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Miller VL-M4 Owner'S Manual Download Page 16

OM-189 530 Page 12

SECTION 4 – INSTALLATION

4-1.

Typical Equipment Location

ST-131 138-A

1

Welding Power Source

2

Side Beam

3

Current Sensing Shunt
Control

4

Weld Control

5

Spool Support

6

Wire Drive Assembly

7

Automatic Welding Gun

1

2

7

4

5

6

3

 

4-2.

Mounting Hole Layout

 ST-083 354-C

7-1/2 in

(190.5 mm)

9/32 in

(7.1 mm)

Dia. 4 Holes

13-1/2 in

(342.9 mm)

4 in

(101.6 mm)

8 in

(203 mm)

10-3/4 in

(273 mm)

7 in

(178 mm)*

* Includes front panel knobs

5/16 in

Dia. 4 Holes

(7.9 mm)

Summary of Contents for VL-M4

Page 1: ...Processes Description 50 60 Hz Visit our website at www MillerWelds com OMĆ189 530C September 2000 MIG GMAW Welding VL M4 Submerged SAW Welding Submerged Arc Controller For Automatic Welding ...

Page 2: ...value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Miller you can count on years of reliable service with proper maintenance And if for some reason the unit...

Page 3: ...ION 12 4 1 Typical Equipment Location 12 4 2 Mounting Hole Layout 12 4 3 Connection Diagram 13 4 4 Connecting Shunt Control 14 4 5 Left Side Panel Connections 14 4 6 Terminal Strip TE1 Connections 15 4 7 Terminal Strip TE1 Connection Information 16 4 8 Remote 14 Receptacle RC2 Information 16 4 9 Terminal Strip TE2 Connections 17 4 10 Terminal Strip TE2 Connection Information 18 4 11 Remote 17 Rece...

Page 4: ...rective 89 336 EEC Machinery Directives 89 392 EEC 91 368 EEC 93 C 133 04 93 68 EEC Standards Arc Welding Equipment Part I Welding Power Sources IEC 974 1 April 1997 Draft Revision Arc Welding Equipment Wirefeed Systems IEC 974 5 May 1997 Draft Degrees of Protection Provided By Enclosures IP Code IEC 529 1989 Insulation Coordination For Equipment With Low Voltage Systems Part I Principles Requirem...

Page 5: ...r that cord plug is connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conductor first double check connections D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill D Turn off all equipment when not in use D Do not use worn damaged undersized or poorly spliced cables D Do not...

Page 6: ... welding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane lighter or matches from your person before doing any welding FLYING METAL can injure eyes D Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off sla...

Page 7: ...d maintained D Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots D Be sure all equipment in the welding area ...

Page 8: ...s is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one ...

Page 9: ...on est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre D En effectuant les raccordements d entrée fixer d abord le conducteur de mise à la terre approprié et contre vérifier les connexions D Vérifier fréquemment le cordon d alimentation pour voir s il n est pas endommagé ou dénudé remplacer le cordon immédiatement s ...

Page 10: ...act D Porter des vêtements de protection dépourvus d huile tels que des gants en cuir une chemise en matériau lourd des pantalons sans re vers des chaussures hautes et un couvre chef D Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES peuvent blesser les yeux D Le soudage l écaillement le passage de la pièce ...

Page 11: ... dispositifs de protection LE RAYONNEMENT HAUTE FRÉ QUENCE H F risque de provoquer des interférences D Le rayonnement haute frequence peut provoquer des interférences avec les équipements de ra dio navigation et de communication les services de sécurité et les ordinateurs D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l install...

Page 12: ...gnétiques basse fréquence Le courant de soudage pendant son passage dans les câbles de sou dage causera des champs électromagnétiques Il y a eu et il y a encore un certain souci à propos de tels champs Cependant après avoir examiné plus de 500 études qui ont été faites pendant une pé riode de recherche de 17 ans un comité spécial ruban bleu du National Research Council a conclu L accumulation de p...

Page 13: ...g fumes can be hazardous to your health 2 1 Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Don t weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watch person ready to use it 3 3...

Page 14: ...abel located on bottom of unit 2 3 Symbols And Definitions A Amperes V Volts Alternating Current X Duty Cycle IP Degree Of Protection Hz Hertz I1 Primary Current Wire Feed Jog Output I2 Rated Current Line Connection Increase Start of Action Stop of Action Single Phase U1 Primary Voltage U2 Load Voltage Off Input Percent Read Instructions ...

Page 15: ...nt Control Net 10 2 lb 4 6 kg Weld Voltage And Amperage Capacity AC Or DC 0 To 100 Volts 0 To 1500 Amperes 3 2 Description This weld control is designed to au tomatically cycle welding events while maintaining constant wire feed speed This unit can be used with constant current constant voltage AC or DC welding power sources having remote contactor control and output control capabili ties for Subm...

Page 16: ...rent Sensing Shunt Control 4 Weld Control 5 Spool Support 6 Wire Drive Assembly 7 Automatic Welding Gun 1 2 7 4 5 6 3 4 2 Mounting Hole Layout ST 083 354 C 7 1 2 in 190 5 mm 9 32 in 7 1 mm Dia 4 Holes 13 1 2 in 342 9 mm 4 in 101 6 mm 8 in 203 mm 10 3 4 in 273 mm 7 in 178 mm Includes front panel knobs 5 16 in Dia 4 Holes 7 9 mm ...

Page 17: ...e Control Cord Flux Valve Cord Welding Cables This unit is supplied with the 5 pin 14 pin and 17 pin cords Select the proper cord and make each of the connections shown For non Miller power sources and wire drive motors Term minal Strip TE2 can be used for hookup See Sections 3 9 and 3 10 Route voltage sense lead through strain relief on user access hole Connect one end to terminal 21 on TE1 see S...

Page 18: ...ive assembly see Section 4 3 Reinstall cover onto shunt control 1 2 3 4 1 Receptacle 2 Keyway 3 17 Pin Receptacle Connection to Shunt Control 4 For Customer Use Connections To Terminal Strips Flux Valve etc Route incoming cables through this strain relief prior to making connections to internal terminal strips 5 14 Pin Receptacle Connection To Welding Power Source 6 5 Pin Receptacle Connection to ...

Page 19: ...ing access door 1 Access Door Loosen securing screws 2 and open access door 2 Terminal Strip TE1 3 Terminal Strip TE1 Label 4 Lead Being Connected To TE1 5 Securing Screw Strip 1 4 in 6 mm insulation off end of lead insert end into proper location on TE1 and tighten appli cable securing screw Close and secure access door 1 3 4 5 2 Tools Needed 1 4 in 6 mm 2 52 197 971 ...

Page 20: ... B3 Not Used 6 Not Used 52 115 VAC with respect to terminal 32 on terminal TE2 used to energize a flux valve 4 8 Remote 14 Receptacle RC2 Information Socket User Accessi ble Via TE2 Terminal Socket Information A 2 24 volts ac from welding power source present whenever power source is On Contactor Control B 4 Normally open set of relay contacts connect A to B when START is pressed C 77 Remote comma...

Page 21: ... opening access door 1 Access Door Loosen securing screws 2 and open access door 2 Terminal Strip TE2 3 Terminal Strip TE2 Label 4 Lead Being Connected To TE2 5 Securing Screw Strip 1 4 in 6 mm insulation off end of lead insert end into proper location on TE2 and tighten appli cable securing screw Close and secure access door 3 4 5 2 Tools Needed 1 4 in 6 mm 3 2 1 ...

Page 22: ...l from shunt control to positive voltmeter terminal Input Signals For Ammeter And Voltmeter E Circuit common for ammeter and voltmeter Ammeter And Voltmeter F Input signal from shunt control to positive ammeter terminal G A normally open set of contacts in the shunt control close when an H arc is detected and connect G to H to signal the motor board that an arc was established Arc Detect L 40 A no...

Page 23: ... 5 OPERATION 5 1 Safety Equipment Wear the following while welding 1 Dry Insulating Gloves 2 Safety Glasses With Side Shields 3 Welding Helmet With Correct Shade Of Filter See ANSI Z49 1 sb3 1 1 94 1 2 3 5 2 Front Panel Controls ...

Page 24: ...OM 189 530 Page 20 A For Non CE Units Use With Section C Ref 802 531 187 706 D 1 5 2 3 4 Á Á Á 6 7 ...

Page 25: ...OM 189 530 Page 21 B For CE Units Use With Section C ref 802 531 196 228 1 5 2 3 4 6 7 ...

Page 26: ... Stop button to end the weld cycle Pressing this button initiates the Burnback delay timer and the Burnback portion of the weld cycle 5 Start Switch After pressing the Start button flux valve relay CR5 energizes immediately and sup plies 115 VAC to an external flux valve via terminal 52 on terminal strip TE1 and termi nal 32 on TE2 Preflux time can be adjusted by the knob on CR6 After this timer t...

Page 27: ...re remains electrically energized after the drive motor stops The Burnback timer starts after the Stop button is pressed By adjusting the control properly the wire neither freezes in the weld puddle nor in the contact tube of the gun If the wire freezes in the puddle in crease the burnback time If the wire freezes in the contact tube decrease the burnback time 3 Mode Switch Use this switch to enab...

Page 28: ...es 1 Fuse F1 Fuse F1 protects the wirefeed motor and motor drive board from over load If Fuse F1 opens the wirefeed motor stops Check for jammed wire binding drive gear or misaligned drive rolls Correct problem and re place F1 2 Fuse F2 Fuse F2 protects the VL M4 internal control circuits and the 115 vac sup plied to pin A of 17 pin receptacle from overload If F2 opens all opera tion stops Correct...

Page 29: ... feed after Start button is Check Start switch PB2 and replace if necessary pressed ensure that all wire feed inching functions are operating prop Check weld latch relay CR5 and replace CR5 if necessary erly before checking this problem Check time delay relay CR6 and replace if necessary Check weld contactor relay CR3 on Relay Board PC1 and replace CR3 if necessary Check burnback time delay relay ...

Page 30: ...OM 189 530 Page 26 SECTION 7 ELECTRICAL DIAGRAM SC 197 809 A Figure 6 1 Circuit Diagram ...

Page 31: ...4 426 CAPACITOR 0 1 uf 2 3 190 635 BUSHING strain relief 1 4 RC1 097 869 CONNECTOR circ MS MET 17skt sz 20 1 C3 C4 134 426 CAPACITOR 0 1 uf 2 5 194 618 LABEL replace with 5A 250V fuse 1 6 097 922 KNOB pointer 875dia x 250 ID 2 7 187 706 NAMEPLATE Miller VL M4 1 7 196 228 NAMEPLATE Miller VL M4 CE 1 8 190 639 SEAL switch gray 3 9 190 640 SEAL switch red 1 10 190 638 SEAL switch black 1 To maintain ...

Page 32: ...T 2W 1K ohm 1 6 190 642 KNOB pointer 625dia x 250 ID 1 R7 028 769 POTENTIOMETER CP std slot 1T 2W 750K ohm 1 7 PB2 PB5 190 626 SWITCH PB MC DPDT 6A 125V panel 4 8 S7 190 630 SWITCH tgl SPDT 5A 125V on none on 1 9 S6 190 630 SWITCH tgl SPDT 5A 125V on none on 1 R8 108 432 RESISTOR MF 25W 2 21K 1 10 189 225 PLATE control run in burn back 1 10 196 230 PLATE control run in burn back CE 1 11 190 642 KN...

Page 33: ...R2 190 644 RESISTOR WW fxd 25W 2 ohm 1 8 R1 190 636 RESISTOR WW fxd 30W 1 ohm 1 9 046 432 HOLDER fuse mintr 250 x 1 250 3 10 F1 F2 F3 073 426 FUSE mintr gl 5A 250V 3 11 PC2 190 632 CIRCUIT CARD ASSEMBLY motor control 1 12 TE2 188 719 BLOCK term 40 amp 12 pole screw 1 189 129 LABEL term mkg 40 amp blk 12 1 13 PC1 190 633 CIRCUIT CARD ASSEMBLY relay 1 14 CR1 2 3 4 190 822 RELAY ENCL 120 VAC DPDT 7 5...

Page 34: ...ponents 1 10 083 083 BRACKET mtg control 2 11 601 158 BLANK snap in 7 8 inch 4 12 083 087 CONTROL BOX shunt 1 13 RC7 189 032 CONNECTOR W LEADS 1 14 025 248 STAND OFF 1 4 20 x 1 1 4 4 15 083 082 BUS BAR jumper 2 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s...

Page 35: ...tting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 Spoolmate 250 Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 2 Items furnished by Miller but manufactured by others such as engines or trade accessories The...

Page 36: ... complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Informati...

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