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OM-842 162074B
August 1997
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Programmable Precision Controller For
Welding Power Source
Intellitig MPC
Visit our website at
www.MillerWelds.com
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From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s 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 couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that bu
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TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . .
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Welding
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. 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 Z87.1 li
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cau
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1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding 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 3. Do not coil or drape cables around your body. years of resea
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SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Identifie un message de sécurité particulier. risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous au
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LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation. (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées Veiller toujours à bien aérer les espaces
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1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou à proxi- Rester à l’écart des organes mobiles comme le mité de surfaces infllammables. ventilateur. Maintenir fermés et fixement en place les portes, Ne pas installer l’appareil à proximité de produits inflammables panneaux, recouvrements et dispositifs de Ne pa
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1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. Règles de sécurité en soudage, coupage et procédés conne
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SECTION 2 – INSTALLATION 2-1. Connecting Remote Pendant Or Equivalent User-Wired Control A user-wired equivalent to the remote pendant may be connected to the control NOTE 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 configuration, if Stop connections are not made, the control unit interprets that as the Stop button being continually pressed. Refer to Figure 8-1 for a circuit diagram o
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2-3. User Relay Contacts The internal control relay contacts accessible through terminal strips 3T and 4T are 1 rated at 20 amperes, 250 volts. 2 3 4 ABCDE F G H J K L M N P R S T UV W X Y Z AA BB CC WELD TIME INITIAL TIME INITIAL SLOPE WELD PEAK FINAL SLOPE FINAL TIME POST FLOW PULSE SIGNAL WIRE FEED CONTACTS S-157 815 Tools Needed: Or Ref. ST-162 477-A / ST-162 841 / Ref. SC-159 862 1 Access Door pulse signal, and for a wire feeder. The pulse signal contacts change state as pulsed output goes
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2-4. Setting DIP Switch SW1 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 4 DIP Switch SW1 2 5 Positions 7 And 8 Set 7 and 8 according to table to se- lect Semi-Automatic Modes 1 thru 1 5. 6 Position 4 Set Off to run diagnostics program. Set On to stop diagnostics pro- gram, and for all other operations. 3 7 Position 3 Use position 3 to select whether pu
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SECTION 3 – OPERATION 3-1. Controls 1 Voltmeter 2 Ammeter 3 Digital Display 3 4 5 6 7 8 10 4 Left/Decrease Button 5 Right/Increase Button 9 6 Parameter Select Button 2 7 Purge Button 1 8 Mode Switch 9 Program/Run/Reset Keyed Switch 10 Remote Pendant Ref. ST-162 479-A / Ref. ST-146 839 3-2. Safety Equipment Wear the following while welding: 12 3 1 Dry, Insulating Gloves 2 Safety Glasses With Side Shields 3 Welding Helmet With Correct Shade Of Filter (See ANSI Z49.1) sb3.1 1/94 3-3. Work Clamp 1 W
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3-4. Ammeter And Voltmeter 1 Ammeter Meter displays weld amperage out- 1 put of unit when welding. 2 Voltmeter Voltmeter displays voltage at the weld output terminals, but not nec- essarily the welding arc due to cable resistance, poor connec- tions, etc. 2 Ref. SC-159 862 3-5. Digital Display 1 Digital Display Use display to enter and read val- ues. If weld sequence steps are 1 shown, the programmed time val- ues decrease as process time runs out. 3-6. Mode Selector Switch 1 Mode Selector Switc
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3-7. Program/Run/Reset Keyed Switch 1 Program/Run/Reset Keyed Switch Program Use to enter, change, and/or ex- 1 ecute a program. Run Use to execute a program only. Key can be removed to prevent unau- thorized access to program. Reset Use before switching between Run/ Program positions when unit is On. For example, use Program position to enter program, move to Reset momentarily, and move to Run to execute program. Remove key if desired. If changing program, move to Reset momentarily before mov-
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3-11. Purge Push Button 1 Purge Push Button Press switch to momentarily ener- gize gas valve and purge air from 1 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. 3-12. Remote Pendant 1 Remote Pendant 1 Use for remote operation in the Au- tomatic and Semi-Automatic modes only. Connect to Remote 4 receptacle. 2 2 Stop Push Button 3 Start/Increase Push Button 4 De
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SECTION 4 – INTRODUCTION TO 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 sequence. This welding power source provides high frequency or scratch starting, preflow timing, start current level control and timing, initial current level control and ti
