Miller MIC-2 Owners manual

0QPY

May

1981

MODEL

MIC-2

FORM:

QM-866A

gETU1~

TO

~QLO~

OWN

ER’S

MANUAL

MILLER

ELECTRIC

718S

BOUNDSST

APPLETON,WI54912

ADDITIONAL

NINSA

PRINTED

COPY
CODE

MFG.

P0

Box

1079

USA

PRICE30CENTS
NO.

4579

IN

U.S.A.

fuMIER

CO.

J~

~

S

5

•

•

~ within

II

-~

LIMITED
hereof,
to

its

Distributor/Dealer that
furnished by
materialasof
rantyismadebyMiller
cessoriesorother

engines,
the

warranties

engines
dateoforiginal

Exceptasspecified

to

components

year, suchasspot
MILLERMATIC

wire including
not

result

Miller

ranted Equipmentinthe

the

ment to

1.

2.

Arc

3.AII

LIMITED

Th

clus

WARRANTY~Subject to

Miller

Electric

Mfg.

Co.,

Appleton,

Miller

is free from defectinworkmanship

the

time

trade

accessories

of their

are

warrantedbytheir

purchase.

having normal

welder

parts

nozzles

from

defectinworkmanshipormaterial.

shallberequiredtohonor

following

the

welders,

riginal

weldin

II

other

eplacementorrepair
atteries

periods

original

user: ANY

power

main

power

(labor

guns

Millermatic

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all

and

placeofdeliverybyMiller.Nowar-

with

items

below,

that
and

respecttoengines,

manufacturedbyothers.

and

other

respective

manufacturer

Miller’s warranty

useful

tips,

comeincontact with

nozzle

event offailure

from

sources

rectifiers

-

1

year

and

feeder/guns

Feeders

parts,

EFFECTIVE

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Wisconsin

and unused

items

lifeofless

and

warranty

resulting

dateofdeliveryofEquip-

components

conditions

Equipment

trade

are

sold

subject

if any . All

for

one

year

does

not

than

contactor

the

where

failure

claims

fromadefect ANY

. .

6

WARRANTY

JUNE11979

dli

previous

warrants

and

ac- therefore

Such

to

from

apply

one

Ill

points,

welding

does

on war-

1

year

3

years

90

days

1

year

. 60

days

months

MILLERwaan es

essedomp

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submittedbythe

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the

with
or,

the
Miller

price Iless
returnofthe

of
mantonthe

ANY
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BREACHOFCONTRACT WHICH,
MIGHT
CUSTOMOFTRADEORCOURSEOFDEALING,

FITNESS

CLUDED

WRITING,
ULTIMATE

USERS
EXPERIENCEDINTHE

WELDING

caseofMiller’s breachofwarrantyorany

respecttothe qualityofany goods,

shall

where

reasonable

noticeofapparent

ANY

EXCEPT

be,atMiller’s

authorizedinwritingbyMillerinappropriate

service

IMPLIED

IMPLIED

AND

costofrepairorreplacementatan

stationor141

reasonable

goodsatCustomer’s

warranty

EXPRESS

WARRANTY,

ARISE

WARRANTYOFMERCHANTABILITYOROF

FOR

PARTICULAR

ALL

AND

DISCLAIMED

AS

MILLER PRODUCTS

PURCHASE

AND

FOR

EOUIPMENT

andSex

led
policy

only,

Miller

may

honor

original

user

within

the foregoing

option

paymentofor

depreciation

defectorfailure,

claim

procedurestobe

WARRANTY

PERFORMANCE,

BY

EOUIPMENT FURNISHEDBYMILLERISEX-

EXPRESSLY

OPERATIONBYPERSONS

GUARANTYORREPRESENTA-

IMPLICATION,

PURPOSE,

BY MILLER.

BY

USE

AND NOT

the exclusive

Ill

repairor121

credit

based

risk

and
Miller

NOT

PROVIDED

AND

BUT

PROVIDED BY

COMMERCIALiINDUSTRIAL

AND

for

upon

actual

expense.

shall

instruct

followed.

ANY

FOR

THIS PROVISION,

OPERATIONOFLAW,

WITH

ARE

INTENDED

TRAINED

MAINTENANCE

FOR

CONSUMERS

periods.

other

remedies

replacement

cases,

authorized

the purchase

usel

Upon

receipt

the

HEREIN

REMEDY

INCLUDING

RESPECT

MILLER

claims

duty

(31

upon

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Millerisnotifiedinwriting within thirty

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1301

days

CONSUMER

TO,

AND

MILLER’S

WARRANTIES

USE.

MILLER’

NO

RESELLERISAUTHORIZEDTOEXTEND

WARRANTIESDONOT

TO,

ANY

CONSUMER.

EXTEND

1-1.

A.

GENERAL

General

INFORMATION

SECTION

AND

SAFETY

1-INTRODUCTION

An

additional
instructions which
most

efficient

signal

word,

need

special emphasistoobtain

operation of

j~J~~jj

this

equipment.

highlights

the

Information
labels,

equipment

and

troubleshooting which

and

followed

presented in this

tags,

and

design,

for

the

plates

installation,

safe

ment.

B.

Safety

The

installation,

operation,

troubleshootingofarc
practices

and
be

and

procedures

the

safetyofothers. Therefore, this equipmentisto

installed,

operated,

personsinaccordance
plicable codes

the

end

Arc

Welding

Owner’s
Safety

pear
word

instructions

throughout

WARNING,

such

of Section

Power

Manual.

this

as,

1-Safety

Source in

specifically

manual

statements

and

maintenance

carefully followed
or

lossoflife.

proceduresorpractices
could resultinserious

manual and on

providedonthe

operation, maintenance,

shouldberead,

and

effective

maintenance,

welding

which

and

maintained

with

but

not limited

equipment

ensure

this

manual and

Rules

the

welding

pertainingtothis

highlightedbythe

include

installation,

various

unit

pertain

understood,

useofthis

equip-

and

requires

personal safety

onlybyqualified

allap-

to,

those

listed

For

Operation

power

Of

source

unitap-

signal

operating,

whichifnot

personal

injury

to

at

1-2.

RECEIVING-HANDLING

this

equipment,

the

unit

have

occurred
damage
by

the

purchaser

lading

and

and
that

clean

carefully

during

may

freight

all

inspect

shipment.

have

occurred in

with

the

bill

willbefurnishedbythe

requestifoccasiontofile

When

ment,itis
(or

1-3. DESCRIPTION

control

associated
tial

Each

depressing

requesting

information

essential

Style)

Numberofthe

designedtointerface

digital voltage control,

welding

power

schedule

the

source.

canbepre-set
PRESSTOSET

that

-

correponding VOLTAGE
preset

feeder

held
madebyan

valuesisdisplayedonthe

digital

down,

meters

while

while

welding,

appropriate

-

Prior

to

packing

for

material

any

damage

Any

claims

transit

from

for

mustbefiled

carrier.Acopyofthe

claim

arises.

Model

concerning

Description

this

and

equipmentbesupplied.

This

unitisa

withadigital

before

and

WIRE

the

PRESSTOSET

selectionofa

external

and

button

FEED

DVC

contact

multiple

wire

constant

welding

and

adjusting

controls.

unit

closure.

schedule is

installing

around

that

may

loss

bill

carrier

on

equip-

Serial

schedule

feeder,

poten-

begins

by

the

The

and

wire

button

or
of

is

2-1.

LOCATION

open

front

for

installation,

Lead

lengths
Mounting
The

service
whenitis
moisture,

2-2.

SCHEDULE CONTROL

ternal
schedule
nections
schedule
tom of

To

initiate

most

controls),aclosure

minals
To

initiate

terminals 2T8

between
between 2T10

closure

mustbeconsidered

holes

are

life

and

subjectedtohigh

corrosive vapors,

controls

(wire

must

are

feed

be

control

unit.

schedule1(schedule1controls

217

and

2T4.

schedule2,a

and

2T9

and

and

between

2T11and

SECTION

-

The location

provided

efficiencyofthe

requiredtoswitch
speed and
madetoterminal

cables

through

mustbemade

closure

2T4; schedule3requiresaclosure

2T4; schedule4requiresaclosure

2T4;

should allow room

maintenance,

when

locating

for

mounting

system

levelsofdust,

and

extreme

CONNECTIONS

heat.

from

voltage)toanother.

strip

cable

clampsonbot

between

mustbemade

and

schedule5requires

2T4.

and

the

unit.

are

reduced

one

2T.

are

the

between

repair.

unit.

dirt,

-

weld

Con-

Route

2-INSTALLATION

to

Ex-

left

ter

When

noneofthese
parameters
unit

and

2-3.

relays

are

wire

AUXILIARY

are

provided

A setofnormally-open

-

contacts
be
Route

To
ween

3T14

2-4.

are

available

madetoterminal

leads

through

energize

relays,aswitch

2T4

and

for

CR16.

TRIGGER CONTROL

relayisprovided
trigger.
unit.

-

and
To

ween

2-5.
TIONS

a

energize

Route

Make

1T2.

energize

2T4

and

GAS

-

A

the

trigger

relay,aswitch

(AND

relayisprovided

gas (and

schedules

determinedbythe

feeder.

RELAY

for

controlling

andasetofnormally-closed

on each

strip

3T

cable

clamponbottomofunit.

closure

3T12

for

CR14,

that,

when

energized,

leads

through

control

connections

closure

3T10.

WATER)

water)

are

energized,

settingsonthe

CONNECTION

auxiliary

relay.

Connections

(see

circuit

mustbemade

3T13

for

CONNECTIONS

actsasthe

cable

clamponbottom

mustbemade

CONTROL

that

can

valve(s).

the

weld

DVC

-

Three

equipment.

must

diagram).

bet

CR15,

and/or

-

gun

between1Ti

bet

CONNEC

be

used

-

A

of

-

-

to

OM-866

Page

1

To

energize

ween

2-6.

INTERCONNECTIONS

WARNING:

•

Do

•

Shut
cannot

connections.

1.

2.

3.

relay,aswitch

2T4 and

not

touch

down

Connect
Control

Connect

Remote
Connect

3T1

ELECTRIC

be

receptacleonthe

Control

receptacleonthe

4.

Remove

closure

1.

SHOCK

live

electrical

welding power

accidentally energized

the

plug

labeled

parts.

source

VOLTStothe Remote

DVC

the

plug

labeled

WIRE

receptacleonthe

the

two

pole plugtothe

wire

feeder.

the

six

prong

gas

control

mustbemade

can

kill.

andbesure

while

making

unit.

FEEDtothe

wire

feeder.

TRIGGER

plug

from

Digital

Voltage

bet

the

it

-

Front

View

rearofthe

the

six

multiple

5.

Connect
schedule
receptacleonthe

6.

Connect
Volts/Connector

unit.

7.

Connect
tactor

Control

to

the

receptacleonthe

nect

the

Control

receptacleonthe

Connect

VOLTS
source.

wire

feeder

pole

receptacle

schedule

the

six

control.

prong

controltothe

rearofthe

the

four

Control

four

pole plug

cable

two

pole

twistlock

the

three

pole

AC

receptacleonthe

and

connect

that

comes

plug

from

six

pole

wire

pole

plug

receptacleonthe

from

the

(supplied

with

bottomofthe

plugtothe

welding

twistlock

the

plug

from

the

multiple

gas

control

feeder.

to

the

115

Volts/Con-

wire

feeder)

unit.
Contactor

power

source.

plugtothe

welding

to

the

115

DVC

Con-

115

power

Cable

*Current

Relay

Connection

- DVC

115

Volts/Contactor

control Cord

I

MP-1

Models Only

Figure

2-1.

Interconnections

Control

-Voltage

wire

115

Volts AC Cord

Cords

ControlCord

Speed

Control

Cord

TA-082 236

3-1.

PRESS

PRESSTOSET
either
schedule.
voltage

the

unit.
digital
WIRE

Page

the

setting

load

Likewise,

wire

SPEED

2

When

voltage

TO

SET

button

mustbedepressed

voltage or

this

buttonisdepressed

displayedonthe

setbythe

the

rateofwire

feederisthe

controlonthis

BUTTON

wire

speed

digital voltage

VOLTAGE

rate of

unit.

SECTION

(Figure

when setting

for

the

controlonthis

feed

displayedonthe

wire

feed setbythe

3-1)-The

desired

the

load

control

3-OPERATION

3-2.

VOLTAGE

VOLTAGE
put

load

voltage

VOLTAGE controlina

is

output

3-3.

turn

mining

load

WIRE

WIRE

the

CONTROL

control

providesameansofdetermining

for

voltage.

SPEED

SPEED
rate

CONTROL

control

at which welding

(Figure

each

schedule.

clockwise

3-1)

direction

(Figure

-

Rotating

increases

3-1)

providesameansofdeter

wire

willbefed

A

ten-turn

-

A

out

the
the

ten-

into

-

-

the

weld

for

each

schedule.

control inaclockwise
wire

feed.

Schedule1(

Rotating

direction

the

WIRE

increases

the

SPEED

rate of

3-4.

dicate

PILOT

which

LIGHT

(Figure

schedule is

3-1)

-

energized.

The

Wire

pilot

lightsin-

Schedule5

Speed Control

WARNING:

SURFACES
damage

•

FUMES
health.

•

See

Welding

Owner’s

hearing.

Wear

AND

Use

enough

from

Section

Power

Manual

ARC

can

correct

GASES

the

breathing

1-Safety

for

VIII.

ISIF~FI1

SECTION

RAYS,

burn

eye,

ventilationtokeep

Sourcesinwelding

basic

SPARKS,

and

eyes

ear,

and body protection.

can

zone.

Rules

welding

skin;

seriously

For

OperationOfArc

safety

A~AlITTAnvr

Figure

4-SEQUENCE

AND
NOISE

harm

fumes

power

information.

and

HOT

can

your

gases

source

AL

3-1.

Front Panel

~

Press

To Set

Button

wire

feedonthe

— I

I

See

(wire

schedule

Section 2-6.

DVC

unit

feed speed

control.

and

and

IN

G~IWater

View

OF

OPERATION

2.

Make

3.

Energize

4.

Set

voltage

wire

5.

Set
voltage)onthe

all

interconnections.

equipment.

and

feeder.
the

five

schedules

multiple

1.

Make any
Sections

necessary

2-3

through 2-5.

internal

connections.

See

6.

Commence
usedata

welding.

time.

Only

one

schedule

OM-866

can

be

Page

3

7.

Remove

equipment

load,

allowacooling

off

when

not

period,

welding.

and

shut

SHIELDING

kill.

•

Shut

GASES

off

gas

HIGH

supply at

CONCENTRATION

can

seriously

source

when

harm health

notinuse.

OF

or

SECTION

ELECTRIC

•

Do

not

touch

ilve

electrical

•

Disconnect unit from
iy

inspectingorservicing.

Troubleshootingofinternal
by

qualified

5-1.

IMPORTANT:

unit

for
clearly
See

the

Periodically

damagbe

ly

at

persons.

INSPECTION

Periodically

legibility.

readable

Parts

All

state and

List

for

inspect

to or

breaksinthe insulating

the plug.

Repairorreplace

AND

labels

part

all

necessary.

5-2.

FUSE

PROTECTION

fusesFland

1T3

1T4 [~j1r~T~L is

I

CR1111

TT’flt

~TR~1~±jII~II

F2.

If oneorboth

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s

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VOLTAGE

CONTROLS

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Y~~YY~

5-MAINTENANCE

SHOCK

input

partstobe

UPKEEP

replaced

numberoflabels.

interconnecting

-

can

kill.

parts.

power

before

performed

inspect the

mustbemaintained in

labelsonthis

where

necessary.

cords

jacket,

This

unitisprotected

fuses

ml

I~I

iT

I

the

should

H

particular

cord(s)

open,

~—o

CRIS

H

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IL.R.14

internal

only

for

the

352
3T3

3T4

3TR

3TT

3T9
3T9

as

by

&

TROUBLESHOOTING

wire

feed

motor would

-

Voltage
the

5-3.
per

of

and

digital voltage

TROUBLESHOOTING-It

installation

this

manual,

properly until

Ensure

a

and

that

that

all

all

welding application.Ifthe

check

control

Ensure

-

perly.
If

that

all

the

troubleisnot remedied

procedures,
Station shouldbecontacted.

rRIGGER

CRI2

WIRE
FEED8<WTT

CR,3

stop

and

operation

wire

feed speed reverttothe

control

and

wire

feeder.

is assumed

has

been

made,

according to Section

and

that

the

unit

has

been

this

trouble

connectionsonall

switches

developed.

equipment

areinthe proper

unit

still does not

position

relays and replaceifnecessary.

associated

the

nearest

3<

2<

DIGS

ALA

A

—.-.-----..

DAN

RED

C

<—O

PLGZ

equipmentisfunctioning

after

performing these

IT

CITS

iTS

Factory

SOLENOID

RCPT.

3

Authorized

2T2

~ ~ 3 TO

211

PIGS

ACI

ITIA

0

25515

-. *05

DTI3I.IA

5< <5

9<

AC

IN 1113

Ac

would

cease.

settings

that

functioning

are

secure

for

function

Service

<1

SOLENOID

<8

PLG4

a~x

AC

ARN

PIGS

on

pro

the

pro

-

2

-

Page

Circuit

Figure

4

5-1.

Circuit

Diagram

Diagram

No.

B-070

858-A

May

1981

MODEL

MIC-2

FORM:

OM-866A

PARTS

LIST

21.

20

19

7

fix

-6

—7

OM-866

Page

Figure

1

A-Complete Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure

1

2

3

4

5

6
7
8

9 1T-3T

10
11
12

13

14
15
16

17
18
19

20 PB1-5

21 Li-S

A

Ri-b

Ti

SRi

CR

13-16

D1-1

F1,2

PLG4

PLG6

RCPT1

PLG5
PLG3

PLG1,2
CR1-12

1

603856

024

366

010

929

036

135

035914

+tSpecial

047

497
tSpecial
052 964
026 202

012633
012571

038 856
048842
079

531

048284
079

534

048283
079 535

010610
056265
048379
079 534
039828
053075
027810

tSpecial

027

811

048 029
079 844

079723
079 725

048

573

007

826

604 525
600 343

600 343
010

311

Complete

POTENTIOMETER,

KNOB,
WASHER,
TRANSFORMER,

RECTIFIER,

Assembly

WW10turn2watt

pointer

flat-spring

control

integrated30amp

ENCLOSURE

LABEL,

general

precautionary

SUB PANEL

RELAY,

DIODE,

FUSE,

HOLDER,

BLOCK,

CONNECTOR,

CLAMP,

HOUSING

TERMINAL,

RECEPTACLE

TERMINAL,
CONNECTOR,
CONNECTOR,
HOUSING

TERMINAL,

CLAMP,
PLUG,4pin
RELAY,

BRACKET,

enclosed24volts dc

rectifier1amp

miniature

glass1amp

fuse-miniature

terminal20amp14pole

female6socket

cable

PLUG&SOCKETS

female1socket

W/PINS

male1pin

clamp-cable
male6contact10amp

PLUG&SOCKETS

female1socket

cable

MS-3106A-145-2P

enclosed24voltsdc4PDT

relay
CONNECTOR,14pin
CLIP,

retaining-socket
SPRING,
SWITCH,

GUARD,

LIGHT,
CORD,
CORD,

CORD,

CORD,

CLAMP,3/4x1/2hole

holddown-relay

push

buttonMCSPDT6amp

switch

indicator-red

No.

183/c

No.

182/c

No.

165/c

No.

165/c

3/8

115-24

volts

400

DPDT flanged

400

volts

straight polarity

1/4x1-1/4

w/cable

(consisting

(consisting

1/2

inch

(consisting

relay

lens28volts

volts

clip

of)

10K

ac

clamps

of)

of)

125

ohm

volts

ac

10
10

10

1
1

1
1
1

4

11

2
2

3

1

2

1

4

4

6

4

2
2

12

12

12
12

5
5

5

12

4

ft

4

ft

15ft

1

ft

+

When

orderingacomponentonmall

tBE

SURETOPROVIDE NO.

TO

HAVE

THE

NSPR

NUMBER.

displayingaprecautionary

5685 WHEN

ORDERING

label,

the

label

REPLACEMENT

PARTS.ITIS

should

alsobeordered.

VERY

IMPORTANT

OM-866

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