Miller PREFLO W/POSTFLOW TIMER Owners manual

November

1993

Form:

OM-1079A

Millerfi

OWNERS

MANUAL

Effective

With

Style

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No.

JA-46

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follow

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trained

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And

115

Volts

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instructions

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qualified

if

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Postflow

this

50/60

AC,

Needed

unit.

understand

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Timer

Interconnecting

and

persons

'

1993

Postflow

For

Hz

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distributor

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414-734-9821

P.O.

Box

1079,

PRIN1EDINUSA

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requesting

following

equipment,

carrier.

information

to

spaces

Model

Serial

Date

check

Assistance

about

record

__________

or

of

Purchase

carton

this

Model

Style

for

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any

for

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Designation

No.

RECEIVING-HANDLING

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9/93

TABLE

OF

CONTENTS

Section

SECTION

SECTION

SECTION

SECTION

SECTION

1-1.

1-2.

2-1.

3-1.

3-2.
3-3.

4-1.

4-2.

No.

-

SAFETY

1

General

Safety

2

SPECIFICATIONS

Descnption

INSTALLATION

3

Installation

Shielding

Welding

4

OPERATOR

Preflow

Postflow

5-

SEQUENCE

PRECAUTIONS

Information

Alert

Symbol

Of

Preflow,

Gas

Control

Gun

Trigger

CONTROLS

Time

Control

Time

Control

OF

And

Safety

And

Signal

Postflow

Connections

Control

OPERATION

AND

SIGNAL

Words

Timer

Connections

WORDS

Page

No.

1

1

1

2

2

3

6

6

SECTION

SECTION

SECTION

Gas

5-1.

5-2.

6-

6-1.
6-2.

6-3.

7-

Diagram
Diagram

8

Figure

Table
Table

Metal

Shutting

MAINTENANCE

Routine

Circuit

Down

Maintenance

Board

Troubleshooting

ELECTRICAL

Circuit

7-1.

7-2.

Wiring

PARTS

8-1.

6-1.

LIST

Complete

Maintenance

6-2.Troubleshooting

Arc

Welding

Handling

DIAGRAMS

Diagram

Diagram

Assembly

LIST

Schedule

(GMAW)

TROUBLESHOOTING

&

Precautions

OF

CHARTS

AND

6

6

7

7

7

8

9

10

TABLES

7

8

OM-1019A

11/93

N-i

SECTION

1

SAFETY

PRECAUTIONS

AND

SIGNAL

WORDS

1-1.

A.

Information

bels,

design,
troubleshooting

followed

B.

The

shooting

and

safety

stalled,

Sons

codes

of

source

GENERAL

General

presented

and

tags,

installation,

for

the

Safety

installation,

of

arc

procedures

of

others.

operated,

in

accordance

such

as,

Arc

Welding

Owners

plates

which

safe

operation,

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which

Therefore,

but

Safety

Manual.

INFORMATION

in

this.manuai

the

on

operation,

should

effective

and

equipment

ensure

and

maintained

with

this

limited

not

Precautions

AND

andonvarious

unit

pertains

maintenance,

be

read,

understood,

of

this

use

maintenance,

requires

personal

this

equipment

onlybyqualified

manual

to,

those

in

and

listedatthe

the

SAFETY

to

equipment

equipment.

and

trouble

practices

and

safety

is

to

all

applicable

welding

power

be

and
and

the

per

end

la

in

1-2.

The

following

used

throughout

different

tify

a
a

a

IMPORTANT
necessaiy

ment.

SAFETY
WORDS

safety

this

levelsofhazard

This

safety

words

WARNING

tiontothe

WARNING

practices

ous

personal

CAUTION

practices

personal

statements

for

the

ALERT

alert

manual

alert

safety

statements

which

injury

statements

which

or

injury

most

SYMBOL

symbol

call

to

and

symbol

CAUTION

and

statements.

be

must

loss

or

be

must

damage

identify

efficient

-

AND

and

attentiontoand

special

is

used

identify

followedtoavoid

of

life.

identify

followed

this

to

special

operation

words

signal

instructions.

with

the

call

to

procedures

procedures

to

avoid

equipment.

instructions

of

this

SiGNAL

are

iden

signal

atten

or

seri

or

minor

equip

10-1/2

(287

mm)

In.

SECTION

Figure

-

2

SPECIFICATIONS

2-1.

Overall

Dimensions

SB.O71

7

(3

613-A

Weight

Net

lbs.

kg)

Ship

11

(5

lbs.

kg)

2-1.

P

The

ically

DESCRIPTION

reflow,

timed

Postf

preflow

low

Turner

and

is

designed

postflow

add

to

electron

capabilities

to

the

50

Series

can

The

50/60

wire

added

be

Preflow,

Hertz

feeders.

either

to

Postflow

power.

The

side

Turner

preflow,

ofadual

operates

postf

wire

low

capabilities

feeder.

115

on

OM-1079

VAC,

Page

1

ELECTRIC

a





Lockout/tagging

ing

removing

red-tagging

ing

Pre

a

digital

1.

2:

INSTALLATION

TIMER

flow,

box.

Loosen

left

Place

wire

the

on

feeder

3-1.

IMPORTANT:

the
control

of

SHOCK

Do

Shut

fee~ier,

ing

specting

touch

not

down

welding

and

disconnect

lockout/tagging

or

installing.

line

disconnect

fuses

from

circuit

device.

(Figure

The

following

Postf!ow

If

desired,

voltage

screws

sidesofthe

the

feeder

same

the

Timer

control

Timer
the

control

(four

wire

Prefiow,

control

direction

align

box.

kill.

can

ilve

electrical

power

procedures

procedures

switch

fuse

box,

breaker

OF

PREFLOW,

3-1)

procedure

on

top

Timer

can

total)

feeder

so

the

the

in

on

both

mounting

(DVC)

Postflow

box

and

with

SECTION

parts.

source

input

consist

in

the

or

other

or

of

the

be

mounted

the

the

control

Timer

front

screws

and

before

of

open

employ

padlock

position,

power

shutting

disconnect

POSTFLOW

for

is

mounting

wire

same

manner.

right

upper

box

wrapper.

on

top

panels

screw

the

on

3-

wire

off

and

feeder

on

top

and

of

the

face

slots

wire

INSTALLATION

3-2.

in

IMPORTANT:
withadual

made

2.

3.

Slide

3.

tighten

SHIELDING

(Figure

to

1.

Disconnect

receptacle

box

side

Connect

1

rear

sert

plugs

rectly),
plug

Connect

the

valve
control

into

keyed

and
snap

the

wire

wire

the

desired

follows:

as

of

plug

the

6-contact

to

of

the

valve

gas

are

and

snap

rear

receptacle

box

gas

so

press

into

Timer

down

feeder

GAS

3-1)

When

using

the

on

and

gas

be

side

gas

the

squeeze

pull

valve

rear

feeder,

the

female

Preflow,

into

plug

so

keyed

press

into

the 6-contact

of

the

as

valve

they

into

they

into

position.

Preflow,

on

follows:

receptacle

will

place

position.

onto

control

CONTROL

the

sure

of

the

valve

of

plug

plug

Postf

6-contact

will

place

male

Postf

the

insert

not

go

until

screws,

box

screws.

CONNECTIONS

Pre

that

wire

plug

the

Postflow

flow,

all

connections

feed

from

wire

retaining

from

receptacle.

disconnected

plug

extending

low

Timer

female

not

together

go

until

retaining

plug

extending

low

Timer

of

rear

the

6-contact

connectors

(the

together

retaining

and

securely

Timer

are

system.

the

feeder

clips

as

gas

control

on

in

from

follows:

plug

clips

the

to

wire

feeder

male

valve

either

Step

the

in

(the

incor

on

from

gas

plug

are

incorrectly),

on

clips

plug

OM-1

079

Page

To

Welding

Trigger

3-1.

Figure

2

Prof

low,

Postflow

Gun

Plug

Timer

To

Gas

Receptacle

Wire

InstallatIon

To

Valve

Feeder

Trigger

On

Wire

On

Receptacle

Feeder

SB.071

613-A

3-3.

WELDING

NEC11ONS

IMPORTANT:

with

dual

a

made

to

the

Connect

1.

rear

GER
control

and

GUN

(Figure

When

using

wire

feeder,

desired

the

of

sideofthe

the

4-pin

Preflow,

receptacle

boxasfollows:

threaded

rotate

TRIGGER

the

be

sure

male

Postflow

the

on

collar

3-1)

Pre

that

wire

plug

front

align

CONTROL

Postflow

flow,

all

connections

feed

extending

Timer

of

the

keyways,

clockwise.

fully

system.

from

the

TRIG

to

wire

feeder

insert

CON

Timer

are

the

plug,

Connect

2.

female

flow,

sert

fully

IMPORTANT:

a

plug

the

dual

digital

must

DDSC

ceptacle

female

4-pin

cord.

the

plug

Postflow

trigger

gun

clockwise.

If

the

schedule

be

connected

that

normally

the

on

plug

welding

extending

Timer

plug,

Pre

flow,

control

to

wire

feeder

Pre

the

on

gun

from

follows:

as

and

Pos

the

DDSC

connects

must

flow,

trigger

the

align

rotate

if/ow

Timeris

(DDSC),

and

to

the

be

connectedtothe

low

Postf

to

plug

of

rear

keyways,

threaded

the

gun

the

TRIGGER

Timer

the

the

collar

used

trigger

plug

trigger

4-pin

Pre

in

with

from

re

REMOTE

Welding

14

Receptacle.

FIgure

3-2.

Connection

Diagram

For

Pref

low,

Postflow

Timer

Front

Used

View

With

Single

Prellow,

Timer

Wire

Feeder

Gas

Control

Cord

Wire

Feeder

Posttlow

S~O491

OM-1079

Page

3

REMOTE

14

Receptacle

DDSC

additional

Wire

Drive

Current

NP

Power

Drive

Relay

Models

Welding

IMPORTANT:

and

for
infoimation.

And

DVC

See

Owners

connection

Motor

Assembly

Connections

Only

Figure

DVC

the

Manuals

Gun

3-3.

Connection

Diagram

DDSC

Control,

For

Pref

And

Postflow

low,

Digital

Wire

Timer

Feeder

Used

With

DVC

Control,

OM-1

079

Page

4

Welding

IMPORTANT:

and

Power

DDSC

for

additional

information.

Source

See

Owners

connection

OVC

the

Manuals

Volta/Contactor

115

Control

Cord

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4-1.

Front

Panel

Controls

SB-Oil

813-A

OM-1079

Page

5

4-1.

The

lecting

PREFLOW

PREFLOW

the

ginning

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wire

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to

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a

1.

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3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

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1.

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ac

set

OF

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OM-1079

Page

6

SECTION

MAINTENANCE

6-

&

TROUBLESHOOTING

6-1.

IMPORTANT:
this
maintained

when

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for

unit

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cautionary

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Service

OM-1079

Page

7

Table

6-2.Troubleshootlng

J

TROUBLE

Gas

valve

will

not

operate.

Wire

not

feeder

feed

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wire.

.

but

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will

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cure.

Dual

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valve

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trigger

trigger

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SECTION

CAUSE

connections

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connections

switch.

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7-

ELECTRICAL

not

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plug

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PLG53

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connections

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from

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from

from

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feeder.

tngger

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8

TOGAS

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Diagram

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0

SECTION

8-

PARTS

LIST

9

23

24~

21

20

Figure

8-1.

Complete

19 18

Assembly

16

17

SG-071

10

11

614-8

OM-1079

Page

10

Item

No.

Dia.

Mkgs.

Part

No.

Figure

8-1.

Description

Complete

Quantity

Assembly

..21

3

4

5

6

7

8

9

10

11

12.,

13

14

15

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17
18

19...

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23
24
25

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PARTS.

OM-1079

Page

11