surfaces.
]
Do not install unit
Do not overload
is
can cause
injury.
.
building wiring
properly sized, rated,
and
near
be
-
flammables.
sure
power
cause
fans.
guards
injury.
eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use
as
supply system
H.F. RADIATION
Use
such
moving parts
to handle this unit.
protected
FALLING UNIT can
from
all doors, panels, covers, and
closed and securely in place.
Keep
can cause
interference.
lifting
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
The
for
responsible
is
user
having a qualified electrician
problem resulting from the
correct any interference
promptly
installation.
OVERUSE
Allow
cooling period;
Reduce current
starting
or
STATIC (ESD)
Put
or
on
follow rated
reduce
duty cycle.
duty cycle
before
again.
to weld
Do not block
handling
OVERHEATING
can cause
filter airflow to unit.
can
grounded
boards
or
If notified
by
equipment
at once.
the FCC about
Have the installation
regularly
interference, stop using
the
checked and maintained.
Keep high-frequency source doors and panels tightly shut,
keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.
damage PC boards.
wrist
strap
BEFORE
parts.
ARCWELDING an
Use proper
static-proof bags and
store, move, or ship PC boards.
cause
interference.
boxes to
Electromagnetic energy can interfere with
electronic equipment such as
computers and computer-driven equipment
sensitive
MOVING PARTS
can cause
such
injury.
Keep
away from
Keep away
moving parts.
from
pinch points
as
robots.
all equipment in the welding
electromagnetically compatible.
Be
such
as
drive
To reduce
possible,
rolls.
sure
WELDING WIRE
can cause
injury.
possible interference, keep weld cables as short as
together, and down low, such as on the floor.
Be
welding operation
equipment.
sure
according
Do not press gun
trigger
until instructed to do
so.
Do not
point gun toward any part of the body,
people, or any metal when threading
welding wire.
is
close
Locate
tronic
area
this
welding
100 meters from any sensitive elec
machine
is
installed and
grounded
to this manual.
If interference still occurs, the user must take extra measures
as moving the welding machine, using shielded cables,
such
using
line
filters,
or
shielding
the work
area.
other
1-4.
Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49. 1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances,
American Welding Society Standard AWS F4.1, from American
Welding Society, 550 NW. LeJeune Rd, Miami, FL 33126
National Electrical
Code, NFPA Standard 70, from National Fire
Batterymarch Park, Quincy, MA 02269.
Protection Association,
Safe Handling of
Compressed
Gases in
Cylinders,
P-i, from Compressed Gas Association,
Highway, Suite 501, Arlington, VA 22202.
CGA
Pamphlet
1235 Jefferson
Davis
Code for Safety in Welding and Cutting, CSA Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
Safe Practices For
Occupation
And Educational
Eye
And Face
Protection, ANSI Standard Z87.i from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
And Welding Processes, NFPA Standard 51 B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Cutting
OM-189 530
Page
3
.1-5.
EMF Information
Considerations About Welding And The Effects Of Low
Electric And Magnetic Fields
Frequency
1.
Keep cables
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: The body of evidence, in the
committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.
However, studies are still going forth and evidence continues to be
2.
Arrange
3.
Do not coil
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding
To
or
magnetic
procedures:
OM-189 530
or
one
or
taping
side and away from the
them.
operator.
drape cables around your body.
Keep welding power
practical.
source
Connect work
to
4.
and cables
as
far away from opera-
tor as
5.
clamp
workpiece
as
close to the weld
as
possible.
fields
in the
workplace,
use
the
following
Pacemakerwearersconsultyourdoctorfirst. If cleared by yourdoctor,
following the above procedures is recommended.
then
Page
cables to
together by twisting
About Pacemakers:
cutting.
reduce
close
4
SECTION 1
-
CONSIGNES DE SECURITE
UTILISATION
LIRE AVANT
-
som
1-1
Signification
Identifie
fl~
Signifie NOTA;
un
nest
etauxdirectives ci-dessous at in de connaItre les
Øviter tout danger.
pas relatif a Ia sØcuritØ.
Dangers relatifs
1-2
au
soudage
a
symboles prØsentØs ci-aprŁs
present
manuel
A
Linstallation, Iutilisation, lentretien et les reparations
des personnes qualifiees.
vent Œtre confiØs qu
A
Au coursde
ne
doi
lutilisation, tenirtoute personne a lØcartet plus par
ticuliŁrement
es
mesures
a prendre pour
Iarc
sont utilisØs tout au long du
pour attirer votre attention et identifier les
risques de danger. Lorsque vous voyez un symbote, soyez
vigilant et suivez les directives mentionnØes atm dØviter tout
danger. Les consignes de sØcuritØ prØsentØes ci-aprŁs ne font
que rØsumer linformation contenue dans les normes de sØcuritØ
ØnumØrØes a Ia section 1 -4. Veuillez lire et respecter toutes ces
normes de sØcuritØ.
Les
F1
Ce groupe de symboles signifie Mise en garde Soyez vigilant Ily a des
risques de danger relies aux CHOCS ELECTRIQUES, aux PIECES EN
MOUVEMENTetaux PIECES CHAUDES. Reportez-vous auxsymboles
message de sØcuritØ particulier.
A
5/97
symboles
Signifie Mise en garde Soyez vigilant! Cette procedure
prØsente des risques de danger! Ceux-ci sont identifies
par des symboles adjacents aux directives.
a
A
des
_nd_fre
Ne pas toucher lŁlectrode
terre ou une
quand
on
est
en
contact avec Ia
piŁce,
Ia
electrode provenant dune autre machine.
Nutiliser quun materiel en bon Øtat. RØparer ou remplacer sur-le
champ les piŁces endommagØes. EntretenirlappareilconformØment
a
ce
manuel.
Porter
harnais de sØcuritØ quand
un
Maintenir solidement
en
place
on
travaille
hauteur.
en
tous les panneaux et
capots.
Fixer le cable de retour de facon a obtenir un bon contact mŁtal-mØtal
avec Ia piŁce a souder ou Ia table detravail, le plus prŁs possible de Ia
soudure.
enfants.
Isoler Ia
pince de masse quand pas
Objet metallique.
mis a Ia
piŁce
pour Øviter le contact
avec tout
UN CHOC ELECTRIQUE
Un
simple
contact avec des
peut
tuer
piŁces Ølectriques peut
provoquer une electrocution ou des blessures graves.
LØlectrode et le circuit de soudage sont sous tension
des que lappareil est sur ON. Le circuit dentrØe et les
circuits internes de Iappareil sont egalement sous
tension ace moment-l. En soudage semi-automatique ou automatique,
le fil, le dØvidoir, le logement des galets dentraInement et les piŁces
metalliques
contact avec le fit de soudage sont sous tension. Des
ou mal mis a Ia terre prØsentent un danger.
en
Ily a DU COURANT CONTINU IMPORTANT dans les
convertisseurs aprŁs Ia suppression de Ialimenta
tion Ølectrique.
ArrŒter les convertisseurs, dØbrancher le courant electrique, et dØ
charger les condensateurs dalimentation selon les instructions
indiquees dans Ia partie entretien avant de toucher les piŁces.
matŁriels mal installŁs
Ne
jamais
toucher
es
piŁces electriques
Porter des gants et des vŒtements de
pas de trous.
sous
tension.
protection secs
ne
comportant
de Ia piŁce et de Ia terre au moyen de tapis ou dautres
moyens isolants suffisamment grands pour empŒcher le contact phy
sique Łventuel avec Ia piŁce ou ta terre.
Sisoler
servir de source electrique courant Ølectrique dans les
humides, dans les endroits confines ou l oi~ on risque de tomber.
Ne pas
se
Se servir dune
procØdØ
de
source
Soudage
Si lutilisation dune
saire,
se
electrique courant electrique
zones
UNIQUEMENT site
~
!t!edangereux~
I
L
V
Le soudage gŁnere des tumØes et des gaz. Leur
inhalation peut Øtre dangereux pour votre sante.
_____________
source
electrique
courant
Ølectrique
servir de Ia fonction de tØlØcommande Si
~appareiI
savŁre nØces
en
est
equipe.
sØcuritØ).
Installeret mettre a laterre correctement cet appareil conformØment
manuel dutilisation et aux codes nationaux, provinciaux et
son
A
IintØrieur, ventiler Ia
veau
votre
tŒte des fumØes. Ne pas respirer
zone
et/ou utiliser
un
Øchappement
de larc pour IØvacuation des fumØes et des gaz de
Si Ia ventilation est insuftisante, utiliser
tion dair homologuØ.
un
au
ni
soudage.
respirateur a alimenta
Lire les specifications de sŁcuritØ des matØriaux (MSDS5) et les ins
tructions du fabricant concernant les mØtaux, les consommables,
les revŒtements, les nettoyants et les dØgraisseurs.
Travailler dans
en
municipaux.
Toujours verifier
Eloigner
les fumØes.
le demande.
Couper lalimentation ou arrŒterle moteuravantde procŁder Iinstal
lation, a Ia reparation ou a lentretien de lappareil. DØverrouiller
lalimentation selon Ia norme OSHA 29 CFR 1910.147 (voir normes
de
~ITh~ I LES FUMEES ET LES GAZ peuvent
un
espace fermŁ seulement sil est bien ventilØ
ou
portant un respirateur a alimentation dair. Demander toujours a
rer
un surveillant dCiment formØ de se tenir a proximitØ. Des fumØes et
des gaz de soudage peuvent dØplacer lair et abaisser le niveau
doxygŁne provoquant des blessures ou des accidents mortels.
Sassurer que lair de respiration no prØsente aucun danger.
En effectuant les raccordements dentrØe fixer dabord le conducteur
de mise a Ia terre approprie et contre-vŁrifier les connexions.
degraissage,
Verifier et sassu
a terre du cordon dalimentation
que le fit de terre du cordon datimentation est bien raccordŁ ala
borne de terre du sectionneur ou que lafiche du cordon est raccordØe
a une prise correctement mise a Ia terre.
-
Verifier
frØquemment le cordon dalimentation pour voir sil nest pas
endommagØ ou dŁnudØ remplacer le cordon immØdiatement sit est
endommagØ un cable dŁnudŁ peut provoquer une electrocution.
Mettre lappareil hors tension quand on ne Iutilise pas.
Ne pas utiliser des cables uses, endommagŁs, de grosseur insuffi
sante ou mat Łpisses.
-
-
Ne pas enrouler
Si Ia
es
cables
autour du
corps.
lefaire directementavec un
piŁce ou le cable de
Ne pas souderdans des endroits situØs a proximitØ doperations de
de nettoyage ou de pulvØrisation. La chaleur et les
rayons de larc peuvent reagir en presence de vapeurs et former
des gaz hautement toxiques et irritants.
Ne pas souder des mŁtaux munis dun revŒtement, tels que lacier
galvanisØ, plaque en p10mb ou au cadmium a moms que le revØte
ment nait ØtØ enlevØ dans Ia zone de soudure, que Iendroit soit
bien ventilØ, et si nØcessaire en portant un respirateur ~ alimenta
tion dair. Los revØtements et tousles mØtaux renfermant ces ØlØ
ments peuvent degager des fumŁes toxiques en cas de soudage.
piŁce soudØe doitŒtre mise a laterre,
cable distinct
-
ne
pas utiliser le connecteur de
retour.
OM-189 530
Page
5
LES RAYONS DE LARC peuvent pro
voquer des brUlures dans les yeux et
Iarc
rayonnement de
du
procØdØ
soudage
de
rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer
des brOlures dans les yeux et sur Ia peau. Des Øtincelles sort projetees
des
genere
le
pendant
U~&F
Ia peau.
sur
Le
rls-.
LES ACCUMULATIONS DEGAZ
blessures
des
ou
de
provoquØr
quent
mØme Ia mort
soudage.
L~J
S
Fermer Ialimentation
non
Veiller
toujours a bien aØrer
rateur dadduction
un casque de soudage muni dun Øcran de filtre appropriØ pour
protØger votre visage et vos yeux pendant le soudage ou pour regar
der (voir ANSI Z49. 1 et Z87. 1 ØnumØrØ dans les normes de sØcuritØ).
du gaz
protecteur
cas
en
de
utilisation.
dair
las espaces confines
servir dun
ou se
respi
homologuØ.
Porter
Porter des
protections approuvØs pour
DES PI¨CES CHAUDES peuvent
voquer des brlures graves.
les oreilles si le niveau sondre est
trop ØlevØ,
Utiliser des Øcrans
et de
ou
des barriŁres pour
protØger des tiers
IØblouissement; demander aux autres personnes de
pas
Ne pas toucher des
re
parties
chaudes a mains
nues
Porter des vŒtements de
ble, resistant
m
de IØclair
ne
arc.
garder
pro
~I
au
feu
protection constituØ dans une matiŁre dura
ou lame) et une protection des pieds.
(cuir
LESOUDAGE peut provoquer
incendie ou une expIosion~
~1
provoquerleurØclatement. DesØtincellespeuventŒtre
projection
le
pØriode
pistolet
ou
Porteurs de stimulateur
projetees de Iarc de soudure. La projection dØtincel
es, des piŁces chaudes etdes Øquipements chauds peut provoquerdes
incendies et des brOlures. Le contact accidentel de electrode avec des
objets metalliques peut provoquer des Øtincelles, une explosion, un
surchauftement ou un incendie. Avant de commencer le soudage,
verifier et sassurer que Iendroit ne prØsente pas de danger.
personnes de Ia
une
de refroidissement avant
Ia torche.
LES CHAMPS MAGN TIQUES peuvent
affecter les stimulateurs cardiaques.
soudage effectuØ sur des conteneurs fermØs tels
que des reservoirs, tambours ou des conduites peut
Le
Se protØger et dautres
metal chaud.
PrØvoir
dutiliser
Les
cardiaque,
dabord
consulter leur mØdecin avant de
operations de soudage a arc,
soudage par points.
des
de
restez a distance.
porteurs dun stimulateur cardiaque doivent
sapprocher
de gougeage
ou
dØtincelles et de
LE BRUIT peut affecter lowe
Ne pas souder dans un endroit l o
sur des substances inflammables.
des Øtincelles
peuvent tomber
Le bruit des processus et des
louIe.
Deplacertoutes les substances inflammables a une distance del 0,7
es recouvrirsoigneuse
m de arc de soudage. En cas dimpossibilitØ
ment avec des protections homologuØs.
Des Øtincelles et des matØriaux chauds du soudage peuvent facile
ment passer dans dautres zones en traversant de petites fissures et
Porter des
affecter
equipements peut
protections approuvØs pour les oreilles Si
Ia niveau sondre est
trap ØlevØ.
des ouvertures.
SurveillertoutdØclenchementdincertdieettenirunextincteurproxi
Si des BOUTEILLES sont endomma
gØes, elles pourront exploser.
mite.
~
Le
soudage eftectuØ
peut dØclencher
un
Ne pas effectuer le
sur un
plafond, plancher, paroi
incendie de lautre
soudage
sur
separation
ou
ctØ.
Des bouteilles de gaz protecteur contiennent du gaz
haute pression. Si une bouteille est endomma
gee, elle peutexploser. Du faitque les bouteillesde gaz
font normalement partie du procede de soudage, les
des conteneurs fermØs tels que des
sous
reservoirs, tambours, ou conduites, a mains quils naient ØtØ prepa
rØs correctement conformØment a AWS F4.1 (voir les normes de
sØcuritØ).
Brancher le cable sur Ia piŁce le plus pres possible de Ia zone de sou
pour Øviter le transport du courant sur une longue distance par
des chemins inconnus Øventuels en provoquant des risques dØlec
trocution et dincendie.
dage
Ne pas utiliser le
poste
de
soudage
pour
degeler
des conduites ge
lees.
En cas de non utilisation, enlever Ia baguette dØlectrode
electrode ou couper Ie fil a Ia pomnte de contact.
du porte
Porter des vŒtements de protection dØpourvus dhuile tels que des
gants en cuir, une chemise en matØriau Iourd, des pantalons sans re
vers, des chaussures hautes et un couvre chef.
Avant de souder, retirer toute substance combustible de
telles quun allumeur au butane ou des allumettes.
I
~-~
vos
poches
DES PARTICULES VOLANTES
peuvent blesser les yeux.
avec
precaution.
les bouteilles de gaz comprime dune chaleur excessive,
des chocs mØcaniques, du laitier, des flammes ouvertes, des Øtin
celles et des arcs.
Proteger
Placer les bouteilles debout en les fixant dans un support station
naire ou dans un porte-bouteilles pour les empŒcher de tomber ou
de se renverser.
Tenir les bouteilles
cuits electriques.
Ne
jamais placer
une
Une electrode de
une bouteille.
Ne
jamais
eloignees des circuits de soudage ou autres cir
souder
torche de
soudage
une
ne
soudage sur une bouteille a gaz.
jamais entrer en contact avec
doit
bouteille
pressurisee
-
risque dexplosion.
Utiliser seulement des bouteilles de gaz protecteur, regulateurs,
tuyaux et raccords convenables pour cette application specifmque;
les maintenir ainsi que les ØlØments associØs en bon Øtat.
Ne pas tenir Ia tŒte en face de Ia sortie en ouvrant Ia soupape de Ia
bouteille.
Le
le passage de Ia piŁce
fil de fer, et le meulage genŁrent
soudage, lØcaillement,
a Ia brosse en
desŁtincellesetdes particules metalliquesvolan
tes. Pendant Ia pØriode de refroidissement des soudures, elles risquent
de projeter du laitier.
Porter des lunettes de sØcuritØ
OM-189 530
manipuler
Page
6
avec
Øcrans latØraux
ou un
Øcran facial.
Maintenir le chapeau de protection sur Ia soupape, sauf
dutilisation ou de branchement de Ia bouteille.
en cas
Lire et suivre les instructions concernant les bouteilles de gaz cornles Øquipements associØs et les publications P-i CGA Ønu
mØrØes dans les normes de sØcuritØ.
prime,
1-3.
Dangers supplØrnentaires
en
relation
avec
linstallation,: le tonctionnement
et Ia maintenance
Risque DINCENDIE OU
ORGANES MOBILES
provoquer des blessures.
DES
DEXPLOSION~
Ne pas
placer Iappareil
proximitØ
Me pas installer
au-dessus
sur,
ou
a
Rester a lØcart
de surfaces infllammables.
lappareil a proximite
de
des organes mobiles
le
comme
ventilateur.
MaintenirfermØs etfixementen
inflammables
produits
peuvent
panneaux,
Ne pas surcharger linstallation Ølectrique sassurer que lalimen
tation est correctement dimensionnØ et protØgØ avant de mettre
lappareil en service.
recouvrements
et
place es portes,
dispositits de
-
LA CHUTE DE LAPPAREIL
blesser.
Utiliser lanneau
de
protection.
LE RAVONNEMENT HAUTE FRE
QUENCE (H.F.) risque de provoquer
des interferences.
peut
Le rayonnement haute frequence peutprovoquer
des interferences avec les Øquipements de ra
levage uniquement pour sou
dio-navigation etde communication,
lever lappareil, NON PAS les chariot, les bouteil
es de gaz ou tout autre accessoire.
engin dune capacite appropriØe pour
lappareil.
En utilisant des fourches de levage pour dØplacer lunitØ, sassurer
que les fourches sont suffisamment longues pour dØpasser du ctØ
oppose de Iappareil.
Utiliser
un
soulever
LEMPLOI
EXCESSIF peut
SURCHAUFFER LEQUIPEMENT.
Demander seulement Ł des personnes qualifiØes familiarisØes
des Øquipements Ølectroniques de faire fonctionner linstalla
avec
tion.
Lutilisateur est tenu de faire corriger rapidement par
les interferences resultant de installation.
pØriode de refroidissement, respec
ter le cycle opØratoire nominal.
RØduire le courantou le cycle opØratoire avantde
recommancer le soudage.
du
LES CHARGES
Si le FCC
reil.
signale des interferences,
arrŒter immØdiatement
Effectuer
rŁguliŁrement
et lentretien
le contrle
ELECTROSTATIQUES
Ia connexion avec Ia barrette de terre
avant de manipuler des cartes ou des piŁces.
pochettes et des boItes antistatiques
ou expØdier des cartes de
pour stocker, dØplacer
circuits imprimes.
LØnergie
sapprocher
des organes mobiles.
Ne pas sapprocher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent pro
voquer des blessures.
ØlectromagnØtique
Ne pas
diriger
le
Ia
gachette
pistolet
vers
avant den avoir
soi, dautres
piŁce mØcanique
soudage.
sonnes ou toute
le fil de
sur
en
per
engageant
de
robots.
soudage aussi courts que possible,
bas que possible (ex. par terre).
Veiller a
ce
une
les grouper, et los poser aussi
distance de 100 metres de tout
equipernent
sensible.
quo
conformØment Ø
ce
poste de soudage soit pose
et mis ~ Ia terre
mode
demploi.
En cas dinterfØrences aprŁs avoir pris los mesures prØcØdentes, ii
incombe a lutilisateur de prendre des mesures supplØmentaires
telles que le dŁplacement du poste, lutilisation de cables blindØs,
lutilisation de filtres de ligne ou Ia pose de protecteurs dans a zone
ce
de travail.
LES CHAMPS MAGNETIQUES peuvent
affecter les stirnulateurs cardlaques.
Porteurs de stimulateur
Ne pas appuyer
recu instruction.
risque
lØquipement do Ia zone de soudage soit com
patible ØlectromagnØtiquement.
Pour rØduire Ia possibilitØ dinterfØrence, maintenir es cables de
electronique
provoquer des blessures.
pour rØduire les inter
Veiller Øce que tout
Veiller a souder a
ORGANES MOBILES peuvent
blindage
provoquer des interferences pour lequipement
electronique sensible tel quo les ordinateurs et
lequipement commandØ par ordinateur tel quo
es
Etablir
Ne pas
de linstallation.
LE SOUDAGE A LARC
risque de
provoquer des interferences.
poste.
primes.
DES
lappa
fØrences Øventuelles.
peuvent endommager les circuits im
Utiliser des
Ølectricien
Maintenir soigneusement fermØs les portes et los panneaux des
sources de haute frØquence, maintenir les Øclateurs a une distance
une
Ne pas obstruer les passages dair
un
qualifiØ
correcte et utiliser une terre et et un
PrØvoir
les services
de sØcuritØ et les ordinateurs.
cardiaque,
restez a dis
tance.
Los porteurs dun stimulateur cardiaque doivent
dabord consulter leur mØdecin avant do sappro
cher des operations de soudage a arc, do gou
geage ou do soudage par points.
OM-189 530
Page
7
1 -4.
Principales
normes
de sØcuritØ
Safety in Welding and Cutting, norme ANSI Z49. 1, de lAmerican
ding Society, 550 NW. Lejeune Rd, Miami FL 33126
Wel
Safe
of
Handling
way, Suite 501,
Safetyand Health Sandards,
OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cut
of Containers That Have Held Hazardous Substances, norme
AWS F4. 1, de lAmerican Welding Society, 550 NW. Lejeune Rd, Mia
mi FL 33126
ting
National Electrical Code, NFPA Standard 70, de Ia National Fire Pro
tection Association, Batterymarch Park, Quincy, MA 02269.
:1 -5.
Information
sur
les
sur le soudage electrique et sur es effets,
champs magnØtiques basse frØquence
Le courant de
soudage, pendant son passage dans
dage, causera des champs OlectromagnØtiques.
pour
lorganisme,
Ies cables de
CGA
Pamphlet
Arlington,
VA 22202.
de sØcuritØ en soudage, coupage etprocØdØs connexes, norCSA Wi 17.2, de lAssociation canadienne de normalisation, vente
de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W
1R3.
me
ForOccupationAnd Educational EyeAnd Face Protec
ANSI Z87. 1, de lAmerican National Standards Institute,
Safe Practices
tion,
norme
1430
Broadway,
New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51 B, de Ia National
Protection Association, Batterymarch Park, Quincy, MA 02269.
comitØ
special
National Research Council aconclu: Laccumulation
Afin de rØduire les
Fire
ruban bleu du
Garder les cables ensembles en les torsadant
attachant avec du ruban adhØsif.
2
Mettre tous les cables du ctØ
3
Ne pas courber pas et
votre corps.
4
de preuves, sui
jugement du comitØ, na pas dØmontrØ que lexposition aux
champs magnØtiques et champs Ølectriques a haute frØquence reprØ
sente un risque a Ia sante humaine.
Toutefois, des etudes sont
toujours en cours et les preuves continuent a Œtre examinØes. En at
tendant que es conclusions finales de Ia recherche soient Øtablies, 1
vous serait souhaitable de rØduire votre exposition aux champs Ølec
tromagnØtiques pendant le soudage ou le coupage.
champs electromagnetiques dans Ienvironnement
travail, respecter les consignes suivantes
i
sou
II y a eu et il y a
certain souci a propos de tels champs. Cependant, aprØs
avoir examine plus de 500 etudes qui ont ØtØ faites pendant une pe
un
Cylinders,
Regles
de
encore un
node de recherche de 17 ans,
in
champs ØlectromagnØtiques
DonnØes
des
Compressed Gases
P-i, de Ia Compressed Gas Association, 1235 Jefferson Davis High
Garder le
de
ne
oppose
de
les
ou en
lopØrateur.
pas entourer pas les cables autour de
poste de soudage
et es cables le
plus
loin
possible
vous.
vant le
OM-i89 530
Page
8
5
Relier Ia
pince
de
masse
le
plus prŁs possible
de Ia
zone
de
soudure.
Consignes
relatives
aux
stimulateurs
cardiaques
Les personnes qui portent un stimulateur cardiaque doivent avanttout
consulter leur docteur. Si vous Œtes dØclarØ apte par votre docteur, II
est alors recommandØ de
respecter
es
consignes
ci-dessus.
SECTION 2- SPECIFICATIONS
Weld Control
2-1.
Specification
Type
Of
Input
Power From
Description
Welding
Single-Phase
115 Volts
AC,
3.5
Amperes, 50/60 Hertz
Power Source
Welding Power Source Type
Constant Current
Welding Processes
Gas Metal Arc
Overall Dimensions
Receptacles, Etc.
Including Knobs,
Weight
Weld Control
Voltage And Amperage
Capacity (AC Or DC)
2-2.
(GMAW)
Constant
And
Voltage (CV),
Submerged
Arc
AC Or
DC, With Contactor And Remote Capabilities
Welding (SAW)
Shunt Control
Length: 11.5 in (292 mm); Width: 11.25 in (286 mm); Height:
Length: 14 in (356 mm); Width: 8.75 in (222 mm); Height: 4
Weld Control
Net: 18 lb
Shunt Control
Weld
(CC),
7 in
(178 mm)
(102 mm)
in
(8.2 kg)
(4.6 kg)
Net: 10.2 lb
0 To 100 Volts
0 To 1500
Amperes
Description
This weld control is designed to au
tomatically cycle welding events
while maintaining constant wire
feed speed. This unit can be used
with
current,
constant
voltage,
AC
sources
having
or
DC
constant
welding power
remote contactor
capabili
Welding
(SAW). Normally open relay con
tacts that work in conjunction with
the weld cycle are available to in
terf ace with other equipment (such
as fixtures and flux valves). See
control and output control
ties for Submerged Arc
Section 3-6 and 3-7 for connection
information on TEl.
For information
on
the wire drive
assembly, see Owners Manual
supplied with the assembly. A cur
rent sensing shunt control is also
provided with the weld control.
OM-189 530
Page
9
SECTION 3- INSTALLATION
3-1.
Typical Equipment
Location
Power Source
1
Welding
2
Side Beam
3
Current
Control
4
Weld Control
Sensing Shunt
5
Spool Support
6
Wire Drive
Assembly
7
Automatic
Welding
Gun
5
3,
.6
2
ST-i 31 138-A
3-2.
Mounting
Hole
Layout
4
in
(101.6 mm)
*
Includes front
panel
knobs
ST-083 354-C
OM-189 530
Page
10
3-3.
Connection
Note ~
Diagram
Customer must supply wire drive
flux for the desired
assembly and drive rolls,
gun,
welding wire, weld cables, and
application.
This unit is
supplied
14-pin, and 17-pin
with the
5-pin,
cords. Select
the proper cord and make each of
the connections shown.
~ For non-Miller power sources
and wire drive motors, Term
minal Strip TE2 can be used
for hookup (See Sections 3-9
and
Route
3-10).
voltage
strain relief
sense
lead
through
hole.
Connect one end to terminal 21 on
TEl (see Section 3-6). Connect
other end of voltage sensing lead
to the workpiece.
on user access
17-Pin Shunt
Control Cord
Voltage
Sensing
Cord
OM-189 530
Page
11
3-4.
Connecting
Shunt Control
A
Ott
Turn
welding
power
and weld control.
source
Select and prepare proper size and
length weld cables according to the
welding power source Owners
Manual. Remove cover from shunt
control.
1
17-Pin
2
Shunt
3
Bus Bar On Shunt
4
Bus Bar On Shunt
Receptacle
Route and connect a weld cable
from selected weld output terminal
on
welding power source to one
on shunt (see Section 3-3).
bus bar
Route and connect another weld
cable from remaining bus bar on
shunt to wire drive assembly (see
Section 3-3).
Reinstall
cover
onto shunt control.
Ref. ST-083 353-C
3-5.
Left Side Panel Connections
1
1
Receptacle
2
Keyway
2
3
17-Pin
Receptacle:
Connection to Shunt Control
4
For Customer Use:
Connections To Terminal
Strips, Flux Valve, etc.
Route
incoming
this strain relief
connections
to
cables
prior
to
through
making
internal terminal
strips.
5
14-Pin
Receptacle:
Welding
Connection To
Power Source.
Example Receptacle
6
5-Pin Receptacle:
Connection to Wire Drive
Motor
To connect
matching interconnect
ing cord to one of the above
receptacles, align keyway, insert
plug, and tighten threaded collar.
Connect remaining end of cord to
matching receptacle on applicable
equipment.
DP-0001
OM-189 530
Page
12
3-6.
Terminal
Strip
TEl Connections
A
Turn
Off welding power
and disconnect in
source
before
put power
access
1
opening
door.
Access Door
Loosen
securing
screws
(2)
access
door.
2
Terminal
Strip
TEl
3
Terminal
Strip
TEl Label
4
Lead
open
Being
and
Connected To
TEl
5
Securing
Strip 1/4
in
Screw
(6 mm)
insulation off
end of lead, insert end into proper
location on TEl, and tighten appli
cable
securing
Close and
screw.
secure access
door.
1
2
1/4 in
4\
(6 mm)
Tools Needed:
5
Ref. 5T-049 258-C / 5T-801 882-A
OM-189 530
Page
13
3-7.
Terminal
Strip
TEl Connection Information
Terminal Number
Receptacle
Location
Function Information
21
M
on
17-Pin
Voltage
40
L
on
17-Pin
Normally
41
T
on
17-Pin
Normally open
42
P
on
17-Pin
+
43
S
on
17-PIn
Circuit
sense
lead
input.
open contacts with respect to
contacts with
respect
24 volts dc for flux valve with
common
to
respect
pin T;
closes when
an arc
is detected.
pin L;
closes when
an arc
is detected.
to
pin S
when
is detected.
an arc
for flux valve.
7
B7
B6
4
B6A
See Section 3-13 on Start / Stop connections
for two units for information.
B3
6
6A
3-8.
Remote 14
RC2 Information
Receptacle
User Accessi
REMOTE ~
Socket
ble Via TE2
Socket Information
Terminal #
A
2
24 volts
source
ac
is
from
welding
power
source
(present
whenever power
On).
Contactor Control
Remote
Output
Electrical
Input
Control
Normally
pressed.
OM-189 530
Page
14
relay
contacts connect A to B when START is
4
C
77
Remote command reference from
D
75
Remote circuit
E
76
Output
G
32
Circuit
I
31
Power
K
33
common
ac
Chassis
is
signal
to
welding power
for 24 and 115 volts
from
source
welding power
source.
common.
command
115 volts
power
GND
open set of
B
welding power
On).
common.
ac
source
source.
circuits.
(present
whenever
welding
3-9.
Terminal
Strip
TE2 Connections
A
Off welding power
and disconnect In
put power before opening
access door.
Turn
source
1
Access Door
Loosen
securing
screws
(2)
access
door.
2
Terminal
Strip
TE2
3
Terminal
Strip
TE2 Label
4
Lead
TE2
5
Securing Screw
open
Strip 1/4
Being Connected
in
(6 mm)
and
To
insulation off
end of
lead, insert end into proper
location on TE2, and tighten appli
cable
securing
Close and
screw.
secure access
door.
Tools Needed:
Ref. ST-049 258-C I ST.801 882-A
OM-189 530
Page
15
3-10. Terminal
Strip
TE2 Connection Information
Terminal Number
Receptacle
2
A
Location
14-Pin
on
Function Information
A
of
normally open set
pressed.
contacts connect terminal 2 to terminal 4 when
relay
START is
Bonl4-Pin
4
77
C
14-Pin
75
Don 14-Pin
Remote circuit
76
E
on
14-Pin
Output
command to
32
G
on
14-Pin
Circuit
common
31
I
on
on
14-Pin
Remote command reference from
115 volts
source
33
K
A
A
B
is
ac
welding power
common.
welding
source.
power
for 24 and 115 volts
from
welding
ac
power
source
Chassis
on
5-Pin
To motor armature
(115
volts dc
motor).
B
on
5-Pin
To motor armature
(115
volts dc
motor).
16
C
on
5-Pin
To motor field.
17
D
on
5-Pin
To motor field.
3-11. Remote 17
Receptacle RC1
circuits.
(present
whenever
welding
power
on).
14-Pin
on
source.
ground.
Information
User
REMOTE 17
Socket
Accessible Via
Socket Information
TEl Terminal #
A
115 volts
ac
Fuse F2.
output protected by
115 VoitsAC
GND
Arnrn~ter A~id Voltmeter
.
B
Circuit
C
Chassis
D
Input signal from
E
Circuit
F
Input signal
G
A
L
Arc Detect
A
common
voltmeter terminal.
for ammeter and voltmeter.
positive
ammeter terminal.
established.
normally
arc
open set of contacts in the shunt control close when an
is detected and connect L to T. These points are user accessi
through
ble
P
42
+24 volts dc for
an arc
terminal
a
strip
TEl.
flux valve is
is detected. These
present
points
on
are user
P with
respect
accessible
to S when
through
termi
strip TEl.
nal
Electrode
K
positive
open set of contacts in the shunt control close when an
is detected and connect G to H to signal the motor board that
41
43
shunt control to
from shunt control to
T
S
ac.
ground.
an arc was
40
for 115 volts
normally
arc
H
common
voltage
this
pin.
Volt
sense
is
shunt control and
picked up through
input
to
Voltage Sensing
M
21
.
lead from work connection
.
is
output
control.
3-12. Remote 5
Receptacle
REMOTE 5
RC3 Information
Socket
User Accessi
ble Via TE2
Terminal #
A
A
To
B
B
To
C
16
To motor field.
D
17
Tomotorfield.
E
33
Chassis
Socket Information
-
+
motor armature
(115
volts dc
motor).
motor armature
(115
volts dc
motor).
Wirefeed Drive
Motor
OM-189 530
Hookups
Page
16
common.
on
this pin to shunt
3-13. Start /
Stop Connections
For Two
(2)
Units
Turn Off weld control and
A
TEl
21
The solid line connection allows each
disconnect
unit to be started
fore
independently,
but
EITHER Stop Button stops both arcs
simultaneously. Making the additional
1
Terminal
dotted line connections starts and
2
Hook-Up Diagram
stops BOTH arcs simultaneously from
Route
customer-supplied cord
from Unit 1 to Unit 2 thru strain re
lief for lead connections between
either VL-M4.
40
Unit 2
Unit 1
41
input power be
opening access door.
Strip
TEl Label
terminal
strips
Remove
jumper between 6
on
TEl.
and 6A
both units.
42
7
Make connections
O---..~
pending
43
B7
O-~
B6
c~
on
the
as
shown de
application.
~OB7
7
B7
,~-O
B6
~ If using
only one VL-M4 or if totally in
dependent operation of multiple units
is desired, a jumper must be installed
B6
between 6 and 6A.
B~
~
B6A
B3
N
B3
6
6
2
6
6A
GA
1B9
120
Hook-Up Diagram
Ref. ST-802 132
SECTION 4- OPERATION
4-1.
Safety Equipment
Wear the
1
following while welding:
Dry, Insulating Gloves
2
Safety
Glasses With Side
Shields
123
3
Welding
Helmet With Correct
Shade Of Filter
Z49.
(See ANSI
1)
sb3.1 1/94
OM-189 530
Page
17
Front Panel Controls
4-2.
7
4
DP-0001
1
Power Switch
Turn this switch ON to energize the VL-M4
Controller. For this unit to operate, 115 vac
must be
to this controller
G
on pins
supplied
14-pin receptacle or on termi
and 32 of terminal strip TE2. Turn
and I of the
nals 31
switch OFF to shut down the controller.
ing wire jogs at the rate set by
Speed Control. To advance the
the Run-In
the gun, press the Inch Down switch. To
tract the wire into the gun, press the Inch
switch.
4
re
Up
Stop Switch
Stop button to end the weld cycle.
Pressing this button initiates the Burnback
delay timer and the Burn back portion of the
weld cycle.
Press the
2
Wire
Speed Control
This control
rate
which
into the weld.
3
adjusts the
welding wire is fed
Inch
Up/Inch
These Inch
push
or
Jog
or
speed
at
5
Press the Start button to start the weld
cycle. The weld continues until the stop but
are
momentary
energize only the drive
motor allowing for a cold wire jog. The weld-
OM-189 530
Page
18
Start Switch
Down Switches
switches
buttons which
ton is
pressed.
6
Output Control
wire out of
This control
adjusts the output of the weld
ing power source. If using a CV (Constant
Voltage) machine, this control adjusts vol
tage. If using a CC (Constant Current) ma
chine, this control adjusts current.
7
Weld Meters
The meters
are provided to monitor the
welding operation (either AC or DC). They
are not intended for exact voltage or amper
age measurements. The Voltage Sense
lead must be properly connected for the
voltmeter to receive a signal and function
correctly.
4-3.
Inside Panel Controls
OP-0002
1
Run-In
Speed Control
2
Burnback Control
3
This control sets the wirefeed speed that
applies between the time the Start button is
pressed and an arc is established. After arc
initiation, the wirefeed speed is set by the
front panel wire speed control. The Run-In
Speed control acts independently of the
other speed control and therefore can be
set above or below the value set by the other
This 0 to 1.0 second adjustable control al
lows setting of the time the wire remains
control.
burnback time. If the wire
freezes in the contact tube, decrease the
burnback time.
electrically energized after
the drive motor
stops. The Burnback timer
starts after the
pressed. By adjusting the
properly, the wire neither freezes in
the weld puddle nor in the contact tube of
the gun. If the wire freezes in the puddle, in
Stop
button is
control
crease
the
Mode Switch
Use this switch to enable or disable the volt
age feedback to the motor control board.
Voltage feedback
is disabled in the CV
Mode.
4
Welding
Wirefeed
Speed Range
Switch
This switch selects the overall
coarse
speed range that can be adjusted
front panel wire speed control.
wire
with the
OM-189 530
Page
19
SECTION 5- MAINTENANCE & TRQUBLESHOOTING
5-1.
Routine Maintenance
1~3:~
5-2.
Replacing
A
Disconnect power before
maintaining.
Fuses
A
Turn
source
Off
welding power
and weld control.
See Parts List for size and
rating of
fuses.
1
Fuse Fl
Fuse Fl
protects
the wirefeed motor
and motor drive board from
over
load. If Fuse Fl opens, the wirefeed
motor stops. Check for jammed wire,
binding drive gear, or misaligned
drive rolls. Correct
place
2
problem
and
re
Fl.
Fuse F2
Fuse F2 protects the VL-M4 internal
control circuits and the 115 vac sup
plied to pin A of 17-pin receptacle
from overload. If F2 opens, all opera
tion stops. Correct problem and re
place
3
F2.
Fuse F3
Fuse F3
protects the
volt
sense
cir
cuit from overload. If F3 opens, volt
age feedback will be lost when using
a
constant current power source with
the VL-M4 in the CC mode. Correct
problem
Push And Turn
Pull OutAnd
Fuse
and
replace
F3.
Push And Turn
Replace
DP-0003
OM-189 530
Page
20
5-3.
Troubleshooting
Table
Trouble
Unit is
Remedy
completely inoperative.
Be
sure
jumper
two units
No wire feed
during inching.
is installed between terminals 6 and 6A
on
terminal
strip
TEl if not
interconnectiing
(see Section 3-13).
Place Power Switch Si in On
Check 115 volts
ac
position (see
input power
and be
Section
sure
it is
4-2).
energized.
Check Fuses Fl and F2, and
replace
Run-In
low; increase Run-In Speed setting (see Section 4-3).
Speed Control
set too
Check wire feed motor, and
repair
if necessary
(see
Section
5-2).
replace if necessary.
or
Check switches 51, PB3, PB4, and PB5, and replace if necessary
Check motor
relay CR2
on
Relay
Board
PCi,
and
replace CR2
(see Section
if necessary
4-2 and Parts
Parts
(see
List).
List).
Have Factory Authorized Service Agent check Relay Board PCi and Motor Drive Board PC2, and
replace if necessary.
Wire feeds wrong direction
during
To
change direction,
motor connections to terminals A and B on terminal
reverse
inching.
sary.
Wire only feeds down whether Inch
Down or Up button is pressed.
Check motor direction
No wire feed after Start button is
Check Start switch PB2, and
pressed (ensure
No wire feed
Relay
Board PCi, and
replace CR4
if necessary
(see
neces
Parts
List).
replace
if necessary.
speed control with Wire
during welding, but
Check weld latch
relay
CR1
on
Relay Board PCi,
Check weld contactor
relay
Check burnback time
delay relay TD1,
CR3
on
Relay
and
Board
and
PCi,
replace
replace
and
CR1 if necessary.
replace
CR3 if necessary.
TD1 if necessary
(see
Parts
List).
Check Wire Speed control R5, and replace if necessary.
control
speed can be controlled with Run-In
speed control.
Check current sensing circuit in shunt box by checking for contact closure
pins G and H on 17-pin receptacle of weld control.
Have
No contactor control for
Factory
Authorized Service
welding power
welding power
source is working properly and that all
connections are correct).
Check weld contactor
No output control for
Check
source
on
if
that all wire feed
inching functions are operating properly before checking this problem).
Speed
relay CR4
strip TE2
(ensure
relay
CR3
Agent
on
check motor board
Relay
Board PCi, and
coming
from shunt box to
P02, and replace if necessary.
replace
CR3 if necessary.
that
welding power
Output
control R4, and
replace
if necessary.
source.
OM-189 530 Page 21
SECTION 6- ELECTRICAL DIAGRAM
0
0
0
0
0
0
0
0
0
O~
~
0
(A
on
(-Inn
.- % - -%> -o
t t 00 <0
0
(A
T1~~
iii
RC2-3))~
RC2-5>>~
RC2-6~~
~
RC12
C,
RC24>)-~___
U
L:~
0
2
0
RC1 1
0
0
UI
t
-(
r
0
~
~c9~
SC-189 284
Figure
OM-189 530
Page
22
6-1. Circuit
Diagram
SECTION 7- PARTS LIST
ItT Hardware is
common
and
not available unless listed.
DP-0001
Figure
Item
Dia.
No.
Mkgs.
7-1. Control Box
Part
No.
Description
Figure
RC3
RC2
RC1
035 523
-
-
094 480
-
-
190 635
-
-
097 869
-.
-.
189 226
-
-
097 922
-
-
187 706
Components
-.
190 639
-.
137 260
-
10
190 640
-.
11
190 638
-
-
-
7-1
-
Control Box
Quantity
Components
1
CONNECTOR, circ MS/MET Sskt sz 16
CONNECTOR, circ MS/MET 14 pin sz 20
BUSHING, strain relief
CONNECTOR, circ MS/MET l7skt sz 20
LABEL, replace with 8A 250V fuse
KNOB, pointer .875dia x .250 ID
NAMEPLATE, Miller VL-M4
SEAL, switch gray
LABEL, warning, electric shock
SEAL, switch red
SEAL, switch black
1
1
1
1
2
1
3
1
1
1
To maintain the factory original performance of your equipment, use only Manufacturers
Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1 89 530
Page
23
1~ Hardware is
common
and
not available unless listed.
DP-0002
Figure
Item
No.
Dia.
Mkgs.
7-2. Inside Access Door
Part
No.
Description
Figure
R5
Al
030 109
Si
vi
R4
190 627
035 897
R7
028 769
PB2-PB5
S7
190 630
S6
190 630
R8
108 432
190 628
190 629
190 642
7
...8
190 626
189 225
11
190 642
R6
030 109
Components
7-2. Inside Access Door
Quantity
Components
POTENTIOMETER, CP std slot iT 2W 5K ohm
METER, amp 2V 0-1500 scale 3.5 in
SWITCH, tgl DPST 6A 125V panel
METER, volt 2V 0-100 scale 3.5 in
POTENTIOMETER, CP std slot iT 2W 1K ohm
KNOB, pointer .625dia x .250 ID
POTENTIOMETER, CP std slot iT 2W 750K ohm
SWITCH, PB MC DPDT 6A 125V panel
SWITCH, tgl SPDT 5A 125V on-none-on
SWITCH, tgl SPDT 5A 125V on-none-on
RESISTOR, MF .25W 2.21K
PLATE, control run-in/burn back
KNOB, pointer .625dia x .250 ID
POTENTIOMETER, CP std slot iT 2W 5K ohm
1
1
4
1
1
1
1
1
1
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-189 530
Page
24
Hardware is
common
and
not available unless listed.
4
2
\
/7
7/
i~
T
/
9, 10
14
(CR3)
14
(CR1)
(CR2)
14
14
(CR4)
~
~
DP-0003
Figure
Item
No.
Dia.
7-3. Case Section
Part
No.
Mkgs.
Description
Figure
1
TEl
188719
189130
2
SRi
190637
3
TD1
190646
4
VR1
046685
5
Ti
190641
R3
R2
190645
Ri
190636
...8
190644
9
10...
046432
F1,F2,F3
..
PC2
TE2
*190634
190632
188719
189129
13
14...
PCi
CR1,2,3,4
*Recommended
Spare
190633
...
190822
w/Components
7-3. Case Section
Quantity
w/Components
BLOCK, term 40 amp 12 pole screw
LABEL, term mkg 40 amp blk 12
RECTIFIER, bridge 1OA 400V
TIMER, delay on break .05 to 3 sec
VARISTOR, 200V 35 joule
TRANSFORMER, control 115V pri 24VCT
RESISTOR, WW fxd 50W 50 ohm
RESISTOR,WWfxd25W2ohm
RESISTOR, WW fxd 30W 1 ohm
HOLDER, fuse mintr .250 x 1.250
FUSE, mintr gi 8A 250V
CIRCUIT CARD ASSEMBLY, motor control
BLOCK, term 40 amp 12 pole screw
LABEL, term mkg 40 amp blk 12
CIRCUIT CARD ASSEMBLY, relay
RELAY, ENCL 120 VAC, DPDT 7.5A/12OVAC
1
1
1
1
1
1
1
1
1
3
3
1
1
1
1
4
Parts.
To maintain the factory original performance of your equipment, use only Manufacturers
Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-189 530
Page
25
Item
No.
Dia.
Part
No.
Mkgs.
Figure
188 627
..
..
..
..
..
..
..
..
..
..
..
..
..
Shunt
072 425
..
2
083 084
..
3
+083086
..
4
134 464
..
5
073 756
..
6
114426
..
1
7
PCi
186 752
..
8
T2
035 759
..
9
083 085
..
10
083 083
..
11
601 158
..
12
083 087
..
13
RC7
189 032
..
14
025 248
..
15
083 082
..
...
.
..
..
+When
ordering
a
Quantity
Description
7-4. Shunt Control
SHUNT, meter
SHIELD, heat
50 MV 1500A
1
1
WRAPPER
1
LABEL, warning general precautionary
STAND-OFF, No. 6-32 x .625
4
HOUSING,termheaderl6pin
1
CIRCUIT CARD, meter converter
TRANSFORMER, control 115/36
1
1
BRACKET, mtg components
BRACKET, mtg control
BLANK, snap-in 7/8 inch
CONTROL BOX, shunt
CONNECTOR W!LEADS
STAND-OFF, 1/4-20 x 1-1/4
BUS BAR, jumper
component originally displaying
a
precautionary label,
1
2
4
1
1
4
2
the label should also be ordered.
To maintain the factory original performance of your equipment,
Replacement Parts. Model and serial number required when ordering
ET Hardware is
common
1
use
only
Manufacturers
and
not available unless listed.
8
1~
9
1~
Figure
OM-189 530
Page
26
7-4. Shunt Control
Suggested
parts from your local distributor.
N
Elf ectlve January 1, 1009
(Equipment with a serial number preface of UKJU or newer)
Warranty
Questions9
This limited
Call
140044-MILLER
LIMITED WARRANTY
Miller Electric
br your local
Motor distributor1
Your distributorlso
gives
you..:.
:
can
hanS
Need fast
~
bein your
retell
purchaser
that
new
no
other
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Miller
after the effective date of this limited warranty
is tree of detects in material and workmanship at the time it is
*
Remote Controls
*
Accessory Kits
*
Replacement
*
Spoolmate
equipment sold
shipped by Miller. THtS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
INCLUDING
THE
WARRANTIES
OF
IMPLIED,
MERCHANTABILITY AND FITNESS.
Millers
warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
.
answers to
*
with
Parts
(No labor)
185
True Bluefi Limited
Warranty
shall not
apply
to:
1.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturers warranty, if any.
2.
Consumable components; such as contact tips, cutting
nozzles, contactors, brushes, slip rings, relays or parts
that fail due to normal wear.
Miller shall honor
in 24 hours,
Suppofl
H
or
Within the
~You always get the fast,
reliable response you
need. Mostreplacement
parts
original
its
to
previous Miller warranties and is exclusive
warranties expressed or implied.
all
Subject to the terms and conditions
Mtg. Co., Appleton, Wisconsin,
below,
warrants
warranty supersedes
guarantees
the
tough welding questions?
Contact your distdb~pr.
:~:The expertise Of the
disfributor ahd Miller Is
there to help your every
step of the way.
3.
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser,
year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to
or one
an
that has been modified by any party other
Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
Equipment
than
International distributor.
which
has
5 Years Parts
for operation outside
equipment.
bean used
specifications
f.
for the
of the
3 Years Labor
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
*
*
Original
main power rectifiers
Inverters
(input
and
AND USE BY COMMERCIALJINDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
output rectifiers only)
AND MAINTENANCE OF WELDING EQUIPMENT.
2.
3 Years
Parts and Labor
In the event of
*
3.
Transformer/Rectifier Power Sources
Plasma Arc
*
Semi-Automatic and Automatic Wire Feeders
*
Inverter Power
*
Intetlitig
*
Engine
Cutting Power
Sources
Driven Welding Generators
(NOTE: Engines are warranted separately by
engine manufacturer.)
the
Parts and Labor
1 Year
Motor Driven Guns
*
Process Controllers
*
Positioners and Controllers
*
Automatic Motion Devices
*
Robots
IHPS Power Sources
*
Water Coolant
cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
of
credit for the purchase price (lass reasonable
or
payment
depreciation based upon actual use) upon return of the
goods at customers risk and expense. Millers option of
repair or replacement will be FOB., Factory at Appleton,
Wisconsin, or FOB. at a Miller authorized service facility as
determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be
allowed.
(w/axception
*
warranty claim covered by this warranty, the
appropriate
Supplies
*
a
exclusive remedies shall be, at Millers option: (1) repair; or
(2) replacement; or, where authorized in writing by Millar in
*
of
Spoolmate 185)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE
FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
NOT PROVIDED HEREIN
IMPLIED WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
BY
MIGHT
ARISE
PROVISION,
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED
AND DISCLAIMED BY MILLER.
ANY EXPRESS WARRANTY
*
HF Units
*
Grids
*
Spot
Systems
AND
Welders
Load Banks
SDX Transformers
Miller
Cyclomatic Equipment
*
Running Gear/Trailers
*
Plasma
Cutting
PLAZCUT
*
Deutz
*
Field
Torches
Engines (outside
North
America)
Options
(NOTE: Field options are covered under True Bluefi
for the remaining warranty period of the product they
are
installed in,
whichever is
or
for
a
greater.)
minimum of
one
year
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights,
U/A Millet
Thiffihit
4.
6 Months
5.
90
*
Days
Batteries
Parts and Labor
MIG Guns/TIG Torches
and
available, but may vary from state
In
Canada, legislation in
additional
warranties
some
other
rights may
be
to state.
provinces provides for certain
remedies
other than as stated
may not be waived, the
limitations and exclusions set out above may not apply. This
Limited Warranty provides specific legal rights, and other
rights may be available, but may vary from province to
herein,
a:
~-
(except APT, ZIPCUT &
Models)
ANY
or
and to the extant that
they
province.
miller_warr
usa
Owoers Record
Please complete and retaIn wltb your personal records.
Serlal/Slyle Number
Model Name
Purchase Date
(Date which equipment
was
delivered to
original customer.)
Distributor
Address
City
lip
Slate
Resources Available
Always provide Model Name and Serial/Style Numlier.
Coutact your Distributor br:
Welding Supplies
To locate distributor nearest you call
1-800-4-A-Miller.
Options
and Consumables
and Accessories
Personal
Safety Equipment
Service and
Repair
Replacement
Miller Electric
1635 West
and
(Servicing
Information
Diagrams
European Headquarters
United
Welding Process Handbooks
Coutac~ the DeilverinD Carrier br:
File
a
claim for loss
54914 USA
lntemÆt~onaI Headquarters-USA
Phone~ 920-7354505
USA & Canada FA)~ 920-735~4i3~
Internaitcinal E4,X 920735-4125
Parts)
Circuit
Company
Spencer Street
Appleton WI
Training (Schools, Videos, Books)
Technical Manuals
Mfg Co
An IllInois Tool Works
Parts
or
-
Krngdom
Phone
FAX
44(0)1626-525556
44(0)1625-537553
www
MtlIerW~td~
corn
damage during
N
shipment.
For assistance in
filing
or
settling claims,
contact your distributor and/or
manufacturers Transportation
N
equipment
Department.
ri/A Miller
N
PRINTED IN USA
'
lliePowerofBb4e
1998 Miller Electric
Mtg. Co.
2/98