Miller SYSTEM 9 Owner'S Manual Download Page 9 | Manualshive

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Summary of Contents for SYSTEM 9

Page 1: ...ovember1983 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 COD...

Page 2: ...apply mant on the warranty claim procedures to be followed S to components having normal useful life of less than one 1 year such as spot welder tips relay and contactor points ANY EXPRESS WARRANTY NO...

Page 3: ...nual AMENDMENT TO SECTION 7 MAINTENANCE TROUBLESHOOTING Amend Figure 7 1 Circuit Diagram For Weld Control see Page 2 on this Errata Sheet Add Figure 7 9 Circuit Diagram For Voltage Regulator Board PC1...

Page 4: ...Li ft 11ff Ev 1 p I Sin 2 p 14C1 p Si 22 o _______________ t ____ J0p JZ a __ 4 Ofi 0t TO a TO PTGfl0 Circuit Diagram No C 097 891 B Figure 7 1 CIrcuit Diagram For Weld Control Effective With Serial N...

Page 5: ...stallation Of Wire Reel 14 3 12 Adjusting Hub Tension 14 SECTION 4 DEFINITIONS OF PROGRAM TERMS 4 1 Program Definitions 14 4 2 Alpha Numeric Display Definitions 15 SECTION 5 OPERATOR CONTROLS 5 1 Powe...

Page 6: ......

Page 7: ...sers to avoid entry of sparks and slag Wear helmet with safety goggles or glasses with side shields underneath appropriate filter lenses or plates protected by clear cover glass This is a MUST for wel...

Page 8: ...ck that area is free of sparks glowing embers and flames An empty container that held combustibles or that can produce flammable or toxic vapors when heated must OM 1537 Page 2 never be welded on or c...

Page 9: ...h regulator to cylinder Before connecting check that the regulator label and cylinder marking agree and that the regulator inlet and cylinder outlet match NEVER CONNECT a regulator designed for a part...

Page 10: ...try of sparks 2 Eye and Head Protection Protect eyes from exposure to arc NEVER look at an electric arc without protection Welding helmet or shield containing a filter plate shade no 12 or denser must...

Page 11: ...line cord with a ground lead is provided with the equipment for connection to a switchbox connect the ground lead to the grounded switchbox If a three prong plug is added for connection to a grounded...

Page 12: ...G PRO CESSES obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 7 AWS Standard A6 0 WELDING AND CUT TING CONTAINERS WHICH HAVE HELD COM BUSTIBLES obtainable from...

Page 13: ...ct a hose from the gas out fitting to the barbed fitting on the wire drive housing 9 5 in 241 3 mm 19 in 482 6 mm 5 16 in 7 9 mm 4 1 8 In 0 J et 2 Holes 105 mm L_ _ 251 mm 9 7 8 In 10 1 2 In 267 mm TA...

Page 14: ...es and procedures which ensure personal safety and the safety of others Therefore this equipment is to be installed operated and maintained only by qualified persons in accordance with this manual and...

Page 15: ...nel to 2T Leads must be shielded twisted pair wire WARNING __________ ELECTRIC SHOCK can kill Do not touch liver electrical parts Shut down the weld control and disconnect input power 115 vac before m...

Page 16: ...minal strip connections 1 Open weld control door 2 Route leads from equipment through strain relief clamp on right side of weld control to terminal strip s 1 T 3T or 4T 3 Connect equipment leads to te...

Page 17: ...through opening in case top panel 5 Using location and the 4 sheet metal screws from Step 2 install and secure MHA 2 to case top panel with two receptacle end to the right 6 Using supplied spacers loc...

Page 18: ...cessary to gain access to lead No 54 15 Using supplied tab connector splice lead No 54 from PLG51 pin 6 to lead No 54 near rear of RC18 16 Disconnect lead from terminal K on strip iT and remove jumper...

Page 19: ...with HEAD NO 2 make electrical connections between 2TJ and ilL When the relays in MHA 2 energize 115VAC is available between 2TJ and 1 TL to control the shielding media valve s 34 Reinstall cover onto...

Page 20: ...and optional water valve opens allowing shielding gas and water to flow before an arc is struck The output used to energize the shielding gas valve could also be used for on off control of other shie...

Page 21: ...ow halt 6 Untimed function not allowing sequence advance or halt C Program The weld program Consists of a related group of sequences that control a weld from start to finish To program a weld informa...

Page 22: ...Definitions I MICRO OK The tests normally associated with power up are performed in sequence and if they all check out MICRO OK appears on the alpha numeric If there is a problem one of the power up d...

Page 23: ...S Figure 5 1 Auxiliary output indicators will be on when the corresponding output is active and off when output is inactive while a program is running During prograrnm ing the indicators will show wha...

Page 24: ...eric During sequences that are coded as untimed the TIME indicator will be blank 5 7 VOLTAGE RESET BUTTON Figure 5 1 The VOLTAGE ERROR RESET is provided to reset the Volts indicator if the preset volt...

Page 25: ...he amount of time remaining in the se quence will be displayed If the unit was halted in an un timed sequence the amount of time elapsed in the se quence up to 999 seconds will be displayed To resume...

Page 26: ...elected is shown on the PROGRAM indicator on the weld control front panel If program zero 0 is selected INVALID will show on the alpha numeric Selecting a valid program number 1 9 will clear the inval...

Page 27: ...programming module MILLER ELECTRIC MPG CO APPLETON WI USA __ _H VOLTS AbE __ H INCH MM CEO SECOPdOS COOS _______ millER I AbC ON SEDON HHH PROGRAM SEI ECT AUXILIARY OUTPUTS Figure 6 1 Programming Modu...

Page 28: ...ructions in Section 3 of this manual and in the welding power source and wire drive motor Owners Manuals 2 Set up object s to be welded 3 Energize equipment and turn on gas and water at source 4 Check...

Page 29: ..._______ VOLTS A 8 HH H INCII MIN C 0 SRi VALUE SERIAL NO SECANDS CODE mulkR CODE AbC ON ObOON PROGRAM _______ SELECT AUXILiARY OUTPUTS CODE iH SEQUENCE PREFLOW 1 SECONDS Step 1 With Unit in standby SE...

Page 30: ...ELLIMATIC SYSTEM 9 Ej_ ___b press to load data PROGRAM MODULE VOLTS A B d press to bed data INCNIMIN C O g press to load data SECONDS CODE SEQUENCE PREFLOW flhuilEul AbC ON R D ON PROGRAM SELECT AUXIL...

Page 31: ...rth remaining sequences In a similar fashIon Load all data through post flow s qu nce SEQUENCE RUN IN b set C aux iliary output to ON and 0 to OFF P 24 0 1 150 SEQUENCE RUNIN 24 0 NEXT PROGRAM PROGRAM...

Page 32: ...for _____ _____ pause sequence status of display after entering data PROGRAM CODE VOLTS INCHES PER MINUTE SECONDS a set A and B auxiliary to OFF C set C and D auxiliary outpisto to OF SEQUENCE e set...

Page 33: ...OFF Next Prog 3 with pause code of 1 2 or 3 next program starts automatically after pause time CODES time entered 0 99 8 sec timed function allow halt only 0 time entered 99 9 sec untimed function al...

Page 34: ...ROGRAM SERIAL NO press to load data b enter code SECONOS COOE 1 2 or 3 miliEu PROGRAM ACCON ObDON CODE PROGRAM looks like this after 3 seconds display ______ SELECT AUXILIARY OUTPUTS VOLT S 2 SECONDS...

Page 35: ...timed function allow halt only 0 time entered 99 9 sec untimed function allow halt only Return to standby after pause press program run button to start next program 1 f 1 allow sequence advance and h...

Page 36: ...OFF D Output ON OFF ON OFF ON ON OFF OFF OFF OFF OFF Next Prog 2 With pause code of 1 2 or 3 next program starts automatically after pause time Even though Run In is being skipped some value of voltag...

Page 37: ...oltage set zero time a code of 1 2 or 3 and press SECONDS CODE button To skip postflow wait until postflow name appears on display set zero time a code of 1 2 or 3 and press SECONDS CODE button MILLER...

Page 38: ...SECONDS CODE button Enter data into weld sequences 1 2 and 3 actually 4 5 and 6 as well as crater burnback and post flow NEXT PROGRAM PROGRAM CODE INCHES PER MINUTE Enter data into pause sequence SEau...

Page 39: ...teries supply power to the memory when the unit is shut off Initially the unit should be left on for 12 hours to ensure that the batteries are fully charged Failure to keep batteries charged may resu...

Page 40: ...I Ca I I 7 T ________ i 1 yL iffi 2 1 U C ASPA I1L P4 I Ii1 JI JVVVV F 12 i S 341 3 0 IS II II Ill 2 34 oOI I 5 GOo IO __________ 10 1 10 01010 21 ri 10 UNI4 I 1 4 II sor SIJAIIO c ____ l32jj I 1 1 4...

Page 41: ...l Th rT 8 Circuit Diagram No B 088 486 A Figure 7 3 Circuit Diagram For Voltage Control Board PC4 Circuit Diagiam No A 084 357 Figure 2 Circuit Diagram For Power Supply Board PC3 OM 1537 Page 35...

Page 42: ...Circuit Diagram No C 084 819 pjo I pit P31 i P31 4 P31 2 I I 10 3 Figure 7 4 Circuit Diagram For Motor Control Board PC5...

Page 43: ...0 0 U 0 z 0 4 C U C 0 0 0 U 0 0 U E 0 U U ui 0 0 U OM 1537 P 37...

Page 44: ...3 C 4 _____ I 1R541 4 4 5 C55 _____ I l 55 O 6 7 7 C56 _____ I R56 O 8 go_ 9 C5 7 _____ I 1R57 10 11 DI 12 12 13 C g _____ I 14 6l Circuit Diagram No A 084 723 A Figure 7 6 Circuit Diagram For Motor P...

Page 45: ...0 I 9 2 11 I 01 f t f f 1 2 091201 I I I I I I I I I 29 1 I 92 I I I II I I I ill _ lOnno A S Cn0_9J 09021 o i a Ill C C c I I I 1 2 01 0 O0 2 00 I I I I I I i Cl 0100 L__ ___ o orAAAAAA1or A A A C2I...

Page 46: ...151 52 L53 LS4 6 01 C 0 EO re 6 I LIMIT SWIILYES 6 GO 6 CUSTORLA 35 U SUPPlIED 0 108 1 c i04 6i I ISV 4 I I PLCIQ 2 __________ _________ 2ACOND I 2 I11 2 CABLE DISPLAY BOARD 1 llI __________ I YC I JT...

Page 47: ...November 1983 FORM OM 1 5371 PARTS LIST Effective With Serial No JD668503 MODEL System 9...

Page 48: ...OM 1537 Page 1 C C 0 a E U U C C h U I It...

Page 49: ...ck grounded 2P3W 15 amp 277 volts 25 049 455 CORD No 182 c order byft 2 ft 26 PLG29 039 635 CONNECTOR BODY twistlock 2P2W 20 amp 250 volts 1 27 071 005 CORD interconnecting consisting of 1 28 PLG16 04...

Page 50: ...41 PANEL shield LH 1 54 084 042 PANEL shield RH 1 55 083 641 SCREW closure door 2 056 462 HOSE gas consisting of 1 01 0 603 FITTING hose brass barbed nipple 1 4 TBG 1 010 606 FITTING hose brass nut5 8...

Page 51: ...EPLACEMENT PARTS Part 1 RC17 No Description Quantity Figure B 070 183 Control Gas RECEPTACLE W PINS Consisting of TERMINAL male RELAY current consisting of CORD No 18 2 c orderbyft SWITCH reed SPST WR...

Page 52: ...osed 24 volts dc DPDT flanged 3 8 iT 038 783 BLOCK terminal 20 amp 12 pole 1 9 C8 i0 028 291 CAPACITOR ceramic 0 1 uf 500 volts dc 3 10 2T 038 782 BLOCK terminal 20 amp 10 pole 1 11 CR1 084 170 RELAY...

Page 53: ...in P62 072 564 CONNECTOR edge 8 pin PLG62 072 566 HOUSING edge connector 8 pin Q50 037 824 THYRISTOR SCR 7 4 amp 200 volts straight polarity R50 030 937 RESISTOR carbon 0 5 watt 10 ohm R51 030 090 RES...

Page 54: ...Figure C2 Circuit Card interface COMPONENTS TO BE REPLACED BY QUALIFIED PERSONNEL ONLY...

Page 55: ...olts dc 4PDT DIODE zener 15 volts 5 watt DIODE rectifier 1 amp 400 volts straight polarity DIODE signal 0 020 amp 75 volts straight polarity OPTO COUPLER transistor isolator CONNECTOR edge 8 pin HOUSI...

Page 56: ...Part No Mkgs No Description Quantity PANEL mtg components CIRCUIT CARD motor speed control Fig D2 Pg 12 CIRCUIT CARD voltage control Fig D3 Pg 14 BUS BAR ground CIRCUIT CARD power supply Fig Dl Pg 10...

Page 57: ...olts straight polarity 6 P13 072 563 CONNECTOR edge 18 pin 1 PLG13 072 565 HOUSING edge connectorl8pin 1 P14 084 196 CONNECTOR edge6 pin 1 PLGI4 084 198 HOUSING edgeconnector6 pin 1 P15 084 197 CONNEC...

Page 58: ...Page 11 COMPONENTS TO BE REPLACED BY QUALIFIED PERSONNEL ONLY Figure D2 Circuit Card Motor Speed Control...

Page 59: ...n 1 P31 084 197 CONNECTOR edge8 pin 1 PLG31 072 566 HOUSING edgeconnector8 pin 1 Q50 51 53 037 200 TRANSISTOR 200MA 40 volts NPN 3 Q52 039 355 TRANSISTOR UJT 1 5MA 40 volts 1 R50 73 83 039 328 RESISTO...

Page 60: ...R88 1 Q5I C62 cj R60 RIOb ABCDEFGHJKLMNPQRST Q I foooooooooooooooooojQ50 C64 cc 63J1 U U D a D50 Dj0 fl c52 L IPY i_L c D62 a fl a u___ 68___ oJ D63 A54 ITTJ R53 R58 i C56 0C50 0 0 H C58 C6 I I j J ri...

Page 61: ...SISTOR carbon 0 25 watt 330 ohm 2 R55 57 67 76 85 035 827 RESISTOR carbon film 0 25 watt 10K ohm 6 R58 61 039 336 RESISTOR carbon film0 25 watt22OK ohm 2 R59 60 035 826 RESISTOR carbon film 0 25 watt...

Page 62: ...5 27 Figure E Door Assembly IC 085 2264 14 4 1 9 10 11 415 22 12 21 Page 15...

Page 63: ...red non glare NAMEPLATE order by model serial no CIRCUIT CARD display HOUSING edge connector 4 pin HOUSING edge connector 6 pin HOUSING edge connector 2 pin SWITCH push button DPOT 10 amp 125 voltsac...

Page 64: ...HUB SPINDLE consisting of 1 2 058 428 HUB spool 1 3 058 628 WASHER steel brake 2 4 010 191 WASHER fiber5 8lDxl 1 2ODxl 8 2 5 085 980 NUT hex5 8 11 1 6 057 971 WASHER flat keyedl 1 2dia 1 7 010 233 SPR...

Page 65: ...1 071 892 RECEPTACLE W SOCKETS consisting of 1 079 534 TERMINAL female 14 086 930 CASE SECTION front bottom rear 1 086 928 WRAPPER 1 086 929 PANEL mtg components 1 015712 GROMMET 5 8lDx7 8mtghole 1 0...

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