Miller Electric OM-842 manual

Processes Description TIG (GT A W ) W elding Stick (SMA W) W elding Programmable Precision Controller For W elding Power Source OM-842 162074B August 1997 Intellitig MPC  Visit our website at www.MillerWelds.com[...]

Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

The following terms are used interchangeably throughout this manual: TIG = GT AW Stick = SMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

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OM-842 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means W arning! Watch O[...]

OM-842 Page 2 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. ARC RA YS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87[...]

OM-842 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. F A[...]

OM-842 Page 4 1-5. EMF Information Considerations About Welding And The Ef fects Of Low Frequency Electric A n d M a g netic Fields W elding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However , after examining more than 500 studies spanning 17 years o[...]

OM-842 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives. Y Identifie un message de s é curit é particulier . [...]

OM-842 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage. LES RA YONS DE L ’ ARC peuvent pro- voquer des br û lures dans le[...]

OM-842 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance Risque D ’ INCENDIE OU D ’ EXPLOSION. D Ne pas placer l ’ appareil sur , au-dessus ou à proxi- mit é de surfaces infllammables. D Ne pas installer l ’ appareil à proximit é de produits inflammables D Ne pas surcharger l[...]

OM-842 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American W el- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Of fice, Washington, D.C. 20402. Recommended Safe Practice for the[...]

OM-842 Page 9 SECTION 2 – INST ALLA TION 2-1. Connecting Remote Pendant Or Equivalent User-Wired Control A user-wired equivalent to the remote pendant may be connected to the control unit. However , connections must be made for a Stop push button even if it is not used in unit operation. Since the Stop button is wired in a normally closed configu[...]

OM-842 Page 10 2-3. User Relay Contacts Ref. ST-162 477-A / ST -162 841 / Ref. SC-159 862 1 Access Door Access door is hinged at top, and held closed with industrial interlock strips. T o open, grasp bottom and pull out firmly . 2 T erminal Strip 3T 3 T erminal Strip 4T 4 Connection Label Use 3T and 4T to connect external equip- ment to internal re[...]

OM-842 Page 1 1 2-4. Setting DIP Switch SW1 Ref. ST-800 194 / Ref. ST -162 477-A Set DIP switch SW1 rocker switch positions as follows: 1 Control Box Front Panel 2 Retaining Screw Location Loosen retaining screw , and open hinged front panel. 3 Microprocessor Board PC5 4 DIP Switch SW1 5 Positions 7 And 8 S et 7 and 8 according to table to se- lect[...]

OM-842 Page 12 SECTION 3 – OPERA TION 3-1. Controls 1 V oltmeter 2 Ammeter 3 Digital Display 4 Left/Decrease Button 5 Right/Increase Button 6 Parameter Select Button 7 Purge Button 8 Mode Switch 9 Program/Run/Reset Keyed Switch 10 Remote Pendant Ref. ST-162 479-A / Ref. ST -146 839 1 2 3 4 5 6 7 8 9 10 3-2. Safety Equipment W ear the following wh[...]

OM-842 Page 13 3-4. Ammeter And V oltmeter 1 Ammeter Meter displays weld amperage out- put of unit when welding. 2 V oltmeter V oltmeter displays voltage at the weld output terminals, but not nec- essarily the welding arc due to cable resistance, poor connec- tions, etc. 1 2 Ref. SC-159 862 3-5. Digital Display 1 Digital Display Use display to ente[...]

OM-842 Page 14 3-7. Program/Run/Reset Keyed Switch 1 Program/Run/Reset Keyed Switch Program Use to enter , change, and/or ex- ecute a program. Run Us e to execute a program only. Ke y can be removed to prevent unau- thorized access to program. Reset Us e before switching between Run/ Program positions when unit is On. For example, use Program posit[...]

OM-842 Page 15 3-1 1. Purge Push Button 1 Purge Push Button Press switch to momentarily ener- gize gas valve and purge air from torch shielding gas line, and to allow shielding gas regulator to be ad- justed without energizing the weld- ing circuit. Switch is only active when the re- peating displays are shown. 1 3-12. Remote Pendant 1 Remote Penda[...]

OM-842 Page 16 SECTION 4 – INTRODUCTION T O PROGRAMMING 4-1. General Programs are created when parameters are defined in a series of displays. Up to four programs can be entered into each of the four modes of operation, for a total of sixteen programs. In addition, programs in certain modes can be linked or combined to run in a user-defined seque[...]

OM-842 Page 17 4-4. Modes Of Operation The microprocessor control has four modes of operation: Automatic, Semi-Automatic, Manual GT AW , and SMA W . In abbreviated form, the modes function as follows: A. Automatic Mode Sequence Ref. SB-139 983 In this mode, the program controls each step of the weld sequence. Pressing the Start/Increase push button[...]

OM-842 Page 18 Ref. SB-139 983 In this mode, time values are not de- fined for initial current, weld/peak current, and final current. The micro- processor control operates in a mo - mentary-contact, single button for- mat. The operator presses the Start/ Increase push button to start the pro- gram, presses it again to signal the en d of initial cur[...]

OM-842 Page 19 In this mode, time values are not de- fined for initial current, initial slope, weld/peak current, and final slope. The operator uses the Start/In- crease and Decrease push buttons to vary the weld current level once initial current starts. The first momentary closure of the Start/Increase push button starts the sequence. Following s[...]

OM-842 Page 20 Ref. SB-139 983 In this mode, a single momentary closure of the Start/Increase push button starts the sequence. The pro- gram continues through the pro- grammed sequence of events until weld/peak current. The operator presses t h e S t a r t/Increase push but- ton to signal the end of weld/peak current, at which time final slope star[...]

OM-842 Page 21 SECTION 5 – PROGRAMMING 5-1. General A. Displays The displays presented by the microprocessor control either provide information to the user , or allow the user to enter infor- mation needed for program execution. The displays vary from mode to mode. Within each mode, the displays are always shown in the same sequence. Pressing the[...]

OM-842 Page 22 Th e program number in a display can be increased by pressing Parameter Select while any of the repeating displays are shown. Thi s allows other programs to be accessed. NOTE 1. Th e first repeating display indicates the program num- ber and that the microprocessor control is ready for program execution. The display shows: PR O G RA [...]

OM-842 Page 23 1 1. If applicable, define the program number (see Section 5-1C). Define the shielding gas preflow time as desired. The range for preflow is 0.0 to 25.0 seconds, in incre- ments of 0.1 seconds. 12. Press Right/Increase, and the display shows: # 0 X ST ART L EVE L T I ME =. X X X AMP S = X X X . X 13. Define the start level time and a[...]

OM-842 Page 24 5. Define the peak time and background time values as desired. Peak time is the length of time the pulse is at the peak level. Background time is the length of time the pulse is at the background level. The ranges for both peak and background times are 0.5 to 5.0 seconds, in increments of 0.5 seconds. 6. Press Right/Increase, and the[...]

OM-842 Page 25 7. Press Right/Increase, and the display shows: #0 X W I R E – F E ED S T ART D E L AY = XX . X SE C . 8. Define the wire feed start delay as desired. Wire feed start delay is the amount of time between the end of initial current and when the wire feed user relay (see Section 2-3) changes states. A delay time of 0 means the wire fe[...]

OM-842 Page 26 If the Process Selector switch is in a dc output position, the choices are Start Only high frequency or Disabled high frequency . 10. When the desired choice is shown, press Right/In- crease to advance to the next display . The display shows: #0 X P R E FL O W TI M E = X X . X 1 1. If applicable, define the program number (see Sectio[...]

OM-842 Page 27 The ranges for both ApK and AbK are 2.0 to 400 am- peres, in increments of 1.0 ampere. 3. Press Right/Increase, and the display shows: # 0 X PEAK T I M E =X . X X B A C K T I M E = X .X X 4. Define the peak time and background time as desired. Peak time is the length of time the pulse is at the peak level. Background time is the leng[...]

OM-842 Page 28 5. Press Right/Increase, and the display shows: #0 X P O S T FL O W TI M E = X X . X 6. Define the shielding gas postflow time as desired. The range for postflow is 0.0 to 25.0 seconds, in incre- ments of 0.1 seconds. 7. Press Right/Increase, and the display shows: #0 X W I R E – F E ED S T ART D E L AY = XX . X SE C . 8. Define th[...]

OM-842 Page 29 8. Press Right/Increase. The microprocessor control will enter the Ready condition. 9. In the Ready condition the microprocessor control is ready to have another program entered or to execute a program. For information on executing a program, see Section 6. 5-4. Manual GT A W Mode If needed, see Section 5-1B f o r information o n sel[...]

OM-842 Page 30 #0 X W EL D A M PS =XXX . X b. Define the weld current as desired. Th e range for weld current varies from 2.0 to 400.0 amps, in increments of 1.0 amperes. c. Press Right/Increase, and go to Section 5-4D. B. Procedure With Pulse Mode On, Pulses Defined In Time V alues 1. The display shows: # 0 X PUL SE A p K = XXX . X P ULS E A bK =X[...]

OM-842 Page 31 5-5. SMA W Mode If needed, see Section 5-1B f o r information o n selecting and defining a parameter. NOTE 1. Turn on welding power source, if applicable. 2. Place the Mode Selector switch in the SMA W position. 3. Place the Program/Run/Reset keyed switch in the Re- set position, and then in the Program position. The initial displays[...]

OM-842 Page 32 5-7. Dry Run Feature Th e Dry Run feature allows a program to be verified by execut- ing it without actually establishing an arc. All timing and contact closures are performed without gas, high frequency , or power source contactor being activated. The Dry Run feature is only available in the Automatic mode an d Semi-Automatic 1 or 5[...]

OM-842 Page 33 Reset follows Program Number 04. T o assign Reset to a Link position, select the function and press Right/In- crease repeatedly to go beyond Program Number 04. T o assign a number when Reset is displayed, select Reset and press Left/Decrease. 9. Repeat Steps 7 and 8 as needed to define the desired function for each Link position bein[...]

OM-842 Page 34 Right/Increase repeatedly to go beyond Program Number 04. T o assign a number when Reset is dis- played, select Reset and press Left/Decrease. If four program s are combined together , it is not necessary for the user to assign a reset. A reset is permanent ly assigned to the fifth Combine position. NOTE 9. Repeat Steps 7 and 8 as ne[...]

OM-842 Page 35 10 . Wea r welding helmet with proper filter lens according t o ANSI Z49.1. 1 1. Be sure applicable remote control device is connected as follows: a. Semi-Automatic 1 Mode: Connect Remote Pendant to Remote 4 receptacle RC2. b. Semi-Automatic 2 Mode: Connect Remote Pendant to Remote 4 receptacle RC2. c. Semi-Automatic 3 Mode: Connect [...]

OM-842 Page 36 control unit maintains the programmed initial current value. Program execution at this point varies according to whether pulsing is enabled or disabled. G o to Step 2 if pulsing is enabled, and Step 3 if pulsing is disabled. 2. When pulsing is enabled: a. Press and hold Start/Increase to increase the weld current output. The peak cur[...]

OM-842 Page 37 12. Enter th e R e a d y c o n d i tion (see Section 5-1F). The op- erator now has control of the welding power source contactor via the remote contactor control connected to the Remote 14 receptacle. 13. Start welding as follows: a. Be sure the desired program is active before ex- ecuting a program. The active program is indicated i[...]

OM-842 Page 38 2. Turn of f welding power source. 3. Turn of f shielding gas supply at the source, if applica- ble. 6-8. Overheating Protection If the unit overheats, the weld sequence goes to postflow and the contactor is deenergized. The user relay contacts stay in th e state they were in before postflow was entered and remain that way until post[...]

OM-842 Page 39 7-2. Diagnostics Program When the diagnostics program starts, the following series of in - formational displays is shown: * S Y NCRO W A V E 3 5 1 * DI A G N O S T I C P R O G R A M TH E FOL LO W I N G PR O G RA M W I L L CHECK YOUR UN I T T O V ER I F Y TH A T I T I S F UNC T I O N I NG PR O P ER L Y A. RAM T est 1. After the four i[...]

OM-842 Page 40 6. If the Left/Decrease push button is not pressed in time, or if the push button is not working correctly , the follow- ing displays appear: ER R O R L E F T BU T TO N I S NO T W OR K I NG P L EASE C O R RE CT ER R O R B E F OR E CON T I NU I NG W I TH THE D I A G N O ST I C TE ST P R O G R A M If the Left/Decrease push button is no[...]

OM-842 Page 41 position. I f this is done in time and the position is work- ing correctly , the display shows: RUN POS I T I ON IS W O R KIN G P R O P E R L Y If the Run position tests okay , go to Step 5. 4. If the keyed switch is not placed in the Run position in time, or if the position is not working correctly , the dis- play shows: E RR OR ! ![...]

OM-842 Page 42 4. I f the Mode Selector switch is not placed in the SMA W position in time, or if the position is not working correct- ly , the display shows: ER R O R ! ! S M A W – MA N U A L I S NO T W OR K I NG If the SMAW position is not working correctly , replace the Mode Selector switch. 5. When the SMA W position tests okay , press Parame[...]

OM-842 Page 43 is done in time and the push button is working correctly , the display shows: BUT T O N I S WO R K I N G P R O P E R L Y If the Purge push button tests okay , go to Step 5. 4. If the Purge push button is not pressed in time, or if the push button is not working correctly , the display shows: BUT T O N I S N O T WO R K I N G P R O P E[...]

OM-842 Page 44 J. Background Relay T est This procedure tests the internal dc background current source. 1. When the repeating test displays are shown (see Sec- tion 7-2C), press Right/Increase or Left/Decrease until the display shows: B A C K GROU ND RE L A Y T E S T 2. Press Parameter Select to begin the test. This ener- gizes the background rela[...]

OM-842 Page 45 0 Ohms OL AB C Figure 7-1. T esting Energized User Relay 4. If the relay is working correctly , the VOM reads the re- sistances shown. In this case, go to Step 5. If the VOM does not read the resistances shown while the relay is energized, contact the nearest Factory Au- thorized Service Station/Service Distributor . 5. Press Paramet[...]

OM-842 Page 46 7. I f the Decrease push button is not pressed in time, or if the Decrease push button is not working correctly , the display shows: BUT T O N I S N O T WO R K I N G P R O P E R L Y If the Decrease push button is not working correctly , r e - place the push button. 8. When the Decrease push button tests okay , press Pa- rameter Selec[...]

OM-842 Page 47 3. When this display appears, the control unit waits three seconds for the specified contact closure. If this is done in time and the solid state contactor is working correct- ly , the display shows: I N P U T CON T A C T OR IS D E T E C T E D If the input contactor detection circuitry tests okay , g o t o Step 5. 4. I f the input co[...]

OM-842 Page 48 SECTION 8 – ELECTRICAL DIAGRAMS SA-132 263 Figure 8-1. Circuit Diagram For Remote Pendant[...]

OM-842 Page 49 Figure 8-2. Wiring Diagram For MPC Module SC-161 093-B[...]

OM-842 Page 50 Figure 8-3. Circuit Diagram For Welding Power Source And MPC[...]

OM-842 Page 51 SC-182 947-B[...]

OM-842 Page 52 SECTION 9 – P ARTS LIST 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 9 23 24 25 27 28 29 30 32 35 33 34 36 38 39 13 31 17 Figure 9-1. Main Assembly ST-162 780 21 26 37 . Hardware is common and not available unless listed.[...]

OM-842 Page 53 Quantity Description Part No. Dia. Mkgs. Item No. Figure 9-1. Main Assembly 1 NAMEPLA TE, (order by model and serial number) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 158 955 COVER, front electrical 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-842 Page 54 Quantity Description Part No. Dia. Mkgs. 132 064 Item No. Figure 9-2. Pendant 1 079 725 GUARD, switch al knurled 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 NAMEPLA TE, (order by model and serial number) 1 . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

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PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Com pany 1635 W est S pencer St reet Applet on, WI 54914 USA International He adquarters – USA USA Phone: 920-735-4505 Auto-A t t ended USA & Canada F A X : 920-735-4134 Int ernati onal FAX: 920-735-4125 European Hea dquarters – Unite[...]