Miller Electric S-21E Page 1 Technical Manual Download

Page: 1 / 48

MiIIe~

November1996

Form:

TM-1571

Effective With Serial No. JJ507797

TECHNICAL MANUAL

Service And Parts

Wire Feed Equipment

WARNING

SERVICING can be hazardous.

• Have all service procedures performed only by

qualified persons following standard safety

practices.

Use MILLER Testing Booklet (Part No.

150 853) when servicing this unit.

Use only genuine MILLER replacement

parts.

S-21E

For help, call Factory

~U~r

FAX:

Or write to:

Service Department:

14-735-4136

MILLER Electric Mfg. Co.

414-735-4505

L................J

RO. Box 1079

Appleton, WI 54912 USA

coverjml

—

SB-124 467

1996 MILLER Electric

Mfg. Co.

PRINTED IN USA

Summary of Contents for S-21E

Page 1: ...ed only by qualified persons following standard safety practices Use MILLER Testing Booklet Part No 150853 when servicing this unit Use only genuine MILLER replacement parts S 21E U For help call Fact...

Page 2: ......

Page 3: ...tion 3 4 3 Welding Gun Connections 5 4 4 Shielding Gas Installation 5 4 5 14 Pin Plug Connection 6 4 6 Welding Wire Installation 6 4 7 Welding Wire Threading 7 4 8 Adjust The Hub Tension 8 4 9 Welding...

Page 4: ...Assembly 10 4 Brush Inspection And Replacement 10 5 Overload Protection SECTION 11 ELECTRICAL DIAGRAMS Diagram 11 1 Diagram 11 2 Diagram 11 3 Diagram 11 4 Diagram 11 5 Circuit Diagram For S 21 E Effe...

Page 5: ...ient operation of this equip ment 1 3 SAFETY PRECAUTIONS AWARNING ELECTRIC SHOCK can kill S Do not touch live electricalparts Protect yourself with dry insulating gloves and clothing Insulate yourself...

Page 6: ...ally but the unit is more subject to loss or damage without a carton 9 If sending unit to factory ship unit as directed by factory Service Department or Transportation Department A STORAGE WARNING ELE...

Page 7: ...e reduced when they are subjected to high levels of dust dirt moisture corrosive vapors and extreme heat A proper installation site should be selected for the wire feeder if the unit isto provide depe...

Page 8: ...lic objects in this compart ment The motor drive assembly is electri cally hotwhenever the weldingcircuitisener gized Loose metal objects in this compartment may create an electrical path between the...

Page 9: ...rive rolls as possible without touching and tighten the se curing knob 5 S 21E Close and secure left case access door 9 TRIGGER RECEPTACLE Connect gun trigger plug to trigger receptacle on the front p...

Page 10: ...Gas valve Fitting 14 Pin Plug Gas cylinder Valve Argon or Argon Mix cylinder SB 109 492 Ref S 0004 Figure 4 4 Front View Of 14 Pin Plug With Pin Locations 4 6 WELDING WIRE INSTALLATION Figure 4 5 AWA...

Page 11: ...ructedtc do so Do notpoint gun towardanypartof the body any conductive surface or other personne when threading welding wire Allowgun to cool before touching FLYING DIRT AND METAL PARTICLES can injure...

Page 12: ...nch points Do notenergize weldingpowersourceor wirE feeder until instructedto do so The welding wire and all metal parts in contaci with it are energized while welding WELDING WIRE can cause puncture...

Page 13: ...work and equipment to cool before handling MAGNETICFIELDS FROM HIGH CURRENTS can affect pacemaker operation Wearers should consult their doctor before going near arc welding gouging or spot 5 21 E we...

Page 14: ...ia control relay CR1 5 Gas valve 051 provides shielding gas during the weld cycle 6 Integrated rectifier SRi converts the 24 volts ac input power to a rectified 35 volts dc Capacitor Cl provides filte...

Page 15: ...0 4 0 0 1 0 4 1 4 4 LI 4 I 0 U E U I 0 U 0 0 1 E U 0 U 0 A c i Q tb 3O c o I 0 ZQ S 21E TM 1571 Page 11...

Page 16: ...me potentiometer R25 allows adjustment of spot time from 0 12 to 2 5 secondsor 0 25 to 5 seconds depending on the setting of Spot Time DIP Switch Sl 4 Spot Continuous switch S51 allows either a nor ma...

Page 17: ...S 21E TM 1571 Page 13 Notes...

Page 18: ...e only minimal pressure and gentle move ment when disconnecting or connecting boardplugsand removingorinstallingboard A 8 3 TROUBLESHOOTING Table 8 1 And Dia gram 8 1 AWARNING ELECTRIC SHOCK can kill...

Page 19: ...nuity to PCi Check PCi according to Diagram 8 2 and Sec tion 8 4 Replace PCi if necessary Wire feeds but there is no gas flow Gas valve GSl Check GS1 for proper coil voltage and connec tions see Diagr...

Page 20: ...z a O 0 21 FI C J CO U oIr 0 0 CO in in L L n I 0 o Ci 0 0 Oc Q C z 0 0 0 a U c a 0 o 0 0 0 o Q 0 n 0 0 q 00 1110 0 0 0 UJ 0 n 0 Ci a a S 0 S S S I TM 1571 Page 16 a 0 Ci 0 LI 4 I I 0 IL E U I 0 0 4 0...

Page 21: ...is secure in receptacle RC2 on Motor Control Board PCl 3 Check that plug PLG3 is secure in receptacle RC3 on Motor Control Board PCl 4 Check that plug PLG4 is secure in receptacle RC3 on Motor Contro...

Page 22: ...leshootingproce dures Follow standard ESD precautions to prevent damaging static sensitive parts during testing oto 6 5 volts dc inputfrom mm to max of WIRE SPEED control with untrigger 19 volts dc In...

Page 23: ...voltages shown are with respect to circuit common lead 24 pin C of plug PLO4 unless otherwise indicated The tolerances are 10 unless otherwise specified 24 volts ac output contactor control with g 24...

Page 24: ...ecting or connecting boardplugsand removingorinstalling board IMPORTANT For all checks be sure to testand verify the continuity of leads between the board and the area wherecheckisperformed Allchecks...

Page 25: ...DIP Switch Si circuit common a contactor control output voltage of 24 volts dc should be present at pin B of receptacle RC2 with respect to circuitcommon When the gun trig ger is released 0volts dc s...

Page 26: ...ng any leads Have only qualified persons familiar with and following standardsafetypractices perform troubleshootingproce dures Follow standard ESD precautions to prevent damaging static sensitive par...

Page 27: ...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 DCcircuit common lead 71...

Page 28: ...SECTION 9 COMPONENT IDENTIFICATION AND LOCATION 6 2 E 1 2 CO 0 6 0 6 E 0 z 6 6 U Ci 0 0 a U 6 S 0 0 0 0 4 U 0 0 J U 0 4 4 4 4 4 4 0 0 E 0 C 0 4 I 0 TM 1571 Page 24 S 21E...

Page 29: ...are pre sent clean the unit monthly B Inspection and Upkeep A ARNING Read and followsafety Informa tion at beginning of entire Section 10 1 be fore proceeding Every sixmonths inspect the gun hoses and...

Page 30: ...WARNING ELECTRIC SHOCK can kill Do nottouch live electricalparts Shut down wire feeder and welding power source and disconnect inputpower employ ing lockout tagging procedures before work ing on feede...

Page 31: ...n to the feeder circuits CBl is located towards thefront of the unit be hindthe left caseaccess door Ifthe motorshould over load or the circuit fail the breaker would trip and shut down the wirefeeder...

Page 32: ...unit Model and Serial or Style Number 2 Use List to find diagram number 3 Call the Technical Publications Department at 414 735 4356 Serial Or Style Number JJ507797 and following Circuit Diagram SB 12...

Page 33: ...3 A I K31 I mci v I mci c I mci o mci O I I mci c mci E I I AOC mci s mci v I I mci A mci c BOARD I RCO A mci A I Rca s mci s I L Circuit Diagram No SB i 24 895 B Diagram 11 1 Circuit Diagram For S 21...

Page 34: ...0 j S I 0 0 0 N 6 C 6 z E 0 U I 0 _ 0 IL U I 0 I 0 It 6 z L 4 U 4 4 4 U 4 w C a 0 I U 0 0 5 I 4 C 0 0 4 0 L 0 IL E 0 I 0 U 4 U I C E U I 0 0 r L 1 I I I CD ci I 0 0 cr 0 I 0 5 E Ii U I S I 0 0 I SM 15...

Page 35: ...mci c mci c mci c MCI F mci o mci n 0 N N 1 Cl 6 z E U I 0 U 0 4 0 I G 0 Rca A MCI A N 0 N I I I 0 0 LI 6 z 4 4 w a I U 0 0 U 0 C I 0 U C 0 4 a 0 I 0 IL E U 0 0 0 I q i I E U L 0 0 SM 1571 Page 31...

Page 36: ...1 0 LI N 6 U 6 z E 0 U C 1 0 U 0 0 IL o C I 0 N 0 N I 6 z I 4 U 4 4 0 4 w N C a 0 I U 0 0 U 0 C I 0 a U C 0 4 0 0 I 0 IL E U L 0 U 0 4 C I 3 E U I 0 U 0 SM 1571 Page 32...

Page 37: ...MiIIeE November1996 Form TM 1571 Effective With Serial No JJ507797 SECTION 12 PARTS LIST S 21E Wire Feed Equipment S 21E TM 1571 Page 33...

Page 38: ...CO 0 N C Ci 0 E 4 U U N in C J 1 4 I 0 IL N C J Ci E a Ci a V TM i571 Page 34 S 21E...

Page 39: ...l number 1 27 134834 HOSE SAE l87lDx 4100D orderbyft 2ft 28 GS1 109930 VALVE 24VAC2wayl 4lPSxl 8orf PriortoJK6l7847 1 010296 FITTING hose brselb m l 4NPTx 625 l8RH Prior to JK617847 1 010 869 FITTING...

Page 40: ...ga Molex 39 00 0038 131 054 CONNECTOR SOCKETS consisting of 113 746 CONNECTOR rect skt 24 l8ga Molex 39 00 0038 115 094 CONNECTOR SOCKETS consisting of 113 746 CONNECTOR rect skt 24 lega Molex 39 00 0...

Page 41: ...el Wire Optional 1 124904 NUT spanner spoolsupport 1 2 124 905 RETAINER spool support 1 3 124 900 SUPPORT reel spool 1 1 Ref 5C 127 305 2 3 Figure 12 2 Reel Wire BE SURE TO PROVIDE MODEL AND SERIAL NU...

Page 42: ...SA 123 147 F Figure 12 3 Motor Control Circuit Card PCi TM 1571 Page 38 S 21E...

Page 43: ...077206 ClO 031 693 Cli 035522 C52 119197 C60 62 053 991 CR1 099018 D1 2 8 12 026202 D3 087294 D5 037250 D6 7 9 10 028351 Dli 032210 092 648 Ji lO 092648 01 039355 Q4 5 6 037 200 07 121129 R2 028284 R...

Page 44: ...IC linear358 2 031 708 CAPACITOR elctlt 220uf 5OVDC 1 000 348 CAPACITOR tantlm 47uf 35V 1 083 182 CAPACITOR cer mono iuf 5OVDC 1 122 723 CAPACITOR cer mono luf 5OVDC 6 032 820 CAPACITOR tantlm 2 2uf 3...

Page 45: ...K ohm RESISTOR MF 25W 10K ohm RESISTOR CF 25W 2 7K ohm 4 10 2 1 1 2 2 1 1 1 3 2 1 RESISTOR CF 25W 10K ohm 2 RESISTOR MF 25W 24 3K ohm 1 RESISTOR CF 25W 22K ohm 1 RESISTOR MF 25W 47 5K ohm 1 RESISTOR M...

Page 46: ...Notes...

Page 47: ...Notes...

Page 48: ......

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