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Miller Electric S-21E Technical Manual

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TECHNICAL MANUAL
A WARNING
SERVICING can be hazardous.
• Have all service procedures performed only by
qualified persons following standard safety
practices.
For help, call Factory
U
Service Department:
414-735-4505
coverjml
SB-124 467
—
MiIIe~
Service And Parts
Wire Feed Equipment
~U~r
©
November1996
Effective With Serial No. JJ507797
S-21E
FAX:
14-735-4136
Mfg. Co.
1996 MILLER Electric
Form: TM-1571
Use MILLER Testing Booklet (Part No.
150 853) when servicing this unit.
Use only genuine MILLER replacement
parts.
Or write to:
U
MILLER Electric Mfg. Co.
RO. Box 1079
L................J
Appleton, WI 54912 USA
PRINTED IN USA

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Summary of Contents for Miller Electric S-21E

  • Page 1 For help, call Factory FAX: Or write to: ~U~r Service Department: 14-735-4136 MILLER Electric Mfg. Co. 414-735-4505 RO. Box 1079 L....J Appleton, WI 54912 USA © Mfg. Co. 1996 MILLER Electric PRINTED IN USA...

  • Page 3: Table Of Contents

    OM-1571B 3/91 — TABLE OF CONTENTS Section No. Page No. SECTION 1 SAFETY PRECAUTIONS AND SIGNAL WORDS 1-1. General Information And Safety 1-2. Safety Alert Symbol And Signal Words 1-3. Safety Precautions SECTION 2- SHIPPING AND STORAGE 2-1. Preparation For Reshipment 2-2.

  • Page 4: Section No

    Section No. Page No. SECTION 8- TROUBLESHOOTING 8-1. Testing Instruments And Information 8-2. Circuit Board Handling Precautions 8-3. Troubleshooting Diagram 8-1. Troubleshooting Circuit Diagram For Wire Feeder 8-4. Motor Board PCi Testing Information Diagram 8-2. Troubleshooting Circuit Diagram For Motor Control Board PCi 8-5.

  • Page 5: Safety Precautions And Signal Words

    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- •...

  • Page 6: Section 2- Shipping And Storage

    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. • Shut down wire feeder and welding power •...

  • Page 7: Section 3- Specifications

    SECTION 3- SPECIFICATIONS Table 3-1. Specifications Input Power Electrode Wire Wire Spool Electrode Wire Weight Requirements Diameter Capacity Capacity Feed Speed 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.
  • Page 8 Pressure Roll Assembly (Shown In Open PosItion) Wire • Spring 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.

  • Page 9: Welding Gun Connections

    For 50 Series style one-piece drive rolls: B. Gun Trigger (Figure 5-1) a. Slide drive roll onto drive roll mounting hub. ‘9= b. Align drive roll with holes. TRIGGER c. Insert securing screws, and tighten. RECEPTACLE For 50 Series style split drive rolls: Connect gun trigger plug to trigger receptacle on the a.

  • Page 10: 14-Pin Plug Connection

    Flow Adjustment Gas cylinder Valve Argon or Argon Mix cylinder 2 Washer CO2 cylinder CO2 Installation Argon Installation SB-109 492 Figure 4-2. Typical RegulatorlFlowmeter Installation 4-5. 14-PIN PLUG CONNECTION (Figures 4-3 And 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 power source.

  • Page 11: Welding Wire Threading

    A. Installation Of Spool-Type Wire (Figure 4-1) 4-7. WELDING WIRE THREADING Remove retaining ring from hub. WARNING: ELECTRIC SHOCK can kill; MOVING PARTS can cause injury. Slide wire spool on hub so that wire feeds off the • Do not touch live electrical parts. bottom of the spool.

  • Page 12: Adjust The Hub Tension

    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) • Do not point gun toward any part of the body CAUTION: LOOSE WELDING WIRE can any conductive surface, or other personnel...

  • Page 13: Section 5-Operator Controls

    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 Receptacle Wire Speed The WIRE SPEED control adjusts the wire feed speed in inches per minute within the wire speed range.

  • Page 14: Shutting Down

    6-2. SHUTTING DOWN WARNING: ELECTRIC SHOCK can kill; TANGLED WELDING WIRE can touch case Stop welding. causing welding power source open-circuit voltage to be present on case if gun trigger is Place POWER switch in the OFF position. pressed. • Do not touch wire feeder case ifgun trigger is Shut down welding power source or generator.

  • Page 15: Diagram 7-1. Block Diagram For Wire Feeder

    •1~ ~(i) .~Q) tb~. I—0 S-21E TM-1571 Page 11...

  • Page 16: Diagram 7-2. Block Diagram For Spotlburnback Time Control Option

    Spot time potentiometer R25 allows adjustment B. SpotlBurnback Time Control Option (Diagram 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. Optional Spot/Burnback Board PC2 provides control of spot weld time and adjustment of burn- Spot/Continuous switch S51 allows either a nor- back time.
  • Page 17 Notes S-21E TM-1571 Page 13...

  • Page 18: Section 8- Troubleshooting

    SECTION 8— TROUBLESHOOTING TESTING INSTRUMENTS AND INFORMA- 8-3. TROUBLESHOOTING (Table 8-1 And Dia- 8-1. TION gram 8-1) The service procedures in this manual require proper testing instruments. Use a good quality digital volt- WARNING: ELECTRIC SHOCK can kill. ohmmeter (DVM) with one megohm input impedance or •...
  • Page 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.

  • Page 20: Diagram 8-1. Troubleshooting Circuit Diagram For Wire Feeder

    ~ ~ U) ~ ~ Z — ~ &E a~ zz:~~ o1t~ — — — — — — — — — — — (oIr-~0) C’J 0..o I— •c~~—-a-- Q~0~n~ • q~00 1110 ~-0)0) •~ ~-n’ Ci)~ — > > TM-1571 Page 16 S-21E...

  • Page 21: Motor Board Pci Testing Information

    8-4. MOTOR BOARD PCi TESTING INFORMA- A. Preliminary Checks TION (Figure 8-1 And Diagram 8-2) Check that jumper plug PLGl is secure in recep- tacle RC1 on Motor Control Board PCl. W ARNING: ELECTRIC SHOCK can kill. Check that plug PLG2 is secure in receptacle Do not touch live electrical parts.

  • Page 22: Diagram 8-2. Troubleshooting Circuit Diagram For Motor Control Board Pci

    WARNING: ELECTRIC SHOCK can kill; MOVING PARTS can cause serious injury. • Do not touch live electrical parts. • Shut down wire feederand welding powersource or stop engine before making or changing meter lead connec- tions and before disconnecting or connecting any leads. •...
  • Page 23 IMPORTANT: For DC, the values are based on a good quality digital 24 volts ac output volt-ohmmeter (DVM) or equivalent reading average (not RMS) to as valve GSi 24 volts ac output values. For AC, the values are RMS readings. The DC voltages wit gun tr~ger contactor control shown are with respect to circuit common lead 24 (pin C of plug...

  • Page 24: Optional Spotlburnback Board Pc2 Testing Information

    Receptacle Receptacle SA-123 147-E Figure 8-1. Motor Control Board PCi Component Locations And Information 8-5. OPTIONAL SPOTIBURNBACK BOARD PC2 EXCESSIVE PRESSURE can break circuit TESTING INFORMATION (Diagram 8-3 And board. Figure 8-2) • Use only minimal pressure and gentle move- ment when disconnecting or connecting board plugs and removingor installing board.
  • Page 25 ceptacle RC2 with respect to circuit common to start the circuit common, a contactor control output voltage of motor and 0 volts dc should be present when the gun +24 volts dc should be present at pin B of receptacle trigger is released to stop the motor.

  • Page 26: Diagram 8-3. Troubleshooting Circuit Diagram For Optional Spot/Burnback Board Pc2

    WARNING: ELECTRIC SHOCK can kill; MOVING PARTS can cause serious Inlury. • Do nottouch live electrical parts. • Shutdown wire feederand welding powersource or stop engine before making or changing meter lead connec- tions and before disconnecting or connecting any leads. •...
  • Page 27 IMPORTANT: For DC, the values are based on a good quality digital volt-ohmmeter (DVM) or equivalent reading average (not RM5) values. ForAC, the values are RMS readings. The DC voltages shown are with respect to DC circuit common lead 71 (pin B ofplug PLG5 I) unless otherwise indicated.

  • Page 28: Section 9- Component Identification And Location

    SECTION 9— COMPONENT IDENTIFICATION AND LOCATION ‘U ‘S.— • — ‘4- 0’ 6)—, &2 E~., ~ .2 • TM-1571 Page 24 S-21E...

  • Page 29: Section 10- Maintenance

    SECTION 10— MAINTENANCE 10-1. ROUTINE MAINTENANCE (Table 10-1) Every six months, inspect the gun, hoses, and cables. If dusty or dirty conditions are present, inspect the unit Every six months inspect the labels on IMPORTANT: monthly. Inspection should consist of the following: this unit for legibility All precautionary labels must be maintained in a clearly readable state and replaced Unlatch and open left case access door.

  • Page 30: 10-2. Aligning Drive Roll And Wire Guide

    10-2. ALIGNING DRIVE ROLL AND WIRE GUIDE 10-3. REINSTALLATION OF HUB ASSEMBLY (Fig- (Figure 10-1) ure 10-2) WARNING: ELECTRIC SHOCK can kill. WARNING: ELECTRIC SHOCK can kill. • Do not touch live electrical parts. Do not touch live electrical parts. •...

  • Page 31: 10-5. Overload Protection

    Remove brushes. hind the left case access door. Ifthe motor should over- load or the circuit fail, the breaker would trip and shut Examine brushes. Replace brushes if they are down the wirefeeder. If CB1 opens, correct the problem chipped or broken or if less than 1/4 in. (6.4 mm) and manually reset the breaker.

  • Page 32: Electrical Diagrams

    SECTION 11 ELECTRICAL DIAGRAMS Table 11-1. List Of Circuit Diagrams And Wiring Diagrams The following is a list of all diagrams for models covered by this manual. To order diagrams needed, proceed as follows: Know unit Model and Serial or Style Number. Use List to find diagram number.

  • Page 33: Jj507797 And Following

    SPOT/BURNBACK PLGIOO .(~a —~ OPTION mcs-s» o-’--cX2—~----’—« ~<*z~O mc4-A K 31 mc3-A» ~<Rc4-B ‘E-.-.<~~ ~< A~-0 mci-v» Ai~-o> ~WhED mci-c» mci-o>~ ~<mci-O I mci-c ACIOI «mci-E £~G~Li< mci-v RC4-C lUIGGER ~AOC mci-s >~ ~< mci-c R~TA~.E mci-A >~ ~< mci-a> —...
  • Page 34 C’) 0’ U,’- 0’ I... 0 IL C” SM-1571 Page 30...

  • Page 35: Effective With Serial No. Jj507797 Thru Jk742028

    0’ I’- 0’ Rca-A mci-c mci-c mci-c MCI -F mci-o mci-n MCI-A SM-1571 Page 31...

  • Page 36: Effective With Serial No. Jk742029 And Following

    0’ 0’ I’- SM-1571 Page 32...

  • Page 37: Section 12- Parts List

    MiIIeE November1996 Form: TM-1571 JJ507797 Effective With Serial No. SECTION 12- PARTS LIST S-21E Feed Equipment Wire S-21E TM-1571 Page 33...
  • Page 38 C— U’ TM-i 571 Page 34 S-21E...
  • Page 39 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly 127 232 DRIVE ASSEMBLY, wire (consisting of) 151 828 PIN, cotter-hair .042 x .750 112 031 LEVER, pressure-roll .275 111 523 BEARING, ball .315 x .866 x 114 415 SCREW, phillips-flat hd 10-24 x .625 adjustment-tension 092 237 KNOB,...
  • Page 40 Item Dia. Part Description Quantity Mkgs. Figure 12-1. Main Assembly (Continued) ..45 134306. FOOT, rubber 1 .2SOdia x 1.375 high ..46.. PLG100..144310. CONNECTOR & PINS, (Prior to KB041147) (consisting of) 134732. CONNECTOR, circ pin push-in 20-24ga Amp 21 3605-1 ..
  • Page 41 Item Part Description Quantity 108 008 Figure 12-2. Reel, Wire (Optional) 124904...NUT,spanner-spoolsupport 905.. RETAINER, spool support 124 900 SUPPORT, reel spool Ref. 5C-127 305 Figure 12-2. Reel, Wire BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. S-21E TM-1571 Page 37...
  • Page 42 SA-123 147-F Figure 12-3. Motor Control Circuit Card PCi TM-1571 Page 38 S-21E...
  • Page 43 Part Dia. Description Quantity Mkgs. 123 148 Figure 12-3. Circuit Card, Motor Control (Fig 12-1 Item 52) A1,2 009159 IC, linear 358 039482 CAPACITOR, elctlt iQOuf 35VDC 039481 CAPACITOR, elctlt 3.3uf 50VDC C3,6,37,38,50 51,53-56,59 122723 CAPACITOR, cer mono .luf 5OVDC ..
  • Page 44 Dia. Part Mkgs. Description Quantity Kit, Spot Control (Field Option) 121 562 093 551 KNOB, pointer 110 375 STAND-OFF SUPPORT, PC Card No 6 screw w/post STAND-OFF, No 6-32 x .500 Ig 098 691 STAND-OFF, No 6-32 x .625 Ig 073 756 122 426 BRACKET, mtg options...
  • Page 45 Dia. Part Description Quantity Mkgs. 121 562 Kit, Spot Control (Field Option) (Continued) D3-6 028 351 DIODE, sig 200mA 75V SP Ji-lo 092 648 RESISTOR, WW fxd zero ohm Qi,2 037 200 TRANSISTOR, NPN 200mA 40V 108 436 RESISTOR, MF .25W 4.32K ohm 035 828 RESISTOR, MF .25W 243 ohm R3,23...
  • Page 46 Notes...
  • Page 47 Notes...

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