Resumen del contenido incluido en la página 1
November1996 Form: TM-1571
Effective With Serial No. JJ507797
MiIIe~
TECHNICAL MANUAL
Service And Parts
S-21E
Wire Feed Equipment
Use MILLER Testing Booklet (Part No.
A WARNING
150 853) when servicing this unit.
SERVICING can be hazardous.
Use only genuine MILLER replacement
• Have all service procedures performed only by
parts.
qualified persons following standard safety
practices.
U For help, call Factory ~U~r FAX: U Or write to:
Service Department: 14-735-4136 MILLER Electric Mfg. Co.
414-735
Resumen del contenido incluido en la página 2
Resumen del contenido incluido en la página 3
OM-1571B — 3/91 TABLE OF CONTENTS Section No. Page No. SECTION 1 - SAFETY PRECAUTIONS AND SIGNAL WORDS 1-1. General Information And Safety 1 1-2. Safety Alert Symbol And Signal Words 1 1-3. Safety Precautions 1 SECTION 2- SHIPPING AND STORAGE 2-1. Preparation For Reshipment 2 2-2. Storage 2 SECTION 3— SPECIFICATIONS 3-1. Description 3 SECTION 4- INSTALLATION OR RELOCATION 4-1. Location 3 4-2. Drive Roll Installation 3 4-3. Welding Gun Connections 5 4-4. Shielding Gas Installation 5 4-5. 14-Pin P
Resumen del contenido incluido en la página 4
Section No. Page No. SECTION 8- TROUBLESHOOTING 8-1. Testing Instruments And Information 14 8-2. Circuit Board Handling Precautions 14 8-3. Troubleshooting 14 Diagram 8-1. Troubleshooting Circuit Diagram For Wire Feeder 16 8-4. Motor Board PCi Testing Information 17 Diagram 8-2. Troubleshooting Circuit Diagram For Motor Control Board PCi 18 8-5. Optional SpotlBurnback Board PC2 Testing Information 20 Diagram 8-3. Troubleshooting Circuit Diagram For Optional Spot/Burnback 22 Board PC2 SECTION 9-
Resumen del contenido incluido en la página 5
SECTION 1 - SAFETY PRECAUTIONS AND SIGNAL WORDS 1-1. GENERAL INFORMATION AND SAFETY • Shut down unit and disconnect input power when servicing unless the procedure specifi- This manual provides theory of operation along with cally requires an energized unit. specific operating, testing, and troubleshooting proce- • Do notleave live unit unattended. dures. It also includes precautionary information rele- vant to these procedures. This manual can be an effec- ARC RAYS, SPARKS, AND HOT SURFACES tiv
Resumen del contenido incluido en la página 6
SECTION 2- SHIPPING AND STORAGE PREPARATION FOR RESHIPMENT STORAGE WARNING: ELECTRIC SHOCK can kill. WARNING: ELECTRIC SHOCK can kill. • Do not touch live electrical parts. • Do not touch live electricalparts. A A • Shut down wire feeder and welding power • Shut down wire feeder and welding power source, and disconnect input poweremploy- source, and disconnect inputpower employ- ing lockout/tagging procedures before ing lockout/taggingprocedures before storing preparing unit for shipping. unit.
Resumen del contenido incluido en la página 7
SECTION 3- SPECIFICATIONS Table 3-1. Specifications Input Power Electrode Wire Wire Spool Electrode Wire Weight Requirements Diameter Capacity Capacity Feed Speed Net Ship 10 to 20 lb. 24 VAC (4.5 to 9 kg) 75-600 ipm 30 lbs. 33 lbs. 3.5 Amps .O23thru .045 in. 8 in. (203mm) spools (1.9-15.2 mom) 50/60 Hz (0.6 thru 1.1 mm) up to 60 lb. at 24 VA~ (13.6 kg) (15 kg) (27.2 kg)_coils 22-1(2 in. (572 mm) 10-112 In. (267 mm) SB-124 467 Figure 3-1. Overall Dimensions 3-1. DESCRIPTION only poweravailablefo
Resumen del contenido incluido en la página 8
Pressure Roll Assembly (Shown In Open PosItion) Hub Wire • Spring 9 Retaining Ring GunlFeeder connector Securing Knob • OPTIONAL Ret. 50497 Ref. SB-125 923 Figure 4-1. Wire Feeder Components It is necessary to install the required drive rolls when set- Loose metal objects in this compartment may create an electrical path between the weld out- ting up this unit and also when changing wire sizes. put circuit and any metal surfaces or compo- IMPORTANT: Base drive rollselection on the following nent
Resumen del contenido incluido en la página 9
5. For 50 Series style one-piece drive rolls: B. Gun Trigger (Figure 5-1) a. Slide drive roll onto drive roll mounting hub. b. Align drive roll with holes. ‘9= c. Insert securing screws, and tighten. TRIGGER RECEPTACLE 6. For 50 Series style split drive rolls: Connect gun trigger plug to trigger receptacle on the a. Align holes on pair of split drive rolls. front panel as follows: align keyways, insert gun plug into trigger receptacle, and rotate threaded collar fully b. Insert securing screw. c
Resumen del contenido incluido en la página 10
Flow Adjustment Gas cylinder Valve Argon or Argon CO Mix cylinder 2 Washer CO2 cylinder SB-109 492 CO2 Installation Argon Installation Figure 4-2. Typical RegulatorlFlowmeter Installation 4-5. 14-PIN PLUG CONNECTION (Figures 4-3And 4-4) The 14-pin plug PLG1 00, on the end of the interconnect- ing cord, provides a junction point for connecting the wire feeder to a welding powersource. This connection provides 24 volt ac power, and contactor control when used with a constant voltage (CV) power sou
Resumen del contenido incluido en la página 11
A. Installation Of Spool-Type Wire (Figure 4-1) 4-7. WELDING WIRE THREADING 1. Remove retaining ring from hub. WARNING: ELECTRIC SHOCK can kill; MOVING PARTS can cause injury. A 2. Slide wire spool on hub so that wire feeds off the • Do not touch live electrical parts. bottom of the spool. • Keep clear of pinch points. 3. Rotate wire spool until hole in spool slides over • Do notenergize weldingpowersource orwirE pin in hub and seats against back flange of the feeder until instructed to do so. h
Resumen del contenido incluido en la página 12
be made when the wire feeder is put into WELDING WIRE can cause puncture Wounds; HOT SURFACES can burn skin. operation. • Do not depress gun trigger until instructed to do 4-8. ADJUST THE HUB TENSION (Figure 4-1) so. • Do not point gun toward any part of the body CAUTION: LOOSE WELDING WIRE can any conductive surface, or other personnel A when threading welding wire. :ause Injury. Keep a firm hold on the wire during installa- • Allow gun to cool before touching. tion, removal, and threading oper
Resumen del contenido incluido en la página 13
SECTION 5- OPERATOR CONTROLS 5-1. POWER SWITCH (Figure 5-1) POWER Access Hole For Gun/Feeder Connector The POWER switch functions as the ON/OFF switch for the wire feeder. 5-2. WIRE SPEED CONTROL (Figure 5-1) WIRE SPEED Gun Trigger ojo Receptacle Wire Speed The WIRE SPEED control adjusts the wire feed speed Control 88-124 467 in inches per minute within thewire speed range. Rotat- ing the WIRE SPEED control clockwise increases wire Figure 5-1. Control Panel View feed speed. The scale is calibrat
Resumen del contenido incluido en la página 14
WARNING: ELECTRIC SHOCK can kill; 6-2. SHUTTING DOWN TANGLED WELDING WIRE can touch case A causing welding power source open-circuit 1. Stop welding. voltage to be presenton case if gun trigger is 2. Place POWER switch in the OFF position. pressed. • Do nottouch wire feeder case ifgun trigger is 3. Shut down welding power source or generator. pressed and wire does not feed. • If wire stops feeding, turn off welding power 4. Turn off shielding gas at source, if applicable. source, and determine t
Resumen del contenido incluido en la página 15
0 4- 0. 0 •1~ 0 4- 1~ 4) 4) LI- 4) I- 0 U- E (U I- 0) (U 0 0 1~ E (U 0) (U 0 -A c~.~ ~(i) .~Q) tb~. ~3O c~o I—0 ZQ) S-21E TM-1571 Page 11
Resumen del contenido incluido en la página 16
B. SpotlBurnback Time Control Option (Diagram 3. Spot time potentiometer R25 allows adjustment of spot time from 0.12 to 2.5 seconds or 0.25 to 5 7-2) seconds depending on the setting of Spot Time DIP Switch Sl. 1. Optional Spot/Burnback Board PC2 provides control of spot weld time and adjustment of burn- 4. Spot/Continuous switch S51 allows either a nor- back time. mal untimed weld cycle or a timed spot weld cycle. 2. Burnback potentiometer R26 allows adjustment 5. Spot time DIP switch 51 provi
Resumen del contenido incluido en la página 17
Notes S-21E TM-1571 Page 13
Resumen del contenido incluido en la página 18
SECTION 8— TROUBLESHOOTING 8-1. TESTING INSTRUMENTS AND INFORMA- 8-3. TROUBLESHOOTING (Table 8-1 And Dia- TION gram 8-1) The service procedures in this manual require proper WARNING: ELECTRIC SHOCK can kill. testing instruments. Use a good quality digital volt- ohmmeter (DVM) with one megohm input impedanceor • Do not touch live electrical parts. A greater and diode check capability (use an analog VOM • Shut down wire feeder and welding power for variable resistor testing). If an oscilloscope is
Resumen del contenido incluido en la página 19
Table 8-1. Troubleshooting TROUBLE CAUSE REMEDY Wire does not feed. Circuit breaker CB1. Check gun liner, hub tension, and drive roll pressure (see Section 4). Reset CBl (see Sec tion 10-5). Loose or improperly made gun Check gun trigger connection (see Section trigger connection. 4-3). Gun trigger. See gun Owner’s Manual. Welding gun shorted. Repair or replace welding gun. Motor Ml. Check connections for continuity to Ml. Check motor brushes (see Section 10-4). Replace Ml if necessary. Motor Co
Resumen del contenido incluido en la página 20
a c 0, O ow O ~ ~ s.a — = ~ ~~ O ~ O~ ca zz:~~ ~ 21 Ci) ~U) ~Z O~, ~ a~ O~ 0 ~ &E ~ ~ a~ ~ ..~ o1t~ +oO 0 ~ ~ ~ ~e N !FI — — — — — — — — — — — ~ C’J CO ~ U) (oIr-~0)0 CO ~ in in ; ; 0) L LI- 4) I- I- 0 IL E (U I- 0) 0 4- 0 I- 0) 4- 0 0 L (0 4 .0 0 I- 0 .~ (n I— 0..o .- E Ci) 0) (U I.. ~ ~ .~ 0. Oc~ ~Q) 0) (U C, z =0 0 0. a U •c~~—-a-- 0. o ~ 0 -. ~0 0 o Q~0~n~ ~ 0 ~ • ~ 0 ~ ~ q~00 ~ 1110 ~-0)0) -~ •~ 0 UJ: 0 ~-n’ 0~ — Ci)~ a a S 0 S S S OJ CO I > > TM-1571 Page 16 S-21E )
