Related Manuals for Miller Electric OM-842
Summary of Contents for Miller Electric OM-842
- Page 1 Visit our website at www.MillerWelds.com Intellitig MPC OM-842 162074B August 1997 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description Programmable Precision Controller For Welding Power Source...
- 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.
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Page 3: Table Of Contents
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage 1-2. Arc Welding Hazards 1-3. Additional Symbols for Installation, Operation, and Maintenance 1-4. Principal Safety Standards 1-5. EMF Information SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION 1-1. -
Page 5: Section 1 - Safety Precautions - Read Before Using
The coatings and any metals containing these elements can give off toxic fumes if welded. som _nd_5/97 OM-842 Page 1... - Page 6 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018. Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. OM-842 Page 3... -
Page 8: Emf Information
To reduce magnetic fields in the workplace, use the following procedures: OM-842 Page 4 1. Keep cables close together by twisting or taping them. 2. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. -
Page 9: Section 1 - Consignes De Securite - Lire Avant Utilisation
été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si nécessaire, en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage. som _nd_fre 5/97 OM-842 Page 5... - Page 10 Pendant la période de refroidissement des soudures, elles ris- quent de projeter du laitier. D Porter des lunettes de sécurité avec écrans latéraux ou un écran facial. OM-842 Page 6 LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou même la mort.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
D Porteurs de stimulateur cardiaque, restez à dis- tance. D Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de s’appro- cher des opérations de soudage à l’arc, de gou- geage ou de soudage par points. OM-842 Page 7... -
Page 12: Principales Normes De Sécurité
établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnéti- ques pendant le soudage ou le coupage. OM-842 Page 8 Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. -
Page 13: Section 2 - Installation
(See Section 2-2) Keyway Plug Threaded Collar Use receptacle to connect supplied remote pendant. User-wired con- trols equivalent to remote control also connected this receptacle. To connect to receptacle, align key- way, insert plug, and tighten threaded collar. OM-842 Page 9... -
Page 14: User Relay Contacts
Use 3T and 4T to connect external equip- ment to internal relay contacts. Pairs of nor- mally closed and normally open contacts are provided for each weld sequence step, the OM-842 Page 10 The internal control relay contacts accessible through terminal strips 3T and 4T are rated at 20 amperes, 250 volts. -
Page 15: Setting Dip Switch Sw1
1 and 2 according to table. Close front panel and tighten retain- = On ing screw after setting SW1. = Off Defined Amperage Adjustment Limit 5 Amperes 10 Amperes 20 Amperes 40 Amperes Tools Needed: Ref. ST-800 194 / Ref. ST-162 477-A OM-842 Page 11... -
Page 16: Section 3 - Operation
SECTION 3 – OPERATION 3-1. Controls 3-2. Safety Equipment 3-3. Work Clamp OM-842 Page 12 Tools Needed: Voltmeter Ammeter Digital Display Left/Decrease Button Right/Increase Button Parameter Select Button Purge Button Mode Switch Program/Run/Reset Keyed Switch 10 Remote Pendant Ref. ST-162 479-A / Ref. ST-146 839... -
Page 17: Ammeter And Voltmeter
Use display to enter and read val- ues. If weld sequence steps are shown, the programmed time val- ues decrease as process time runs out. Mode Selector Switch Use switch to select mode of operation. Ref. SC-159 862 OM-842 Page 13... -
Page 18: Program/Run/Reset Keyed Switch
3-10. Left/Decrease Push Button To zero a parameter value, select pa- rameter and press Right/Increase and Left/Decrease switches at the same time. OM-842 Page 14 Program/Run/Reset Keyed Switch Program Use to enter, change, and/or ex- ecute a program. -
Page 19: Purge Push Button
Foot Control Open valve on cylinder just before welding. Torch trigger or foot control turns weld output and gas flow on and off. Close valve on cylinder when fin- ished welding. sb5.2* 2/92 – S-0621-C / ST-159 059 OM-842 Page 15... -
Page 20: Section 4 - Introduction To Programming
32% Electrode Positive More Penetration 68% Electrode Negative 50% Electrode Positive Balanced 50% Electrode Negative OM-842 Page 16 Weld/Peak Final Current Slope Final Current Postflow In most cases, the weld sequence shown here is used in programming the control. Which steps are pro- grammable and what initiates each step varies from mode to mode. -
Page 21: Modes Of Operation
Pressing the Stop push button be- fore the start of weld/peak current stops program execution and starts postflow. Pressing the Stop push button after the end of weld/peak has been signalled has no effect. Ref. SB-139 983 OM-842 Page 17... - Page 22 Postflow: Time programmed/Volume set by gas meter. Weld/peak current cannot be increased or decreased during welding. Stop push button functions throughout sequence if Stop Button Detect is en- abled in the program. Figure 4-3. Semi-Automatic 3 Mode Sequence OM-842 Page 18 Weld/Peak Final Current Slope...
- Page 23 Stop push button stops program execu- tion and starts postflow. If Stop But- ton Detect is disabled, pressing the Stop push button has no affect. Postflow starts if the arc is manually broken. Ref. SB-139 983 OM-842 Page 19...
- Page 24 If remote control is used, the maximum output that can be commanded is defined when the program is created. The minimum is the minimum output the welding power source is capable of. OM-842 Page 20 Weld/Peak Final...
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Page 25: Section 5 - Programming
L I M I T A M P S 3 5 1 * M F G . L I M I T A M P S OM-842 Page 21... -
Page 26: Automatic Mode
< X X .> This display indicates whether the Process Selector switch is set for ac or dc output. The first repeating display scrolls into view, and the se- quence repeats. OM-842 Page 22 5-2. Automatic Mode NOTE NOTE # 0 X S T A R T A. - Page 27 T I M E = X X X .X A p K = X X X .X A b K = X X X .X T I M E = X .X X T I M E = X .X X OM-842 Page 23...
- Page 28 The ranges for both ApK and AbK are 2.0 to 400 am- peres, in increments of 1.0 ampere. OM-842 Page 24 Press Right/Increase, and the display shows: # 0 X P U L S E S / S E C =...
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Page 29: Semi-Automatic Mode
DIP switch SW1 (see Section 2-4) before using the following procedure to enter a program. C O N T R O L X X % X X % F R E Q U E N C Y OM-842 Page 25... - Page 30 S L O P E T I M E = X X .X Define the initial slope time as desired. OM-842 Page 26 The range for initial slope time is 0.0 to 25.0 seconds, in increments of 0.1 seconds. Press Right/Increase, and the display shows:...
- Page 31 C U R R E N T X X X .X A M P S S L O P E T I M E = X X .X F I N A L A M P S = X X X .X OM-842 Page 27...
- Page 32 D R Y R U N U S E R E M O T E OM-842 Page 28 If desired, press Start/Increase on the Remote Pend- ant to carry out a dry run of the program (see Section 5-7 for information on the dry run feature). To place the microprocessor control in the Ready condition, press Right/Increase.
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Page 33: Manual Gtaw Mode
T I M E = X X .X S T A R T L E V E L A M P S = X X X .X M O D E I S * * > X X < OM-842 Page 29... - Page 34 P U L S E A p K P U L S E A b K OM-842 Page 30 Define the ApK and AbK values as desired. ApK defines the peak current during pulsing. AbK defines the background current. The ranges for both ApK and AbK are 2.0 to 400 am- peres, in increments of 1.0 ampere.
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Page 35: Smaw Mode
Ready condition is active (see Section 5-1F). A R C C O N T R O L 0 0 0 C O N T R O L < X X X X X X X > OM-842 Page 31... -
Page 36: Dry Run Feature
4, program 2 would be assigned to link position one, program 1 would be assigned to position two and program 4 OM-842 Page 32 would be assigned to position three. A reset would be as- signed to position four to indicate the end of the linked programs. -
Page 37: Combining Programs
S E L E C T ” C O M B I N E ” P O L A R I T Y < X X .> P O S I T I O N X X X X X X X OM-842 Page 33... -
Page 38: Section 6 - Sequence Of Operation
OM-842 Page 34 D R Y R U N ” C O M B I N E ” U S E... - Page 39 E. Operation Procedures For Semi-Automatic 4 Mode When the unit is in the Ready condition (see Section 5-1F), momentarily press Start/Increase to begin the weld sequence. After arc initiation at initial current, the OM-842 Page 35...
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Page 40: Gas Tungsten Arc Welding (Gtaw) In The Manual Mode
Increasing and decreasing the weld current output can go on indefinitely. OM-842 Page 36 g. If the weld current output is decreased to the pro- grammed final current, the program enters final current and goes to postflow. -
Page 41: Shielded Metal Arc Welding (Smaw)
Select until the program number increases beyond 4. The Link mode will be active. Press Parameter Select again to enter the Combine mode. Press Start/Increase on the Remote Pendant to begin combined program execution. 6-7. Shutting Down Stop welding. OM-842 Page 37... -
Page 42: Overheating Protection
Initial Slope relay Weld Time relay Final Slope relay Final Time relay OM-842 Page 38 A L L O W C O O L B E F O R E C O N T I N U I N G... -
Page 43: Diagnostics Program
P R O G R A M P L E A S E P U S H B U T T O N B U T T O N P R O P E R L Y OM-842 Page 39... - Page 44 D I A G N O S T I C T E S T P R O G R A M OM-842 Page 40 If the Parameter Select push button is not working cor- rectly, replace the push button. When the Parameter Select push button tests okay, the repeating test displays appear.
- Page 45 S W I T C H T E S T T U R N K N O B P O S I T I O N P O S I T I O N P R O P E R L Y OM-842 Page 41...
- Page 46 If the Mode Selector switch is not placed in the Semi-Automatic position in time, or if the position is not working correctly, the display shows: OM-842 Page 42 E R R O R ! ! If the Semi-Automatic position is not working correctly, replace the Mode Selector switch.
- Page 47 C O N T A C T O R T E S T V O L T M E T E R F O R V O L T S OM-842 Page 43...
- Page 48 Use the Right/Increase or Left/Decrease push button to access another test, or stop the diagnostics pro- gram. OM-842 Page 44 L. Arc Starter Relay Test This procedure tests the arc starter relay. Indirectly, the Arc Starter Board PC8 is also tested.
- Page 49 B U T T O N W O R K I N G P R O P E R L Y If the Decrease push button tests okay, go to Step 8. N O T B U T T O N OM-842 Page 45...
- Page 50 C U R R E N T D E T E C T T E S T OM-842 Page 46 Press Parameter Select. The display scrolls through the following two displays: P U T N O T C O N T I N U E Connect a suitable cable across the output terminals.
- Page 51 Factory Authorized Service Station/Service Distributor. When input contactor closure tests okay, press Param- eter Select to exit the test. Use the Right/Increase or Left/Decrease push button to access another test, or stop the diagnostics program. OM-842 Page 47...
- Page 52 SECTION 8 – ELECTRICAL DIAGRAMS SA-132 263 Figure 8-1. Circuit Diagram For Remote Pendant OM-842 Page 48...
- Page 53 SC-161 093-B Figure 8-2. Wiring Diagram For MPC Module OM-842 Page 49...
- Page 54 Figure 8-3. Circuit Diagram For Welding Power Source And MPC OM-842 Page 50...
- Page 55 SC-182 947-B OM-842 Page 51...
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Page 56: Section 9 - Parts List
SECTION 9 – PARTS LIST Hardware is common and not available unless listed. ST-162 780 Figure 9-1. Main Assembly OM-842 Page 52... - Page 57 ..........OM-842 Page 53 Quantity...
- Page 58 To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-842 Page 54 Description Figure 9-2. Pendant GUARD, switch al knurled .
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- Page 63 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 64 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 &...