Miller SYSTEM 9 GAS CONTROL HUB & SPINDLE WIRE REEL Owner's Manual
  1. Manuals
  2. Brands
  3. Miller Manuals
  4. Welding System
  5. SYSTEM 9 GAS CONTROL HUB & SPINDLE WIRE REEL
  6. Owner's manual
Miller SYSTEM 9 GAS CONTROL HUB & SPINDLE WIRE REEL Owner's Manual

Miller SYSTEM 9 GAS CONTROL HUB & SPINDLE WIRE REEL Owner's Manual

Gas control hub & spindle wire reel
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
t~e
0~
096~
OWN ERS
MANUAL
November1983
FORM: OM-1537B
Effective With Serial No. J0668503
MODEL
SYSTEM 9
GAS CONTROL
HUB
&
SPINDLE
WIRE REEL
ITIIIIER
MILLER ELECTRIC MFG. CO.
778 S.
BOUNDS
SI,
P.O. Box 1079
APPLETON,
WI
54912 USA
NWSA CODE NO. 4579
PRINTED
IN
U.S.A.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the SYSTEM 9 GAS CONTROL HUB & SPINDLE WIRE REEL and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Miller SYSTEM 9 GAS CONTROL HUB & SPINDLE WIRE REEL

Summary of Contents for Miller SYSTEM 9 GAS CONTROL HUB & SPINDLE WIRE REEL

  • Page 1 FORM: OM-1537B Effective With Serial No. J0668503 096~ MODEL SYSTEM 9 GAS CONTROL & SPINDLE WIRE REEL OWN ERS ITIIIIER MANUAL MILLER ELECTRIC MFG. CO. 778 S. BOUNDS P.O. Box 1079 APPLETON, 54912 USA NWSA CODE NO. 4579 PRINTED U.S.A.
  • Page 2 Distributor/Dealer that all and unused Equipment duty furnished Miller is free from defect workmanship of Millers breach of warranty any other In the case exclusive remedies quality goods, material of the time...
  • Page 3 ERRATA SHEET After this manual printed, refinements equipment design occurred. This sheet lists exceptions data appearing later In this manual. AMENDMENT TO SECTION MAINTENANCE & TROUBLESHOOTING Amend 7-1. Circuit Diagram For Weld Control (see Page this Errata Sheet) Figure Board PC12 7-9.
  • Page 4 8 9 1 - B C - 0 9 7 D i a g r a m LT,i1 _ _ _ _ _ _ _ _ _ 2_au: ; f z i i i : 1 ~ _ _ _ C i r c u i t ~ ~ J i i i ~ J F 9 4 7 2 1 7...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Section No. Page SECTION SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE Introduction General Precautions 1 -3. Welding Standards Booklet Index INTRODUCTION SECTION 2 General Information And Safety Receiving-Handling Description SECTION 3 INSTALLATION 3-1. Location Gas Connections Shielding 3 -3.

  • Page 7: Introduction

    SOURCE SECTION SAFETY RULES FOR OPERATION OFARC WELDING POWER 1-i. INTRODUCTION learn experience. welding cutting, (and chipping) the eyes protect personal experience, like Learning safety through from radiant energy and flying metal. Replace cover child harmful, wasteful, -3A.2. touching glass when broken, pitted,...
  • Page 8 container has first highly toxic gas, and other lung and eye irritating be welded cut, unless never A6.O, ducts. The ultraviolet (radiant) energy of the been cleaned described AWS Standard arc can also trichioroethylene listed 3 in Standards index. decompose chloroethylene form phosgene.
  • Page 9 Coil hose prevent kinks and tangles. marking each cylinder. must excess safety when the cylinder properly assurance Protect hose from damage by sharp edges, handled. and open flame. sparks, slag, with Identifying only cylinders content. rely color Examine hose regularly leaks, and loose of gas marked...

  • Page 10: 1-3. Arc Welding

    equivalent water). Bubbles Protect filter plate with clear plate. Liquid gallon cover dicate leak. Clean off soapy after test; dried water soap Cracked shield should is combustible. broken helmet radiation through burns. cause worn; pass User Responsibilities Cracked, broken, loose filter plates replaced must...
  • Page 11 Shock Prevention Electrode Holders Exposed hot conductors Fully other bare metal insulated electrode holders should be used. Do in the welding circuit, ungrounded, electrically-HOT holders with protruding screws. equipment fatally shock whose body person becomes conductor. DO NOT STAND, SIT, LIE, Connectors LEAN OR TOUCH...

  • Page 12: Standards Booklet Index

    switches) ON of red-tag prevent accidental turning Standard A6.0, WELDING cables Disconnect from welding TING CONTAINERS WHICH HAVE HELD COM power. power pull all 115 volts line-cord plugs. BUSTIBLES source, obtainable from American Welding Society, Jeune open power circuit change polarity while P.O.
  • Page 13 5/16 in. (7.9 mm) 4-1/8 2 Holes J:?et~ (105 9.5 in. (241.3 (482.6 9-7/8 (251 10-1/2 (267 mm) TA-080 3-1/2 26-1/2 In. (89 mm) (673.1 25-27/32 in. (656.4 mm) 9-1/2 TAO8O (241.3 TC-085 225-A Add 1 in. (25.4 mm) connectors. (12.7 mm) 1/2 in.

  • Page 14: 1. General Information And Safety

    SECTION INTRODUCTION Wire Feed Open-Circuit Input Power Speed Voltage Control Requirements Weight Depends Welding 50-800 115 Volts AC 83 lbs. Power Source Open-Circuit (1.3-20.3 mpm) Amperes (37.6 kg.) Voltage 2-1. Figure Specifications GENERAL INFORMATION AND SAFETY RECEIVING-HANDLING Prior installing this material equipment, clean all...
  • Page 15 have 5/8-18 left Terminal in and fittings strip is located water water out component panel. hose from the hand threads. Connect supply from the front door water Loosen the and open door screws gas control assembly. Connect fitting gain 2T. Route leads from imit switches water access...

  • Page 16: 6. Weld Control Interconnections

    Connect insulated wires from shielded twisted 6. WELD CONTROL INTERCONNECTIONS wire (Belden 8760 equivalent) pair to contacts (Figures 3-3 and 3-5) switch. normally-open momentary-contact Cut off shielding wire. Repeat for each limit ELECTRIC SHOCK WARNING: kill. ____ switch required. touch live electrical parts.

  • Page 17: 7. Field Installation Of Mha-2

    Weld Output Connections (Figure 3-4) IMPORTANT Depending location, the weld ______________ may have be removed from its control (5ystem Select, and attach weld mounting accomplish this installation. Retain a/I prepare output minals size v~eld cables hardware removed for reinstal/ation unless according specifically proper...
  • Page 18 VAC/Contactor Control Deltawsid. WeldIng Power Source TA-O87 With MHA-2 Interconnection Diagram 3-6. Figure Disconnect lead from terminal Disconnect PLG9 from microprocessor board strip link between terminals K and L PCi. Turn plug that keying fingers are on remove jumper Slide removed lead back bottom when holding plug...

  • Page 19: 3-10. Installation Of Reel-Type Wire

    Connect shaft remaining end of lead from Step through of the sert of holes in sets terminal spindle strip (hole selection size support depends of wire spool). Ensure that the brake washers properly seated in the hub. Using supplied cable ties and clips, secure leads...

  • Page 20: Installation Of Wire Reel

    Slide the wire reel the hub. Rotate wire reel Pull the four fingers until they be rotated onto until hub is seated in reel. of the reel. guide toward center Depress spring-loaded Install wire reel four stops onto over taining ring, slide retaining ring into proper...

  • Page 21: Alpha Numeric Display Definitions

    outlined 4-2. be used in Table When codes through used, program will the end of the start next Pause sequence. When codes 4 through program will after used, next start limit switch closure. When code 0 is 14-084 633 the unit will advance next Figure 4-1.

  • Page 22: Operator Controls

    the~weld WRITE! Tape ready receive information make If this incomplete. happens program stored in memory. To the memory, the gain /DATA BAD/ numeric. alpha access appears weld control RUN-SET UP switch be in the RUN must reset/diagnostic switch main printed Circuit position.

  • Page 23: Jogging Controls

    Program Select Button Sequence Advanc. Burton Digital Displays Voltage Error .Reset Burton Purge Button Stop Jog Up Button Down Button Run/Setup Switch Burton Button Wire Speed ic oss Control 5-1. Weld Control Front Panel View Figure CONTROLS 5-1) AUXILIARY OUTPUT INDICATORS 3.

  • Page 24: 8. Purge Push Button

    Next Program Indicator The TIME indicator down time when counts sequence timed sequence of the weld program counts The NEXT PROGRAM indicator displays the number elapsed time 999 seconds) when in untimed (1-9) of the weld program that is follow the weld pro sequence.

  • Page 25: Mini-Cassette Tape Operation

    If the seqt~ence coded for program is being pressing advance, begins sequence run. run, PROGRAM RUN button has effect. pressing the button will have effect the sequence. 5-12. HALT/RESUME PUSH BUTTON (Figure If unit is in halt mode (see Section 5-12) just 5-1)
  • Page 26 program is transtered from the into selected, /INVALID/ tape will show program zero weld control memory, place RUN/SET alpha-numeric. Selecting valid program number UP switch in the SET UP READ/ (1-9) will clear the position. invalid. numeric. should alpha appear A weld program include following...

  • Page 27: Program Run Push Button

    Postflow input through programming sequence those sequences had time If the Weld 2 zero set. module. Program allowed quence MILLER ELECTRIC APPLETON HALT/RESUME button and the INTELLIMAYIC unit halted, there SYSTEM 9 would be Crater, Burnback, Postflow. However, PROGRAM MODULE...

  • Page 28: 4. Running A Program

    Run the program indicated with timed Pause Ensure that all input connections, output sequence and different program (see Ex and interconnections run a made according ample structions Section 3 of this manual and in the welding wire drive power source motor program with than three weld...
  • Page 29 MILLER ELECTRIC RFG APPLETON~ Step INTEWMATIC SYSTEM 9 SEQUENCE PROGRAM MODULE With Unit standby: _______ VOLTS A&8...
  • Page 30 SECONDS CODE millER ~ICPES PROGRAM _______ CODE MI~oU re A&CON ObOON CODE SE CO PROGRAM SELECT AUXILIARY OUTPUTS Step MILLER ELECTrnC ~EG APPLITOA. SEQUENCE III}*__ INTELLIMATIC load data SYSTEM press PROGRAM MOOULE VOLTS ___-~I;JI~II~1 value enter of volts INCII/MIN. C&C...
  • Page 31 COOS INCHES PROGRAM .15O MINUrE mullER AbCON SPOON CODE fl L SE CO 0.50 PROGRAM SELECT AUXILIARY OUTPUTS SEQUENCE MIlLER EI.ECTEIC MPG APPlETON INTELLIMAflC WELD SYSTEM 9 PROGRAM MODULE VOLTS 0~5~0~ lat.r. esconds NEXT VOLTS PROGRAM display looks INCH/MIPE Ilk, this VALUE SERIAL NO.
  • Page 32 Step programming pause sequence. SILLER ELECTS~C SIPS APPLETON SEQUENCE IN1EWMATIC load data SYSTEM 9 press PAUSE PROGRAM MODULE VOLTS _________ A and B O~O~ auxiliary -4--__d. load data press NEXT INCMIMIN. C&D VOLTS SET VALUE PROGRAM and D SERIAL NO. auxiliary outpisto SECONOS...
  • Page 33 Program Time Weld Weld Weld Burn Standby Post Flow Crater Standby Run,ln Back Flow (Pause) Volts (0-99.9) 30.0 26.5 24.0 26.0 Feed Speed (0-800) (0-99.9) (0-9.99) (0-99.9) (0-99.9) (0-9.99) (0-99.9) (0-.999) (0-99.9) (0-99.9) 22.5 00.0 Time 00.0 .075 (1,2,3) (16) (16) (1,2,3) (16)
  • Page 34 MILLER ELECTRIC MEG &flt(TOpd IPITELLIMATUC sEauENcE SYSTEM9 skip weld PROGRAM MOOULE ______ VOLTS WELD 3 . _ _ . _ . . _ . 4 P . J I ~ 1 I ~ I I ~ 1 INCH/MEN. enter zero...
  • Page 35 Program Time Weld Standby Weld Weld Burn Post (Pause) Standby Flow Run. Crater Back Flow 22.5 Volts (0-99.9) 25.0 20.0 22.0 22.0** Feed Speed (0-800) (0-99.9) (0-9.99) (0-99.9) (0-99.9) (0-99.9) (0-9.99) (0-.999) (0-99.9) (0-99.9) 10.5 22.0 Time. 15.0 (1,2,3) (1,2,3) (16) (16) (16)
  • Page 36 Program ~cl, F..RunlnTime Weld Weld Weld Burn Post Standby* Crater (Pause) Standby Flow Run In Back Flow 26.0 26.0 28.5 25.0 22.0 22.0 Volts (0-99.9) Speed (0-800) 360** Feed (0-99.9) (0-9.99) (0-99.9) (0-99.9) (0-99.9) (0-9.99) (0-.999) (0-99.9) (0-99.9) Time (1,2,3) (16) (16) (1,2,3)
  • Page 37 Program 3/4 (6 weld sequences) Enter program data using procedure outlined example Programs 1 and ELECTRIC MPG MILLER CO.. APPLETON INTEWM*1IC SYSTEM 9 PROGRAM MODULE skip crater; time, zero code of 1. 2 VOLTS 3 and data enter __________ SECONDS/CODE by pressing button.
  • Page 38 MILLER ELECTRIC MPG APPLETON INTELUMATIC SYSTEM PROGRAM MODULE VOLTS AfrO Press SECONDS/CODE button INCH/MIN C&O transfeP from STANDBY SET VALUE SERIAL NO. PREFLOW. Bypass PREFLOW by pressing SECONDS/CODE button when corresponding SECONDS CODE. display. quence name bypass RUN-IN: millER some...

  • Page 39: Maintenance & Troubleshooting

    SECTION MAINTENANCE & TROUBLESHOOTING ELECTRIC SHOCK kill. 2. INSPECTION AND UPKEEP WARNING __________ e/ectrica/ parts. touch five Disconnect unit from input before internal IMPORTANT Periodically inspect labels this power _______________ unit for legibility. iy inspecting servicing. precautionary labels be main must tained clearly...
  • Page 40 C - 0 9 1 2 / 3 4 G O o . 1 0 , 1 . 1 0 ) , I O , D i a g r a m oOI~I~~ ~ c ~ ~ ~ _ _ _ _ 0 1 0 1 0 S I J A I I O ;...
  • Page 41 ,l~Th rT~8 Circuit Diagiam No. A-084 357 Figure Circuit ?-2. Diagram For Power Supply Board PC3 Circuit Diagram B-088 486-A Figure 7.3. Circuit Control Diagram Voltage Board OM-1537 Page...
  • Page 42 C - 0 8 4 D i a g r a m C i r c u i t B o a r d p j o - I C o n t r o l p i t , M o t o r D i a g r a m C i r c u i t...
  • Page 43 OM-1537 P.~.37...
  • Page 44 >1 )H-~---~o-----~2 _____ >4 1R541 >5 C 50 _____ >6 l~55} >7 (R56}~O-- _____ >8 >9 _____ 1R57} >10 6< 7< >12 >13 _____ >14 A-084 723-A Circuit Diagram For Motor Power Board PC7 7-6. Circuit Diagram Figure OM-1537Page38...
  • Page 45 I C O S I C : C 2 ~ 0 ~ 1 6 0 - 3 ~ o ~ 1 _ _ / 1 1 C 1 ~ L ~ E ~ 0 ( I O C w W 6 9 ! G O C W ( ) I I I ) 0 ~ ~ ~ 1 I C 1 d S I C...
  • Page 46 S W I I L Y E S S U R E C U S T O R L A C - 0 9 1 S U P P l I E D M u l L Y I A I J , L I M I T I11~2 1 L J ;...
  • Page 47 November 1983 FORM: OM-1 5371 Effective With Serial No. JD668503 MODEL System PARTS LIST...
  • Page 48 >. OM-1537 Page...
  • Page 49 Item Dia. Part Mkgs. Description Quantity Figure Main Assembly DOOR ASSEMBLY Figure 084 044 PANEL, shield-door 059712 CLIP,cable 045 852 CLIP,11/i6dia Figure PANEL, mtg-components-upper 057084 BUSHING,snapl/4IDx3/8 0.275 lDxO.O48waIIxl 010 199 TUBING, 030941 RESISTOR,WWfixedl00watt5ohm 030949 HEATSINK 084 184 BRACKET, mtg-resistor 011 991 amp25O volts CIRCUITBREAKER,...
  • Page 50 Dia. Part Item Mkgs. Description Quantity Figure Main Assembly (Contd.) CAPACITOR, ceramic0.1 uf500voltsdc C4,5 028 291 038 659 BLOCK, terminal 20 3T,4T pole PANEL mtg-components-lower Figure C12-15, 825 CAPACITOR/RESISTOR R5-8 084 041 PANEL, shield 084 042 shield PANEL, 083 641 SCREW, closure-door 056 462...
  • Page 51 Item Dia. Part Mkgs. Description Quantity Figure 070 183 Control, Gas RECEPTACLE W/PINS RC17 090 246 (Consisting male 079 535 TERMINAL. Reed 079 687 RELAY, (consisting current .CORD, No. 18 2/c(orderbyft) 1 ft 057 091 SWITCH, reed SPST WRAPPER 047 947 LABEL, general precautionary 010 494...
  • Page 52 Dia. Part Item Mkqs. Description Quantity Components Upper (Fig 2 Item 4) Figure Panel, 084 871 PANEL, components 084 556 CIRCUITCARD,interface(FigC2Pg8) 036 135 TRANSFORMER, controlll5-24voltsac 079 497 RESISTOR,WWfixed25watt2000 030 651 RESISTOR,WWfixed25wattl0ohm 035 914 RECTIFIER, integrated volts enclosed 24 volts dc DPDT CR2-4 052 964 RELAY,...
  • Page 53 Dia. Part Mkgs. Description Quantity 084 619 Circuit Card. SCR Network 5 Item Figure (Fig 031 721 CAPACITOR, mylar0.22uf200voltsdc film 0.47 uf 400 volts dc 044 602 CAPACITOR, poly 053-59 028 291 CAPACITOR, ceramic 0.1 uf 500 volts dc 026 202 DIODE, rectifier 1 amp...
  • Page 54 Q U A L I F I E D O N L Y C O M P O N E N T S P E R S O N N E L R E P L A C E D i n t e r f a c e C a r d , C i r c u i t...
  • Page 55 Dia. Part Mkgs. Description Quantity 088 556 Circuit Interface Figure Card. (Fig 5 Item 009 159 ICjinear358 A50-54 CAPACITOR, electrolytic 100 uf 35 voltsdc 039 482 005 023 CAPACITOR, tantalum 2.2 uf 20 volts ceramic 0.1 uf 50 volts 052-57,65,66 073 739 CAPACITOR, CAPACITOR,...
  • Page 56 Dia. Part Item Description Mkgs. Quantity 3 Item 51) Panel, Components Lower (Fig Figure 084 605 PANEL, components 084 592 CIRCUIT CARD, speed control (Fig motor control (Fig 088 187 CIRCUIT CARD, voltage 084 681 BAR, ground 070 665 CIRCUIT CARD, supply (Fig power...
  • Page 57 Part Dia. Mkgs. Description Quani:ity Circuit Figure Card. Power Supply (Fig 9 Item Ni-cad size Batt 083 918 BATTERY, TERMINAL, clip battery 1000 uf 35 083 973 CAPACITOR, electrolytic volts dc C50,51 uf 35 voltsdc 039 482 CAPACITOR, electrolytic CAPACITOR, ceramic 0.1 uf 50 volts dc C53-55 083 899...
  • Page 58 COMPONENTS TO REPLACED BY QUALIFIED PERSONNEL ONLY Circuit Card. Motor Control Figure Speed Page...
  • Page 59 Dia. Part Mkgs. Description Quantity 084 592 Circuit Card, Motor Speed Control (Fig Figure Item A51-53 009 159 linear electrolytic 100 uf 35 vottsdc 039 482 CAPACITOR, CAPACITOR, mylar0.OO22uf200voltsdc C52,61 073 739 CAPACITOR, ceramic0.1 uf 50 volts C53,62 CAPACITOR, mylar 0.033 volts dc CAPACITOR, mylar...
  • Page 60 - c J R 1 0 3 R 1 0 5 I N U ~cFJ~I~ R I O b 3 C 6 7 ~C7l I T T J - - - 0 C 5 0 ~ - L ~ I P Y I~j~J Q U A L I F I E D a L 4 U...
  • Page 61 Dia. Part Mkgs. Description Quantity Card. Figure 088 187 Circuit Voltage Control (Fig 9 Item linear 4136 052 133 linear 358 A51-53 009 159 linear 083 956 CAPACITOR, tantalum 5.6 uf 35 volts dc 031 677 CAPACITOR, ceramic 0.1 uf 50 volts C53,55-59,68 073 739 000 861...
  • Page 62 -415 IC 085 2264 Figure Door Assembly Page...
  • Page 63 Item Dia. Part Mkgs. Description Quantity Door Assembly (Fig 2 Item Figure 084 034 trim-horizontal BAR, 084 373 BEZEL/FILTER, red-non glare NAMEPLATE, (order model & serial no.) 091 752 CIRCUIT CARD, display PLG1O 083 172 HOUSING, edge connector PLG12 084 198 HOUSING, edge connector...
  • Page 64 Part Item Description Quantity Figure Hub & Spindle Assembly 072 094 HUB & SPINDLE (consisting HUB, spool 058 628 WASHER, steel brake .WASHER,fiber5/8lDxl-1/2ODxl/8 010 191 085 980 .NUT,hex5/8-11 057 971 .WASHER,flat-keyedl-1/2dia 010 233 SPRING, compression SHAFT, spool support 058 427 RING, retaining spool...
  • Page 65 Optional Parts (Contd.) Dia. Part Mkgs. Description Quantity 071 006 CORD, (consisting motor HOUSING PLUG & PINS (consisting 047 636 079 535 TERMINAL, male 166/c (order 073 139 CORD, lOft cable 079 739 CLAMP, RECEPTACLE W/SOCKETS (consisting female 079 534 TERMINAL, CASE front/bottom/rear...

This manual is also suitable for:

System 9

Table of Contents