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Miller Electric cyclomatic DWF3 Owner's Manual

Cold wire feeder system
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Model DWF–3 Cold Wire Feeder System
Read and follow these instructions and all
safety blocks carefully.
Have only trained and qualified persons
install, operate, or service this unit.
Call your distributor if you do not understand
the directions.
cover 5/94
OWNER'S
MANUAL
cyclomatic
Automatic Control For Supplying Filler Wire Into The Weld
GTAW And PAW
Stepper Motor For Accurate, Repeatable Feed Rates
120/240 Volts AC Input Power To Control Unit
Overload Protection
Automatic Wire Retract At End Of Weld Cycle
1996 MILLER Electric Mfg. Co.
August 2000
Form: OM-179 078
Effective With Serial No. KG041900
Give this manual to the operator.
For help, call your distributor
or: MILLER Electric Mfg. Co., P.O. Box 1079,
Appleton, WI 54912
414-734-9821
PRINTED IN USA

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Summary of Contents for Miller Electric cyclomatic DWF3

  • Page 1 August 2000 Effective With Serial No. KG041900 cyclomatic Give this manual to the operator. For help, call your distributor or: MILLER Electric Mfg. Co., P.O. Box 1079, Appleton, WI 54912 1996 MILLER Electric Mfg. Co. Form: OM-179 078 414-734-9821 PRINTED IN USA...
  • Page 2 ISO 9001 Quality System Standard. service information for your particular model are also provided. 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.
  • Page 3 ARC WELDING SAFETY PRECAUTIONS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The safety information given below is only a summary of the more complete safety information that will be found in the Safety Standards listed on the next page.

  • Page 4: Principal Safety Standards

    3. Do not allow tools to cause sparks when working on a battery. 4. Do not use welder to charge batteries or jump start vehicles. 5. Observe correct polarity (+ and –) on batteries. 1. If the engine is warm and checking is needed, follow steps 2 and 3.
  • Page 5 THIS MANUAL HAS BEEN DESIGNED FOR EXPERIENCED WELDING EQUIPMENT OPERATORS AND MUST BE READ COMPLETELY BEFORE USING THIS EQUIPMENT. IF YOU LACK EXPERIENCE OR ARE UNFAMILIAR WITH THE PRACTICES AND SAFE OPERATION OF WELDING EQUIPMENT, PLEASE CONSULT YOUR FOREMAN. DO NOT ATTEMPT TO INSTALL, OPERATE, OR PERFORM MAINTENANCE ON THIS EQUIPMENT UNLESS YOU ARE QUALIFIED AND HAVE READ AND UNDERSTAND THIS MANUAL.

  • Page 6: Table Of Contents

    Considerations About Welding And The Effects Of Low Frequency Electric And NOTE Magnetic Fields The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields – Background Paper, OTA-BP-E-53 (Washington, DC: U.S.

  • Page 7: Description

    SECTION 1 INTRODUCTION Cold wire feed systems are designed for accurate application of filler wire into the weld or braze area. The DWF–3 is designed to be used for GTAW and PAW processes. The Digital Wire Feeder System is made up of a positive feeding wire drive with a zero backlash 3–axis wire manipulator.
  • Page 8 SECTION 1 DESCRIPTION You may also order a combination of the wire guide mechanism, tip, conduit assembly, and conduit liner together as follows: .020 – .062 in dia. 179 165* *This includes all tips necessary for operation of .020 – .062 in dia. wire in one package. Figure 1.1, DIGITAL WIRE FEED SYSTEM OM-179 078...

  • Page 9: Installation

    SECTION 2 GENERAL SET–UP A standard DWF–3 system is illustrated in Figure 2.1 with the necessary interconnections shown for a typical installation. The parts are listed below: CONTROL UNIT WIRE DRIVE UNIT WIRE GUIDE ASSEMBLY CONTROL UNIT LOCATION The control unit should be placed in a location which provides easy access to the controls and proper air ventilation for cooling.
  • Page 10 SECTION 2 INSTALLATION Figure 2.1, DIGITAL WIRE FEED INSTALLATION OM-179 078...
  • Page 11 SECTION 2 INSTALLATION Figure 2.2, CONTROL UNIT OUTLINE OM-179 078...

  • Page 12: Wire Guide Mounting

    SECTION 2 INSTALLATION Figure 2.3, DRIVE UNIT OUTLINE WIRE GUIDE MOUNTING The guide mechanism portion of the wire guide assembly is made to accommodate a standard 1–3/8 in (34.9 mm) diameter machine torch barrel (see Figure 2.4). Guide tips are available for specific wire sizes from .020 in to .094 in diameter.
  • Page 13 SECTION 2 ITEM OM-179 078 Figure 2.4, WIRE GUIDE ASSEMBLY TABLE 2.1 WIRE GUIDE ASSEMBLY PART NMBR – BODY MANIPULATOR MACHINED – PIVOT–WIRE MANIPULATOR – KNOB, VERT. ADJ–WIRE MANIPULATOR – CLAMP, WIRE MANIPULATOR – RACK–WIRE MANIPULATOR – CLAMP, TORCH – COUPLING, MANIPULATOR TWECO –...

  • Page 14: Conduit Length Adjustment

    SECTION 2 CONDUIT LENGTH ADJUSTMENT The conduit as supplied is an assembled unit 36 in (914 mm) long. If shorter lengths are desired, the conduit may be cut and reassembled according to the following steps. Disassemble existing fitting on one end. Save the fitting components. Wrap hose with masking tape at cut–off point and cut square to length through taped area using a sharp cut–off wheel or a fine–tooth hack saw.
  • Page 15 SECTION 2 Lubricate nipple and socket threads. For stainless steel fittings, use a molydisulfide base lubricant (e.g., Molykote Type G); lubricants containing chloride are not recommended. Other material combinations use standard petroleum lubricants. Hold the nipple with hex in vise. Push hose over nipple with twisting motion until seated against nipple chamfer.

  • Page 16: Remote Controls

    SECTION 2 REMOTE CONTROLS A number of remote capabilities are available with the DWF–3 system. On the rear panel of the control unit a connector is provided for remote operation. The remote connector, in addition to providing for the remote control connections, provides the user access to other wire feeder signals.

  • Page 17: Operation

    SECTION 3 PRECAUTIONS Verify the following before connecting power to control unit. Make certain the drive unit is grounded. Check that all connections are secure and properly installed. All connections should be made to the torch and power supply before applying power to the control unit. Should the cover of the control unit be removed for any reason, be sure the AC line cord is disconnected.

  • Page 18: Sequence Of Operation

    SECTION 3 OPERATION Figure 3.2, DWF–3 REAR PANEL START DELAY: Allows for a delay between the time a weld cycle is initiated and the time when wire feeding begins; START DELAY is presettable in 0.1 second increments, from 0.0 to 9.9 seconds. STOP DELAY: Allows for a delay between the time when a weld cycle is terminated and the time when wire retracts then stops feeding.

  • Page 19: Remote Signals

    SECTION 3 OPERATION indicated on the digital display; set the SPEED CONTROL selector switch to the STANDARD position. Positioning the MANUAL START/REMOTE START switch to the MANUAL START position will now initiate a wire feed cycle. The digital display will blink during START DELAY time. At the end of START DELAY, wire will begin to feed and the speed will be indicated on the display.
  • Page 20 SECTION 3 OPERATION Figure 3.3, REMOTE WIRING CABLE The remote start function requires a signal of +5 to 24 VDC. This signal is applied to pin C of J3. The common is from the DWF–3 (this signal is optically isolated from the DWF–3); therefore, the signal common need not be attached to the control unit ground.
  • Page 21 SECTION 3 OPERATION Figure 3.5, INHIBIT FUNCTION WIRING OM-179 078...

  • Page 22: Maintenance And Repair

    SECTION 4 MAINTENANCE REQUIREMENTS The DWF–3 wire feed system has no special scheduled maintenance requirements. However, periodic inspection of control and wire drive are helpful in preventing equipment failures. Replace any worn or broken parts found. Periodic dust and oil removal from both the control and drive is recommended. GENERAL PRECAUTIONS Figure 4.1 shows a control unit for the DWF–3 system.
  • Page 23 SECTION 4 Figure 4.1, CONTROL UNIT ASSEMBLY OM-179 078 – CABLE ASSY, DWF–3 DRIVE INTERFACE – SWITCH, JOG FWD/REV OR 120/240 VOLT 179 140 CIRCUIT BREAKER ETA TYPE, 1 AMP 179 098 SWITCH, JOG FWD/REV 179 097 SWITCH, SPEED CONTROL STAND/REMOTE –...

  • Page 24: Drive Unit Assembly

    SECTION 4 DRIVE UNIT ASSEMBLY Figure 4.2 shows an exploded view of the drive unit; user replaceable parts are listed in Table 4.2. TROUBLESHOOTING LINE VOLTAGE IS EXPOSED INSIDE THE CONTROL UNIT. TAKE PRECAUTION TO AVOID ELECTRIC SHOCK WHEN COVER IS REMOVED. The TROUBLESHOOTING section of this manual is not intended to be a step–by–step guide to problem solving of all possible failure modes.
  • Page 25 SECTION 4 TROUBLE INDICATION Incorrect wire feed speed. Motor turns but wire does not feed. TABLE 4.2 PARTS LIST FOR DRIVE ASSEMBLY ITEM OM-179 078 REPAIR STEPS Check input signal (TP15 on Controller/Driver circuit board). Replace speed pot or circuit board if necessary. Verify that thumbscrew is fully seated.
  • Page 26 SECTION 4 Figure 4.2, DWF–3 DRIVE ASSEMBLY EXPLODED VIEW OM-179 078 – TUBING SHRINK – BLACK – SCREW SCH HEX 10–24 X .375 – SCREW CONE PT. 10–24 X .50 – SCREW PANHD PHIL 6–32 X 3/8 – SPACER, BEARING 0.020 THICK –...
  • Page 27 SECTION 4 The standard setting for the DWF–3 is 0.512 in. However, the following lengths may be obtained by inserting jumpers from P1, P2, P3, and P4 on the U12 IC Circuit to +12V and ground as shown: TABLE 4.3 AVAILABLE RETRACT LENGTHS LENGTH DESIRED INCHES 0.085...

  • Page 28: Circuit Description

    SECTION 5 REFER TO FIGURE 5.1 ”SCHEMATIC DIAGRAM OF DWF–3 CONTROL UNIT”. SPEED CONTROL CIRCUITS There are two speed control circuits in the DWF–3 control unit. One is for the Jog and Retract functions, and is a preset speed. The other is for wire feed during the weld cycle and this speed is variable. Variable speed motor pulses originate at U1, a voltage controlled oscillator.
  • Page 29 SECTION 5 CIRCUIT DESCRIPTION Figure 5.1, SCHEMATIC DIAGRAM OF DWF–3 CONTROL UNIT OM-179 078...
  • Page 30 SECTION 5 CIRCUIT DESCRIPTION Figure 5.1, SCHEMATIC DIAGRAM OF DWF–3 CONTROL UNIT (Continued) OM-179 078...
  • Page 31 SECTION 5 CIRCUIT DESCRIPTION OM-179 078...
  • Page 32 SECTION 5 CIRCUIT DESCRIPTION Figure 5.1, SCHEMATIC DIAGRAM OF DWF–3 CONTROL UNIT (Continued) OM-179 078...
  • Page 33 SECTION 5 CIRCUIT DESCRIPTION 1078–0012 Figure 5.2, DIGITAL DISPLAY AND DRIVER SCHEMATIC OM-179 078...
  • Page 34 Notes OM-2218 Page 7...
  • Page 35 Warranty Questions? Call LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold for your local after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.
  • Page 36 Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 2000 Miller Electric Mfg. Co. 6/00 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA &...

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