February
1980
FORM:
OM-1086
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON
WI
54912
USA
ADDITIONAL
COPY
PRICE
25
CENTS
NWSA
CODE
NO.
4579
PRINTED
IN
U.S.A.
MODEL
CS-3
HilliER
OWN
ERS
MANUAL
L1P ~_~
L~P
L&P
j~
LIMITED
WARRANTY
EFFECTIVE:
JUNE
1,
1979
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY-Subject
to
the
terms
and
conditions
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
submitted
by
the
original
user
within
the
foregoing
periods.
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
(
furnished
by
Miller
is
free
from
defect
in
workmanship
d
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
material
as
of
the
time
and
place
of
delivery
by
Miller.
No
war-
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
ranty
is
made
by
Miller
with
respect
to
engines,
trade
ac-
therefore
shall
be,
at
Millers
option
(1)
repair
or
(2)
replacement
cessories
or
other
items
manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of
their
respective
manufacturers,
if
any
.
All
Miller
service
station
or
(4)
payment
of
or
credit
for
the
purchase
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
date
of
original
purchase,
return
of
the
goods
at
Customers
risk
and
expense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
clai-
~
Except
as
specified
below,
Millers
warranty
does
not
apply
mant
on
the
warranty
claim
procedures
to
be
followed.
to
components
having
normal
useful
life
of
less
than
nile
Ill
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
~
MILLERMATIC
parts
that
come
in
contact
with
the
welding
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA
wire
including
nozzles
and
nozzle
insulators
where
failure
does
lION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
not
result
from
defect
in
workmanship
or
material.
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
~
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
Miller
shall
be
required
to
honor
warranty
claims
on
war-
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
~
within
the
following
periods
from
the
date
of
delivery
of
Equip-
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
(
ment
to
the
original
user:
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EX
CLUDED
AND
DISCLAIMED
BY
MILLER.
1.
Arc
welders,
power
sources
and
components
.
.
1
year
2.
Original
main
power
rectifiers
3
years
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
(labor
-
1
year
only)
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
3.
All
welding
guns
and
feeder/guns
90
days
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
4.
All
other
Millermatic
Feeders
1
year
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
5.
Replacement
or
repair
parts,
exclusive
of
labor
.
60
days
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
6.
Batteries
6
months
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER
WARRANTIES
DO
NOT
EXTEND
provided
that
Miller
is
notified
in
writing
within
thirty
130)
days
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
of
the
date
of
such
failure.
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
4~1
j
~,
j
~
j~
j~
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
Effective
With
Style
No.
JA
19
AMENDMENT
TO
SECTION
2
-
INSTALLATION
&
OPERATION
Spot
Time
Time
Range
F
~
RETUR~T~O~
~
~ULDEp~
TB-047
181-A
Figure
2-1.
Installation
Of
Control
Unit
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Amend
Figure
2-1.
Installation
Of
Control
Unit
Burnbeck
Time
Control
Spot-Continuous
Switch
Replaced
With
Item
Or
Dia.
Pg
No
Mkgs
4
5
9
14
23
RC1
24
RC2
Pg
2
Part
No.
010
476
605
156
605
156
048
726
048
283
079
534
048 282
079
535
Description
Quantity
010 476
604
571
604
571
045
483
BUSHING
(qtychg)
CORD,portableNo.
184C(orderbyft)
CORD,
portable
No.
184C
(order
byft)
CASE
SECTION
5
3
ft
4
ft
1
048
283
079
535
Deleted
RECEPTACLEW/PINS
(description
chg)
.
TERMALE,
male
1
pin
1
4
Deleted
045
493
080
328
079
534
079531
604
571
CORD,
trigger
(consisting
of)
.
RECEPTACLE
W/SOCKETS,
free
hanging
(consisting
of)
.
.
TERMINAL,
female
1
socket
.CLAMP,cable29/64
.
CORD,
portable
No.
184C(orderbyft)
1
1
4
1
3
ft
OM-1086
Page
A
SECTION
1
-
INTRODUCTION
1
-
1.
GENERAL
-
This
manual
has
been
prepared
especially
for
use
in
familiarizing
personnel
with
the
design,
installation,
operation,
maintenance,
and
troubleshooting
of
this
equipment.
All
information
presented
herein
should
be
given
careful
consideration
to
assure
optimum
performance
of
this
equipment.
1
-
2.
RECEIVING-HANDLING
-
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
and
freight
bill
will
be
furnished
by
the
carrier
on
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
it
is
essential
that
Model
Description
and
Serial
(or
Style)
Number
of
the
equipment
be
supplied.
1
-
3.
DESCRIPTION
-
This
control
Unit
iS
designed
to
add
spot
welding
and
burnback
capability
to
the
SWINGARC
DIGITAL
-1
and
-2,
and
50
series
con
trol/feeders.
When
installed,
this
unit
will
provide
selec
tion
of
either
continuous
or
spot
welding
capability
without
having
to
change
any
interconnecting
wiring
between
the
welding
power
source,
control/feeder,
control
unit,
or
gun.
Mode
change
is
accomplished
via
the
SPOT-CONTINUOUS
switch.
When
in
the
CON-
TINUOUS
position,
the
control
unit
spot
weld
functions
are
shunted
out
of.the
circuit
thereby
providing
weld
control
through
the
control/feeder
and
burnback
capability
through
the
control
unit.
When
in
the
SPOT
position,
the
control
unit
provides
electronically
timed
spot
welding
capability.
1
-
4.
SAFETY
-
Before
the
equipment
is
put
into
operation,
the
safety
section
at
the
front
of
the
welding
power
source
or
welding
generator
manual
should
be
read
completely.
This
will
help
avoid
possible
injury
due
to
misuse
or
improper
welding
applications.
The
following
definitions
apply
to
CAUTION,
IMPOR
TANT,
and
NOTE
blocks
found
throughout
this
manual:
CAUTION
____________
Under
this
heading,
installation,
operating,
and
maintenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
hazard
to
personnel.
IMPORTANT
______________
Under
this
heading,
installation,
operating,
and
maintenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
result
in
damage
to
equipment.
t~iIi~
Under
this
heading,
explanato,y
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
SECTION
2-
INSTALLATION
b
OPERATION
2-1.
INSTALLATION
(Figure
2-1)
CAUTION
___________
Prior
to
installing
the
unit,
ensure
that
the
control/feeder
and
we/ding
power
source
are
both
com
pletely
disconnected
from
their
respective
power
sup-
piles.
IMPORTANT:
If
this
unit
is
used
with
a
dual
con
trol/feeder,
only
the
Left
gun
can
be
used
for
spot
welding.
Make
all
connections
to
the
left
portion
of
the
dual
control/feeder.
1.
Loosen
the
screws
on
top
of
the
control.
Set
this
unit
on
top
of
the
control
and
secure
by
tighten
ing
the
screws.
Trigger
Receptacle4
Spot
Time
Control
Time
Range
Switch
2.
Connect
the
6
prong
male
plug
from
the
con
trol/feeder
gas
valve
into
the
6
pole
female
plug
PLG3.
3.
Connect
the
6
prong
male
plug
PLG4
from
this
unit
to
the
6
pole
receptacle
on
the
rear
of
the
control/feeder.
4.
Connect
the
4
pin
male
plug
PLG2
from
this
unit
to
the
TRIGGER
receptacle
on
the
front
of
the
control/feeder.
5.
Connect
the
4
pole
female
plug
PLG1
from
this
unit
to
the
115
Volt/Contactor
receptacle
on
the
rear
of
the
control/feeder.
6.
Connect
the
115
VoIt/Contactor
Control
cable
(supplied
with
control/feeder)
to
receptacle
RC1.
7.
Connect
the
gun
to
the
TRIGGER
receptacle.
~
If
this
unit
is
used/n
conjunction
with
the
DDSC
control,
the
gun
trigger
plug
must
be
con
nected
to
the
DDSC
control
and
the
plug
from
the
DDSC
control
that
normally
goes
to
the
TRIGGER
receptacle
on
the
control/feeder
must
go
the
TRIGGER
receptacle
on
this
unit.
2
-
2.
SPOT-CONTINUOUS
SWITCH
(Figure
2-1)
-
When
the
SPOT-CONTINUOUS
switch
is
in
the
SPOT
position,
the
control
provides
a
timed
welding
operation.
When
in
the
CONTINUOUS
position,
the
spot
weld
functions
of
the
control
unit
are
not
available.
The
control/feeder
operates
normally
and
a
burnback
time,
as
set
on
the
control
unit,
is
available.
6
4
3
Burnback
Time
Control
Spot-Continuous
Switch
TB-047
181
Figure
2-1.
Installation
Of
Control
Unit
OM-1086
Page
1
2
-
3.
TIME
RANGE
SWITCH
(Figure
2-1)
-
The
TIME
RANGE
switch
provides
two
spot
weld
time
ranges.
Placing
the
switch
in
the
upper
position
pro
vides
a
time
range
of
.2
to
2.5
seconds.
Placing
the
switch
in
the
lower
position
provides
a
time
range
of
2.5
to
5
seconds.
2
-
4.
SPOT
TIME
CONTROL
(Figure
2-1)
-
The
SPOT
TIME
control
provides
the
capability
to
select
the
desired
spot
weld
time
within
the
range
selected.
Rotating
the
SPOT
TIME
control
clockwise
increases
the
spot
weld
time.
This
control
is
calibrated
in
percentage
and
should
not
be
misconstrued
as
an
actual
time
setting.
2
-
5.
BURNBACK
TIME
CONTROL
(Figure
2-1)
-
The
BURNBACK
time
control
is
provided
to
pro-
1.
Ensure
that
proper
connections
have
been
made
as
instructed
in
Section
2.
2.
Turn
on
all
associated
equipment.
3.
Place
the
SPOT-CONTINUOUS
switch
in
the
desired
position.
4.
If
in
the
CONTINUOUS
position,
set
the
BURN-
BACK
time
control
and
proceed
as
normal.
5.
If
in
the
SPOT
position
proceed
as
outlined
in
the
following
steps.
6.
Position
TIME
RANGE
switch
to
time
range
desired.
vent
the
electrode
wire
from
sticking
to
the
workpiece
after
the
weld
is
complete.
The
control
prevents
this
by
providing
an
adjustable
time
period
(up
to
a
maximum
of
.25
seconds)
that
the
electrode
wire
remains
elec
trically
hot
after
the
wire
has
stopped
feeding.
Rotating
the
BURNBACK
time
control
clockwise
in
creases
the
burnback
time.
This
control
is
calibrated
in
percentage
and
should
not
be
misconstrued
as
an
actual
time
setting.
If
the
electrode
wire
sticks
to
the
workpiece,
the
BURN-
BACK
time
control
setting
should
be
increased.
If
the
electrode
wire
burns
back
into
the
contact
tube,
the
BURNBACK
time
control
setting
should
be
decreas
ed.
CAUTION
___________
Prior
to
we/ding,
it
is
imperative
that
pro
per
protective
clothing
(welding
coat
and
gloves)
and
eye
protection
(glasses
and
welding
helmet)
be
put
on.
Failure
to
comply
may
result
in
serious
or
permanent
bodily
damage.
9.
Position
gun
and
commence
spot
welding.
I~IIIl~
Once
the
SPOT
TIME
control
begins
to
time,
the
gun
switch
must
not
be
re/eased
until
the
comple
tion
of
the
spot
weld
cycle.
If
the
gun
switch
is
opened
during
the
weld
cycle
the
cycle
will
not
finish.
SECTION
4-
TROUBLESHOOTING
CAUTION:
_______
Hazardous
voltages
are
present
on
the
in
ternal
circuit,y
of
this
unit
as
long
as
power
is
con
nected.
Disconnect
power
before
attempting
any
in
spection
or
work
on
the
inside
of
the
unit.
Troubleshooting
of
internal
circuitry
should
be
perform
ed
by
qualified
personnel
only.
The
following
chart
is
designed
to
diagnose
and
provide
remedies
for
some
of
the
troubles
that
may
develop
in
this
unit.
It
is
assumed
that
proper
installation
has
been
made,
ac
cording
to
Section
2
of
this
manual,
and
that
the
unit
has
been
functioning
properly
until
this
trouble
developed.
Use
this
chart
in
conjunction
with
the
circuit
diagram
while
performing
troubleshooting
procedures.
If
the
trouble
is
not
remedied
after
performing
these
pro
cedures,
the
nearest
Factory
Authorized
Service
Sta
tion
should
be
contacted.
In
all
cases
of
equipment
malfunction,
the
manufacturers
recommendations
should
be
strictly
followed.
IMPORTANT
Ensure
that
all
connections
at
the
control/feeder
and
control
unit
are
secure
and
that
all
switches
are
in
the
proper
position
for
the
welding
ap
plication
before
proceeding
with
troubleshooting.
SECTION
3-
SEQUENCE
OF
OPERATION
7.
Adjust
SPOT
TIME
control.
8.
Set
BURNBACK
time
control.
Page
2
TROUBLE
PROBABLE
CAUSE
REMEDY
Gas
(and
water)
valve
will
not
operate.
Plug(s)
not
secure
in
receptacle(s).
Ensure
that
plugs
are
secure
in
receptacle(s).
Control/feeder
energizes
but
will
not
feed
wire.
Switch
Control
plug
loose
or
a
loose
lead
in
the
switch
control
plug.
Secure
switch
control
plug
in
receptacle
on
control
unit.
Secure
loose
lead
in
switch
control
plug.
Electrode.
wire
feeds
but
is
not
electrically
hot.
Gas
(and
water)
valve
operates.
Plug
from
welding
power
source
contactor
control
receptacle
loose
or
loose
lead(s)
in
the
plug
or
receptacle.
Secure
plug
in
receptacle
at
control
unit
and
welding
power
source.
Ensure
the
leads
inside
of
receptacle
and
plug
are
secured
to
their
respective
terminals.
Wire
feeds
when
in
CONTINUOUS
positon
but
not
in
SPOT.
Component
defective
in
printed
circuit
board
in
control
unit.
Replace
printed
circuit
board.
SPOT-CONT
I
NUOUS
switch
improperly
wired.
Check
wiring
of
switch.
To
FEEDER
GAS/WATER
4~
RECEPTACLE
5-
TO
GAS/WATER
a:
VALVES
BAN
3>
2>
8LK
TO
POWER
SOURCE
1
I15VAC/CONTACTOF1
2
FROM
GUN
I
TRIGGERS
3
I-----
-
-
To
TO
FEEDER
______J
EXIT
FROM
P.C.
S0ARD
2
3
324445501
o
0
0
0
0
0
iT
ABC
DEF
1>
PLG3
Figure
4-1.
Circuit
Diagram
Circuit
Diagram
No.
B-048
835-B
OM-1086
Page3
February
1980
FORM:
OM-1086
PARTS
LIST
MODEL
CS-3
TC.047
182
I
t
N
(0
.9
eq
U.
U,
I-
N
I-
C)
(4
OM-1086
Page
i
Figure
~
Main
Assembly
Item
Dia.
Factory
No.
Mkqs.
Part
No.
SCREW,
sheet
metal
-
hex
washer
hd
No.
8
x
3/8
SCREW,
machine
-
steel
truss
hd
6-32
x
3/8
SCREW,
self
-
tapping
round
hd
6-32
x
3/8
SCREW,
machine
-
steel
truss
hd
6-32
x
5/8
SCREW,
machine
.
steel
round
hd
6-32
x
3/4
WASHER,
lock
-
steel
split
No.
6
NUT,
steel
-
hex
6-32
Description
Quantity
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
049
173
WRAPPER
1
048
907
CIRCUIT
CARD
ASSEMBLY,
spot
timer
(See
Fig.
B
Page
3)
1
081
738
TUBING,
steel
5/16
OD
x
17
ga
4
010
476
BUSHING,
strain
relief
5/8
x
.570
4
605
156
CORD,
portable
No.
18
4C
(order
by
ft.)
3
ft.
079531
CLAMP,cable
2
048
284
HOUSING
PLUG
&
SOCKETS
(consisting
of)
1
079
534
.
TERMINAL,
female
1
socket
4
079
878
HOUSING
PLUG
&
PINS
(consisting
of)
1
079
535
.
TERMINAL,
male
1
pin
.
4
605
156
CORD,
portable
No.
18
4C
(order
by
ft.)
4
ft.
056
265
CONNECTOR,
male
6
contact
10
amp
1
048
842
CONNECTOR,
female
6
socket
w/cable
clamps
1
052 246
CABLE.
power
5C
3-20/2-18
(order
by
ft.)
3
ft.
052 246
CABLE.
power
5C
3-20/2-18
(order
by
ft.)
2
ft.
048
726
CASE
SECTION,
front/bottom/back
1
iT
038
772
BLOCK,
terminal
20
amp
6
pole
....
1
048
725
BRACKET,
mounting
-
relay
1
080
148
SOCKET,
relay
11
pin
1
CR53
080
388
RELAY,
24
volts
ac
3PDT
1
048
848
SPRING,
hoiddown
-
relay
1
S51
011
611
SWITCH,
toggle
DPDT
15
amp
125
volts
1
024 366
KNOB,
pointer
NAMEPLATE
(order
by
model
and
serial
numbers)
2
1
048
283
RECEPTACLE,
4
pin
flanged
size
11
(consisting
of)
1
079
534
.
TERMINAL,
female
1
socket
4
048
282
RECEPTACLE,
4
socket
flanged
size
11
(consisting
of)
1
079
535
.
TERMINAL,
male
1
pin
4
RC
1
24
RC2
F
actory
Part
No.
Description
Attaching
Hardware
604 804
602
070
602
143
602
072
604
850
602
198
601
859
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1
086
Page
2
Figure
B
Circuit
Card
Assembly,
S,iot
Timer
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Page
3
Dia.
Factory
Mkgs.
Part
No.
Description
Quantity
Figure
B
048
907
Circuit
Card
Assembly,
S~,ot
Timer
(See
Fig.
A
Page
2
Item
2)
C51,56
031
633
CAPACITOR,electrolytic80uf25voltsdc
2
C52,53
031
643
CAPACITOR,
ceramic
0.01
uf
500
volts
dc
2
C54
032
943
CAPACITOR,
tantalum
4.7
uf
35
volts
dc
1
C54
032
820
CAPACITOR,
electrolylic
2.2
uf
35
volts
dc
1
C55
032
943
CAPACITOR,
tantalum
4.7
uf
35
volts
dc
1
CR51
048
906
RELAY,
enclosed
12
volts
ac
3PFT
1
CR52
032945
RELAY,24voltsdcDPDT
1
032
946
SOCKET,
relay
2
051,54
026
202
DIODE,
1
ampere
400
volts
straight
polarity
4
D55
037
243
DIODE,
zener
18
volts
I
watt
1
Q51,52
022
135
THYRISTOR,4amp200volts
2
053,54
037 289
TRANSISTOR,
unijunction
5OMA
35
volts
2
R51 030 055
RESISTOR,
carbon
2
watt
10
ohm
1
R52,54,65
030 024
RESISTOR,
carbon
0.5
watt
1000
ohm
3
R53
030 630
RESISTOR,
WW
fixed
11
watt
100
ohm
1
R55,57
030
937
RESISTOR,
carbon
0.5
watt
10
ohm
2
R56
030 709
RESISTOR,
carbon
1
watt
150
ohm
1
R58
030
004
RESISTOR,
carbon
0.5
watt
10K
ohm
1
R59
030
738
POTENTIOMETER,
carbon
1
turn
2
watt
500K
ohm
1
R60
.030
145
POTENTIOMETER,
carbon
1
turn
0.25
watt
2000
ohm
1
R61,64
030
025
RESISTOR,
carbon
0.5
watt
100
ohm
2
R62
030
131
POTENTIOMETER,
carbon
1
turn
2
watt
50K
ohm
1
R63
030 853
RESISTOR,
carbon
0.5
watt
2200
ohm
1
R66
030
024
RESISTOR,
carbon
0.5
watt
1000
ohm
1
R67,68
030
025
RESISTOR,
carbon
0.5
watt
100
ohm
2
R69
032 819
RESISTOR,
carbon
0.5
watt
390K
ohm
1
S52
011
770
SWITCH,
toggle
SPDT
5
amp
125
volts
1
COMPONENTS
TO
BE
REPLACED
BY
QUALIFIED
PERSONNEL
ONLY.
TA-047
180
/