Miller HE787389 Owner's manual

Miller
Brand
Miller
Model
HE787389
Category
Welding System
Type
Owner's manual

This manual is also suitable for

February
1976
FORM:
OM-1510
Effective
with
serial
No.
HE787389
MODEL
MS
Weld
Control
STOCK
NO.
079
065
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
ADDITIONAL
COPY
PRICE
80
CENTS
OWNERS
MANUAL
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
NWSA
CODE
NO.
4579
%
LIMITED
WARRANTY
MILLER
Electric
Mfg.
Co.,
Appleton.
Wisconsin,
warrants
all
new
equipment
to
be
free
from
defects
in
material
and
factory
workmanship
for
the
periods
indicated
below,
provided
the
equipment
is
installed
and
operated
according
to
manufacturers
Instructions.
MILLER
Electric
Mfg.
Cos
obligation,
under
this
warranty,
is
expressly
limited
to
replacing
or
repairing
any
defective
part
or
correcting
any
manufacturing
defect
without
charge
during
the
warranty
period
if
MILLERS
inspection
confirms
the
existence
of
such
defects.
MILLERs
option
of
repair
or
replacement
will
be
f.o.b.
factory
at
Appleton,
Wisconsin
or
f.o.b.
a
MILLER
authorized
service
facility,
and
therefore
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
The
warranty
period,
beginning
on
the
date
of
sale
to
the
original
purchaser.user
of
the
equipment,
will
be
as
follows:
-~
C
1.
Arc
welders,
power
sources,
and
components
1
year
2.
Original
main
power
rectifiers
3
years
(unconditionally)
3.
MHG-20E,
20K
and
all
guns
90
days
4.
All
other
Millermatic
Feeders
1
year
5.
Mag-Diesel
engine
on
DEL-200
6
months
6.
All
other
engines
1
year
The
labor
expense
on
installing
original
main
power
rectifiers
after
being
in
service
one
year
will
be
the
owners
responsibility.
C
Engine
Warranties
are
covered
by
the
engine
manufacturers,
subject
to
their
procedures
and
to
be
handled
through
their
C
S
authorized
local
Service
Stations
or
agencies.
No
warranty
will
be
made
in
respect
to
trade
accessories,
such
being
subject
to
the
warranties
for
their
respective
manufacturers.
c
MILLER
Electric
Mfg.
Co.
will
not
be
liable
for
any
loss
or
consequential
damage
or
expense
accruing
directly
or
indirectly
from
s
the
use
of
equipment
covered
in
this
warranty.
c
C)
C
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
C
implied.
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exceptions
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data
appearing
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this
manual.
AMENDMENT
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FUNCTION
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Circuit
Diagram
For
Models
Effective
With
Serial
No.
HH050890
And
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circuit
Diagram
No.
C-053
192
OM-1510
Page
C
TABLE
OF
CONTENTS
Paragraph
No.
Page
No.
SECTION
1
INTRODUCTION
1-
1.
General
1
1
-
2.
Receiving-Handling
1
1
-
3.
Description
1
1-4.
Safety
1
SECTION
2INSTALLATION
2-1.
Location
1
2-
2.
Electrical
Input,
Contactor
Control
And
Voltmeter
Connections
2
2
-
3.
Shielding
Gas
Connections
2
2
-
4.
Secondary
Connections
2
2-
5.
Weld
Head
Connections
2
2
-
6.
Remote
Gas
Control
&
Remote
Fixture
Start
Connections
2
2-
7.
Remote
Start,
Stop,
And
Emergency
Stop
Connections
3
SECTION
3
FUNCTION
OF
CONTROLS
3-1. Weld
Start
Switch
3
3-
2.
Weld
Current
Control
3
3-
3.
Stop
Switch
3
3
-
4.
Emergency
Stop
Switch
3
3-
5.
Inch
Up
And
Inch
Down
Switches
3
3
-
6.
Purge
Switch
3
3-7.
PowerOn
Light
3
3-8.
Circuit
Breaker
3
3-9.
Meters
3
3-10.
Burnback
Control
3
3-11.
Run
In
Control
4
3-12.
Pre
Flow
Control
4
3-13.
Post
Flow
Control
4
3-14.
Weld
Time
Control
4
A.
Spot
Weld
Mode
Of
Operation
4
B.
Full
Automatic
Mode
Of
Operation
4
C.
Semi-Automatic
Mode
Of
Operation
4
3-1
5.
Operational
Mode
Connections
4
A.
Full
Automatic
Operation
4
B.
Spot
Weld
Operation
4
C.
Semi-Automatic
Operation
4
PARTS
LIST
Circuit
Breaker
Shielding
Gas
Output
~Receptac1e
Shielding
Gas
Input
Receptacle
Remote
Gas
Control
&
Remote
Fixture
Start
Receptacle
RC
1
\
Figure
2-2.
Front
Panel
and
Bottom
View
CAUTION
Ensure
that
the
115
volts
ac
power
Su~nd
welding
power
source
are
deenergized
before
electrical
con
nections
are
made.
Do
not
connect
the
conductors
to
the
115
volts
ac
power
supply
and
welding
power
source
until
all
electrical
connections
have
been
made
totheweldcontrol.
2-2.
ELECTRICAL
INPUT.
CONTACTOR
CONTROL.
AND
VOLTMETER
CONNECTIONS
(Figure
2-2)
A.
Weld
Control
Connections
Insert
plug
PLG3
into
the
weld
control
receptacle
RC3.
Ro
tate
the
plug
threaded
outer
ring
clockwise
Onto
the
recep
tacle
threaded
body
as
far
as
possible.
This
action
will
secure
the
plug
in
the
receptacle.
B.
Electrical
Input
Connections
Connect
the
supplied
electrical
input
cord,
labeled
115,
to
the
115
volts
ac,
single
phase,
60
hertz
power
supply.
It
is
recommended
that
the
welding
power
source
115
vac
recep
tacle
be
used
as
the
115
vac
power
supply.
Connect
the
two
input
conductors,
colored
white
and
black,
to
the
115
volts
ac
power
supply
and
connect
the
ground
conductor,
colored
green,
to
a
proper
ground.
Use
whatever
grounding
method
that
is
acceptacle
to
the
local electrical
inspection
authority.
The
green
ground
conductor
is
connected
to
the
weld
control
chassis
and
is
for
grounding
purposes
only.
Do
not
connect
the
green
ground
conductor
to
any
one
of
the
115
volts
ac
power
supply
terminals
as
this
will
result
in
an
electrically
hot
weld
control
chassis.
C.
Contactor
Control
And
Voltmeter
Connections
Locate
the
supplied
contactor
control
and
voltmeter
cord,
labeled
CONTACTOR~
Connect
the
two
contactor
control
conductors,
colored
white
and
black,
to
the
welding
power
source
contactor
Control
circuitry.
Connect
the
voltmeter
conductor,
colored
green,
to
the
welding
power
source
negative
(-)
secondary
terminal.
2-
3.
SHIELDING
GAS
CONNECTIONS
(Figure
2-2)
Connect
a
hose
of
suitable
length
and
construction
from
the
shielding
gas
supply
to
the
weld
control
GAS
-
FROM
SUP-
PLY
gas
receptacle.
Connect
the
supplied
hose
from
the
weld
control
GAS
-
TO
WELD
HEAD
gas
receptacle
to
the
gun
gas
receptacle.
Both
of
the
weld
control
gas
receptacles
have
5/8-lB
right-handed
threading.
2.4.
SECONDARY
CONNECTIONS
(Figure
2.2)
Connect
cables
of
suitable
length,
size,
and
construction
between
the
following
points:
A.
Welding
power
source
positive
(+)
secondary
terminal
to
weld
control
positive
(+)
secondary
terminal.
B.
Weld
control
negative
(-)
secondary
terminal
to
gun
secondary
terminal.
C.
Welding
power
source
negative
(-)
secondary
terminal
to
weidment
(workpiece).
Refer
to
the
welding
power
source
Owners
Manual
for
suitable
cable
size
and
Construction.
The
weld
control
secondary
terminals
are
112
in
diameter
so
corresponding
size
cable
connectors
should
be
used
at
these
points.
2-
5.
WELD
HEAD
CONNECTIONS
(Figure
2-2)
Insert
plug
PLG4
into
the
weld
control
receptacle
RC4.
Rotate
the
plug
threaded
outer
ring
clockwise
Onto
the
recep
tacle
threaded
body
as
far
as
possible.
This
action
will
secure
the
plug
in
the
receptacle.
Insert
PLG
from
the
weld
head
into
receptacle
AC.
Rotate
the
plug
threaded
Outer
ring
clockwise
Onto
the
receptacle
threaded
body
as
far
as
possible.
This
action
will
secure
the
plug
in
the
receptacle.
2-6.
REMOTE
GAS
CONTROL
&
REMOTE
FIXTURE
START
CONNECTIONS
(Figure
2.2)
If
remote
control
of
a
shielding
gas
valve
or
relay
is
desired,
connect
the
leads
from
the
gas
valve
or
relay
to
pins
C
and
D
of
plug
PLG1.
This
valve
or
relay
must
be
able
to
operate
with
.25
amp
or
less
@
115
volts
ac.
This
valve
or
relay
will
be
energized
and
deenergized
in
unison
with
the
gas
valve
GS1
within
the
weld
control.
If
remote
control
of
a
fixture
relay
is
desired
connect
the
leads
from
the
relay
to
pins
A
and
B
of
plug
PLG1.
This
relay
must
be
able
to
operate
with
.5
amp
or
less
@
115
volts
ac.
This
relay
will
be
energized
and
deenergized
in
unison
with
the
weld head
motor.
Insert
plug
PLG1
into
weld
control
receptacle
RC1
and
rotate
the
plug
Outer
threaded
ring
clockwise
onto
the
recep
tacle
threaded
body.
This
action
will
secure
the
plug
in
the
receptacle.
Remote
Start,
Stop,
&
Emergency
Stop
Receptacle
RC2
________
115
VAC
Input,
________________
Voltmeter,
&
-o
c~
'~
Contactor
Control
~
11
Receptacle
Rc3
Negative
Secondary
Terminal
Emergency
Stop
Switch
Positive
Secondary
Terminal
Weld
H~a
d
Receptacle
RC4
TB-079
064-1
U
Page
2
SECTION
1
-
INTRODUCTION
Electrical
Input
To
Weld
Control
Max.
Voltage
Applied
To
Weld
Head
Overall
Dimensions
(Inches)
Weight
(Pounds)
Net
I
Ship
I
35
I
37
j
115
Volts
AC
Single
Phase
60
Hertz
100
Volts
DC
Height
-
15-3/8
Width
-
11-3/4
Depth
-
5-1/4
Figure
I-i.
Specifications
1
-
1.
GENERAL
This
manual
has
been
prepared
especially
for
use
in
familiar
izing
personnel
with
the
design,
installation,
operation,
main
tenance,
and
troubleshooting
of
this
equipment.
All
informa
tion
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
equipment,
it
is
essential
that
Model
Description
and/or
Stock
Number
and
Serial
(or
Style)
Numbers
of
the
equipment
be
supplied.
1
-
3.
DESCRIPTION
This
weld
control
has
silicon
control
rectifiers,
diodes,
and
transistors
in
the
timing,
speed,
and
brake
circuits
for
pre
cision
control
and
dependable
service.
The
printed
Circuit
board
can
be
easily
replaced
as
a
unit
if
required.
This
weld
control
is
designed
for
use
with
a
constant
potential
welding
power
source.
This
weld
control
includes
controls
for
gas
metal-arc
spot
welding.
A
simple
jumper
relocation
Converts
control
from
one
process
to
the
other.
Ten-foot
interconnecting
cords
and
gas
hose
are
included.
The
following
definitions
apply
to
CAUTION,
IMPORTANT,
and
NOTE
blocks
found
throughout
this
manual:
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
safety
hazard
to
personnel.
I
I
11rTA;~I
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
result
in
damage
to
equip
ment.
NOTE
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
A
proper
installation
site
should
be
selected
for
the
weld
control
if
the
unit
is
to
provide
dependable
service,
and
re
main
relatively
maintenance
free.
A
proper
installation
site
permits
freedom
of
air
movement
into
and
out
of
the
weld
control,
and
also
least
subjects
the
I
~
TB-079
064-1
unit
to
dust,
dirt,
moisture,
and
corrosive
vapors.
The
instal
lation
Site
should
also
permit
easy
access
to
the
weld
control
for
Operational
and
maintenance
functions.
Lead
lengths
must
be
considered
when
locating
the
control.
Holes
are
provided
in
the
weld
control
back
panel
for
mount
ing
purposes.
Figure
2-1
gives
overall
dimensions
and
mount
ing
hole
layout.
1
-4.
SAFETY
I
I
I
U
I
SECTION
2
-
INSTALLATION
I
I
2-
1.
LOCATION
(Figure
2-1)
Figure
2-1.
Overall
Dimensions
and
Mounting
Hole
Layout
OM-1510
Page
1
3-11.
RUN
IN
CONTROL
(Figure
3-11
The
RUN
IN
Control
provides
a
means
of
determining
the
rate
at
which
welding
wire
will
be
fed
into
the
weld
prior
to
arc
initiation.
After
arc
initiation,
the
wire
feed
speed
is
governed
by
the
WELD
CURRENT
Control.
Rotating
the
RUN
IN
Control
in
a
clockwise
direction
will
increase
the
rate
of
the
wire
feed.
When
the
RUN
IN
Control
is
set
at
0,
wire
will
feed
at
the
slowest
speed;
when
set
at
10,
the
wire
will
feed
at
the
fastest
speed.
The
scale
which
surrounds
the
RUN
IN
Control
is
calibrated
in
increments
of
one
ranging
from
0
to
10.
Due
to
this
cali
bration,
it
should
be
noted
that
if
this
scale
is
being
used
to
select
a
wire
feed
speed
setting,
only
a
fraction
of
the
range
in
use
is
being
selected
and
not
an
actual
wire
feed
speed
rate.
3-12.
PRE
FLOW
CONTROL
(Figure3-1)
An
adjustable
shielding
gas
PRE-FLOW
Control
is
provided
for
controlling
the
period
of
time
shielding
gas
will
be
allowed
to
flow
before
the
welding
wire
is
fed
and
subse
quent
arc
initiation.
The
PRE
FLOW
Control
governs
the
operation
of
a
Pre-Flow
Timer
within
the
weld
control.
Rotating
the
control
in
a
clockwise
direction
will
increase
the
pre-flow
time.
The
scale
surrounding
the
PRE
FLOW
Control
is
calibrated
arbitrarily.
As
soon
as
the
WELD
START
Switch
(or
Remote
Start
Switch)
has
been
closed,
the
Pre-Flow
Timer
will
begin
to
time
out
the
selected
period
of
pre-flow
time.
Once
the
timer
has
timed
out,
the
gas
valve
will
remain
open,
the
welding
wire
will
begin
to
be
fed,
and
the
contactor
will
close
pro
viding
weld
power.
The
timer
will
then
automatically
reset
and
be
ready
for
another
weld
cycle.
3-13.
POST
FLOW
CONTROL
(Figure
3-1)
An
adjustable
0
to
1
second
shielding
gas
POST
FLOW
Con
trol
is
provided
for
controlling
the
period
of
time
shielding
gas
will
be
allowed
to
flow
after
the
arc
is
extinguished.
The
POST
FLOW
Control
governs
the
operation
of
a
Post-Flow
Timer
within
the
weld
control.
Rotating
the
control
in
a
clockwise
direction
will
increase
the
post-flow
time.
The
scale
surrounding
the
POST
FLOW
Con
trol
is
calibrated
arbitrarily.
As
soon
as
the
arc
has
been
extinguished,
the
Post-Flow
Timer
will
begin
to
time
out
the
selected
period
of
post-flow
time.
Once
the
timer
has
timed
out,
the
gas
valve
will
close
and
thereby
terminate
shielding
gas
flow.
The
timer
will
then
automatically
reset
and
be
ready
for
another
weld
cycle.
3-14.
WELD
TIME
CONTROL
(Figure
3-1)
A.
Spot
Weld
Mode
Of
Operation
An
adjustable
03
to
ZO
second
WELD
TIME
Control
is
pro
vided
for
controlling
the
period
of
time
weld
power
will
be
available
for
spot
welding
in
this
mode
of
operation.
The
WELD
TIME
Control
governs
the
operation
of
a
Spot
Timer
within
the
welding
power
source.
Rotating
the
control
in
a
clockwise
direction
will
increase
the
spot
time.
The
scale
surrounding
the
WELD
TIME
Control
is
calibrated
arbitrarily.
The
Spot
Weld
Timer
will
begin
to
time
out
as
soon
as
an
arc
is
initiated.
When
the
time
set
on
the
WELD
TIME
Control
has
elapsed,
weld
current
will
cease
and
the
Post-Flow
Timer
will
be
started.
B-
Full
Automatic
Mode
Of
Operation
The
WELD
TIME
Control,
in
this
mode
of
operation,
adjusts
the
crater-fill
time
from
0.3
to
2.0
seconds.
The
crater-fill
time
is
the
time
between
the
applied
signal
for
weld
cycle
stopping
and
the
actual
welding
wire
stopping.
Rotating
this
control
clockwise
will
increase
the
crater-fill
time.
The
scale
surrounding
the
WELD
TIME
Control
is
calibrated
arbi
trarily.
C.
Semi-Automatic
Mode
Of
Operation
The
WELD
TIME
Control,
in
this
mode
of
operation,
is
in
operative.
3-15.
OPERATIONAL
MODE
CONNECTIONS
(Figure
3-1)
A.
Full
Automatic
Operation
The
Full
Automatic
mode
of
operation
should
be
used
when
fixture
welding.
The
weld
control,
when
shipped,
is
con
nected
for
Full
Automatic
operation.
To
connect
for
Full
Automatic
operation:
1.
Connect
the
red/white
jumper
lead
between
terminals
1
and
6
of
terminal
strip
iT.
2.
Connect
the
yellow
lead
to
terminal
6
of
terminal
strip
1
T.
B.
Spot
Weld
Operation
One
of
the
two
Spot
Weld
modes
of
operation
should
be
used
when
spot
welding
is
desired.
To
connect
for
one
of
these
Spot
Welding
Operations:
Mode
1:
To
start
arc
time
from
arc
initiation,
connect
the
red/white
jumper
lead
between
terminals
1
and
6
of
terminal
strip
iT.
Connect
the
yellow
lead
to
terminal
7 of
terminal
strip
iT.
Mode
2:
To
start
arc
time
from
the
end
of
the
shielding
gas
pre-flow
time,
connect
the
red/white
jumper
between
terminal
I
and
7
of
terminal
strip
iT.
Connect
the
yellow
lead
to
terminal
7 of
terminal
strip
iT.
C.
Semi-Automatic
Operation
The
Semi-Automatic
mode
of
operation
should
be
used
when
portable
gun
welding
is
desired.
In
this
mode,
the
WELD
TIME
and
POST
FLOW
Controls
will
be
inoperative.
To
con
nect
for
Semi-Automatic
operation:
1.
Connect
the
red/white
jumper
lead
between
terminals
1
and
8
of
terminal
strip
iT.
2.
Connect
the
yellow
lead
to
terminal
7 of
terminal
strip
iT.
3.
Remove
the
green
jumper
lead
from
terminals
1
and
3
of
terminal
strip
iT.
4.
Connect
a
normally
open
switch
to
pins
D
and
E of
plug
PLG2.
Insert
plug
PLG2
into
receptacle
RC2
and
rotate
the
plug
outer
threaded
ring
clockwise
onto
the
receptacle
threaded
body.
This
action
will
secure
the
plug
in
the
receptacle.
Page
4
2-7.
REMOTE
START,
STOP,
&
EMERGENCY
STOP
CONNECTIONS
(Figure
2-2)
If
remote
control
of
the
weld
cycle
starting
is
desired,
con
nect
the
leads
from
a
normally
open
switch
to
pins
A
and B
of
plug
PLG2.
If
remote
control
of
the
weld
cycle
stopping
is
desired,
con
nect
the
leads
from
a
normally
open
switch
to
pins
A
and
C
of
plug
PLG2.
If
remote
control
of
the
weld
cycle
emergency
stopping
is
desired,
connect
the
leads
from
a
normally
closed
switch
between
pins
D
and
E
of
plug
PLG2.
In
addition,
remove
the
lumper
lead
between
terminals
2
and
3
of
terminal
strip
iT.
(See
figure
3-1.)
Insert
plug
PLG2
into
the
weld
control
receptacle
RC2.
Rotate
the
plug
threaded
outer
ring
clockwise
onto
the
recep
tacle
threaded
body
as
far
as
possible.
This
action
will
secure
the
plug
in
the
receptacle.
SECTION
3-
FUNCTION
OF
CONTROLS
3-1.
WELD
START
SWITCH
(Figure
2-2)
Rotating
the
WELD
START
Switch
to
the
ON
position
will
apply
115
volts
ac
to
the
unit
and
thereby
place
it
in
an
operational
condition,
ready
to
energize
the
weld
head
and
permit
shielding
gas
to
flow.
Rotating
the
WELD
START
Switch
to
the
OFF
position
will
shut
the
weld
control
down.
CAUTION__.!
Even
though
the
WELD
START
Switin
the
OFF
position
and
the unit
is
apparently
shutdown,
115
volts
will
still
be
present
at
the
input
terminals
of
the
WELD
START
Switch
for
as
long
as
the
115
volts
cable
is
connected
to
its
activated
source.
Depressing
(closing(
the
WELD
START
Switch
push
button
(or
Remote
Start
Switch)
when
the
WELD
START
Switch
is
in
the
ON
position
will
commence
the
preset
weld
cycle.
If
the
WELD
START
Switch
push
button
(or
Remote
Start
Switch
I
is
depressed
when
the
WELD
START
Switch
is
in
the
OFF
position,
the
weld
cycle
will
not
commence.
The
preset
weld
cycle
will,
in
any
event,
commence
with
shielding
gas
pre-f
I
ow.
The
WELD
START
Switch
(or
Remote
Start
Switch(
may
remain
closed
subsequent
to
weld
cycle
initiation,
but
must
be
opened
and
reclosed
to
initiate
another
weld
cycle.
3-
2.
WELD
CURRENT
CONTROL
(Figure
2-2)
The
WELD
CURRENT
Control
provides
a
means
of
deter
mining
the
rate
at
which
welding
wire
will
be
fed
into
the
weld
exclusive
of
the
run-in
wire
feed
speed
as
governed
by
the
RUN
IN
Control.
Rotating
the
WELD
CURRENT
Con
trol
in
a
clockwise
direction
will
increase
the
rate
of
wire
feed.
When
the
WELD
CURRENT
Control
is
set
at
0,
wire
will
feed
at
the
slowest
speed;
when
set
at
10,
the
wire
will
feed
at
the
fastest
speed.
The
scale
which
surrounds
the
WELD
CURRENT
Control
is
calibrated
in
increments
of
one
ranging
from
0
to
10.
Due
to
this
calibration,
it
should
be
noted
that
if
this
scale
is
being
used
to
select
a
wire
feed
speed
setting,
only
a
fraction of
the
range
in
use
is
being
selected
and
not
an
actual
wire feed
speed
rate.
3-
3.
STOP
SWITCH
(Figure
2-2)
Depressing
(closing(
the
STOP
Switch
push
button
(or
Remote
Stop
Switch)
will
stop
the
weld
head
motor
and
begin
the
burnback
and
post-flow
functions.
3-
4.
EMERGENCY
STOP
SWITCH
(Figure
2-2)
Depressing
(opening(
the
EMERGENCY
STOP
Switch
push
button
(or
Remote
Emergency
Stop
Switch)
will
stop
the
entire
weld
cycle
except
for
burnback.
3-
5.
INCH UP
&
INCH
DOWN
SWITCHES
(Figure
2-2)
Depressing
the
INCH
UP
Switch
energizes
the
weld
head
motor
to
retract
the
welding
wire
from
the
weld
at
the
run-in
speed
established
by
the
RUN
IN
Control.
Depressing
the
INCH
DOWN
Switch
energizes
the
weld
head
motor
to
advance
the
welding
wire
to
the
weld
at
the
run-in
speed
established
by
the
RUN
IN
Control.
In
both
the
inch-up
and
inch-down
modes,
the
contactor
in
the
welding
power
source
and
the
gas
control
circuitry
remain
deenergized.
3-
6.
PURGE
SWITCH
(Figure
2-2)
The
PURGE
Button
is
a
normally
open
momentary
contact
switch.
This
switch
will
energize
the
gas
solenoid
GS1
and
purge
the
shielding
gas
line
of
the
gun.
The
PURGE
Button
also
allows
the
shielding
gas
regulator
to
be
adlusted
without
energizing
the
welding
circuit.
3-
7.
POWER
ON
LIGHT
(Figure
2-2)
The
POWER
ON
pilot
light,
when
illuminated,
indicates
that
the
weld
control
is
energized.
3-8.
CIRCUIT
BREAKER
(Figure
2-2)
The
circuit
breaker
provides
protection
to
the
weld
control
and
weld head
motor.
In
the
event
the
weld
control
or
weld
head
motor
should
be
placed
in
an
overload
condition,
the
breaker
would
trip
and
suspend
all
output.
Should
this
breaker
trip,
the
reset
button
would
have
to
be
manually
depressed
in
order
to
reset
the
circuit
breaker.
3-
9.
METERS
(Figure
2-2)
This
weld
control
is
equipped
with
a
dc
ammeter
and
a
dc
voltmeter.
These
meters
are
connected
to
the
welding
power
source
output.
The
voltmeter
will
indicate
the
dc
voltage
at
the
welding
power
source
secondary
terminals,
but
will
not
necessarily
indicate
the
actual
voltage
at
the
welding
arc.
If
the
welding
cables
are
excessively
long,
or
have
poor,
loose
connections,
the
difference
between
actual
arc
voltage
and
the
voltage
at
the
welding
power
source
secondary
terminals
may
be
considerable.
3-10.
BURNBACK
CONTROL
(Figure
3-1)
The
BURNBACK
Control
regulates
the
amount
of
welding
wire
that
protrudes
beyond
the
end
of
the
contact
tube
at
the
completion
of
a
weld
cycle.
In
other
words,
the
BURN-
BACK
Control
adlusts
the
welding
wire
burnback
time
from
0
to
.5
second.
By
adjusting
this
control
properly,
the
weld
ing
wire
will
neither
freeze
in
the
weld
puddle
or
the
contact
tube.
Rotating
the
BURNBACK
Control
clockwise
increases
the
amount
of
welding
wire
burnback
towerd
the
contact
tube.
The
scale
surrounding
this
control
is
calibrated
arbitrarily.
Figure
3-1.
Inside
Front
Panel
View
TB-003
748
OM-1510
Page
3
II5VAC
CONTACTOR
Figure
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IA
IS
5CR
r
TIME
S
CW.~JFLOW
WELOr
LE~POST
SI
RI
2I~
22~
-
Ear
IIWT
CaN.
-~
_8N~
____
2
IS
IT
~
1~~~j19
lB
20
4~
~
~
___
___
~
~!
____
~
~2~5R~
____
I~*I
_____________
-
~
014
D~5
013
016
p36
4021
~D2R
022
05
02
033
ii
45
032
034
~I
C6
-
~
~C~T
Iii
0NL;F
REQUIRED
L
)
~
)C~
)a~
~I7
)~
~L~J
)~
116
COl
736
T5B
__________________________
PROGRAM
BOARD
3~
700
i~
i~i~
r~i
121
1311
121
LI
2~s
4
1~o
ISA
Q~l
REMOSIE
IUMPER
112
10173
WREN
REMOTE
EMERGENCy
STOP
5
USED
SC2
ITS
)
055
-7
PLG2E
~
EMER.
STOP
Circuit
Diagram
No.
C-003
161A
OM-1510
Page
5
February
1976
FORM:
OM-1510
MODEL
MS
Weld
Control
079
065
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
P~JRCHASED
PARTS
LIST
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
Effective
with
serial
No.
HE787389
STOCK
NO.
NWSA
CODE
NO.
4579
.~iN7t0
U
OM-1510
Page
1
Item
Dia.
Factory
No.
Mkgs.
Part
No.
Figure
A
Main
Assembly
(Contd)
Description
BE
SURE
TO
PROVIDE
STOCK,
MODEL,
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Quantity
49
074
870
WASHER,
fiber
-
shoulder
41/64
ID
x
i-3/8ODx3/8
......
2
50
073
211
BEZEL,
meter~
double
(attaching
hardware
M
&
U)
1
51
V
073
726
METER,
volt
dc
0-50
scale
1
52
A
076
419
METER,
amp
dc
0-800
scale
1
53
Ri
030
131
POTENTIOMETER,carbon
1
turn
2watt5OK
ohm
1
54
PB1,S1
073
773
SWITCH,
push
button
DPDT
NC/NO
120
volts
ac
1
55
PB2,6
073
723
SWITCH,
push
button
2NC/2NO
150
volts
red
2
56
PB3
073
722
SWITCH,
push
button
2NC/2NO
150
volts
black
1
57
PB4
073
719
SWITCH,
push
button
iNC/i
NO
150
volts
black
1
58
PB5
073
720
SWITCH,
push
button
iNC/i
NO
150
volts
yellow
1
59
Ci
073
290
CAPACITOR,
electrolytic
2
uf
600
volts
(attaching
hardware
B
&
M)
1
60
Ti
073
630
TRANSFORMER,
filament
0.04
amp
115
volts
(attaching
hardware
B
&
M)
1
61
TR1
030
112
THYRECTOR,
protector
-
surge
ac
1
62
2T
073
644
BLOCK,
terminal
20
amp
2
pole
(attaching
hardware
C
&
M)
1
63
073
651
STRIP,
marking
-
terminal
2
pole
i
64
075
308
CIRCUIT
CARD
ASSEMBLY
(attaching
hardware
B,
C
&
M)(See
Fig.
A2
Page
5)
.
i
65
NAMEPLATE
(order
by
stock,
model,
and
serial
numbers)
1
66
024 366
KNOB,
pointer
1
67
CB1
073
676
CIRCUIT
BREAKER,
manual
reset
7
amp
1
68
PL1
073
753
LIGHT,
indicator
120
volts
ac
red
lens
1
69
078
034
FASTENER,
screw
2
70
073
483
RETAINER,
screw
2
71
074
421
NUT,
speed
-
push
on
.485
dia
1
72
R2,4,5,6
073
642
POTENTIOMETER,
carbon
1
turn
0.5
watt
5000
ohm
4
73
R3
073
640
POTENTIOMETER,
carbon
1
turn0.5
watt
10K
ohm
1
74
075
457
BRACKET,
mounting
-
potentiometer
1
75
074
485
LABEL,
burn
back
run-in
1
76
073
568
KNOB,
pointer
5
77
073
2i0
STRIP,
marking
terminal
8
pole
1
78
iT
073
944
BLOCK,
terminal
15
amp
8
pole
(attaching
hardware
C
&
M)
1
Attaching
Hardware
A
602
062
SCR
EW,
machine
-
steel
round
hd
4-40
x
3/8
.
.
.
.
2
B
602
068
SCREW,
machine
-
steel
round
hd
6-32
x
3/8
.
..
.
12
C
602
071
SCREW,
machine
-
steel
round
hd
6-32
x
1/2
10
D
602
070
SCREW,
machine
-
steel
truss
hd
6-32
x
3/8
2
E
602
143
SCREW,
self
tapping
-
round
hd
6-32
x
3/8
15
F
602
080
SCREW,
machine
-
steel
round
hd
8-32
x
3/8
4
G
602
089
SCREW,
machine
-
steel
round
hd
10-32
x
3/8
10
H
602
091
SCREW,
machine
-
steel
round
hd
10-32
x
1/2
3
J
603
586
WASHER,
flat
-
steel
SAE
No.
6
4
K
602
237
WASHER,
flat
-
steel
No.
8
4
L
605
247
WASHER,
lock
-
steel
split
No.
4
2
M
602
198
WASHER,
lock
-
steel
split
No.
6
28
N
602
200
WASHER,
lock
-
steel
split
No.
8
5
P
602
203
WASHER,
lock
-
steel
split
No.
10
13
0
601
858
NUT,
steel
-
hex
4-40
2
U
60i
859
NUT,
steel
-
hex
6-32
5
R
601
860
NUT,
steel
-
hex
8-32
2
S
601
862
NUT,
steel
-
hex
10-32
3
Page
3
Item
Dia.
Factory
No.
Mkgs.
Part
No.
Description
Quantity
Figure
A
Main
Assembly
075
456
PANEL,
inside
-
control
box
(attaching
hardware
G
&
P)
074
486
LABEL,
pre-flow
post
flow
weld
time
2
RC6
074
998
SPACER,
support
1
3
073
730
CONNECTOR,
edge
22
pin
(attaching
hardware
D
&
M)
1
4
075
318
CIRCUIT
CARD
ASSEMBLY
(attaching
hardware
B
&
M)(See
Fig.
Al
Page
4)....
5
CR
1,2
075
071
SWITCH,
reed
2
6
Shunt
074
461
SHUNT,
meter
5OMV
800
amp
1
7
079
209
COVER,
blank
.
water
valve
(attaching
hardware
H,
P.
&
5)
1
8
R7
073 760
RESISTOR,
heat
sink
25
watt
2500
ohm
(attaching
hardware
A,
L,
&
Q)
1
9
RC1
073
687
RECEPTACLE,
4
socket
MS-3102A-14S-2S
(attaching
hardware
E)
1
10
075
477
CABINET,
control
1
073
108
STR~PP~NG,
adhesive
back
11
RC2
073 328
RECEPTACLE,
7
socket
97-3102A-18-9S
(attaching
hardware
E)
1
12
RC3
073
505
RECEPTACLE,
6
pin
MS-3102A-18-12P
(attaching
hardware
B,
E,
M
&
U)
1
13
RC4
073
248
RECEPTACLE,
6
socket
97-3102A-20-17S
(attaching
hardware
E)
1
14
073
347
GROMMET,
rubber
3/16
ID
x
5/16
hole
x
1/16
groove
2
15
073
176
BRACKET,
mounting-
resistor
(attaching
hardware
F,
K
&
N)
1
16
R8,9
074
154
RESISTOR,
WW
fixed
100
watt
1.6
ohm
2
073
177
STUD,
brass
8-32
x
4-3/8
2
073
915
WASHER,
centering
3/4
4
073
876
WASHER,
flat
-
mica
1/2
ID
x
1
OD
x
1/16
4
003
028
WASHER,
flat
-
brass
No.
8L
4
601
831
NUT,
brass
-
hex
8-32
4
17
078
478
COVER,
resistor
(attaching
hardware
B,
J
&
M)
1
18
075
073
CABLE,
motor
lOft
(consisting
of)
1
19
PLG4
073
264
.
PLUG,
6
pin
97-3106A-20-17P
1
20
073
297
.
CLAMP,
cable
AN-3057-12
2
21
073
139
.
CORD,
portable
No.
16/6
conductor
(order
by
foot)
10
ft.
22
RC5
073265
.
RECEPTACLE,6socket97-3101A-20-17S
.
1
23
079
255
CORD
ASSEMBLY,
interconnecting
loft
(consisting
of)
1
24
073 332
.
CLAMP,
cable
97-3057-10
1
25
600
737
.
CORD,
portable
No.
16/3
conductor
(order
by
foot)
22
ft.
26
PLG3
073
507
.
PLUG,
6
socket
MS-3106A-18-12S
1
27
073
331
CLAMP,
cable
97-3057-10-6
1
28
073
756
SPACER,
hex
1/4
x
5/8
x
6-32
thread
4
29
PLG2
073
330
PLUG,
7
pin
97-3106A-18-9P
1
30
075
455
PANEL,
inside
-
cabinet
(attaching
hardware
G
&
P)
1
31
079
281
SCREW,
cap
-
brass
hex
hd
5/8-11
x
3
2
32
602
218
WASHER,
lock
-
steel
split
5/8
2
33
075
776
TERMINAL,
connecting
2
34
079
224
WASHER,
flat
-
bronze
SAE
5/8
2
35
074872
TUBING,fiber4l/64IDx
1-3/8ODx1/2
2
36
073
689
CLAMP,
cable
97-3057-6
1
37.
PLG1
073
685
PLUG,
4
pin
MS-3106A-14S-2P-639
1
38
079
212
HOSE,
gas
10
ft
(consisting
of)
39
073
827
.
NIPPLE,
barbed
3/16
hose
1
40
056
849
.
NUT,
brass
-
hose
3/8-24
right
hand
41
073839
.
FERRULE,
brass
2
42
604
550
.
HOSE,
whippet
3/16
x
1
(order
by
foot)
10
ft.
43
010
606
.
NUT,
brass
-
swivel
5/8-18
right
hand
1
44
056
851
-
NIPPLE,
brass
-
hose
3/16
1
45
074
933
SHIM,
valve
46
010
604
ADAPTER,
brass
-
gas
1/4-18
NPT
5/8-18
female
2
47
073
863
ELBOW,
brass
-
pipe
street
90
degree
1/8
x
1/4
2
48
GS1
073
378
VALVE,
115
volts
ac
2
way
1/8
IPS
port
3/32
orifice
(attaching
hardware
G
&
P)
.
OM-1
510
Page
2
___
Lcii
I
013
R
EC34
~
~~~REC23
REC33
REC35
REC36
~REC22
REC15D
~
~REC2O
R22
I,
C161
012
.014
~
N
-J
J
~
~
(~Q
Figure
Al
Circuit
Card
Assembly,
Program
TA-075
317
**Diagram
markings
for
these
diodes
are:
REC
1,
4-18,
20-23,
27,
29,
32-36.
BE
SURE
TO
PROVIDE
STOCK,
MODEL,
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-l
510
Page
4
Dia.
Mkgs.
Factory
Part
No.
Description
Quantity
Figure
Al
075
318
Circuit
Card
Assembly,
Program
(See
Fig.
A
Page
2
Item
4)
Cl
073
715
CAPACITOR,
tantalum
0.15
uf
200
volts
1
C2
073
731
CAPACITOR,
electrolytic
100
uf
35
volts
dc
1
C3,15
073
714
CAPACITOR,
tantalum
0.22
uf
35
volts
2
C4
073
716
CAPACITOR,
tantalum
0.1
uf
50
volts
1
C5,1
2,21
073
740
CAPACITOR,
ceramic
0.01
uf
50
volts
3
C6,9,14,18
073
739
CAPACITOR,
ceramic
0.1
uf
50
volts
4
C7,8,1
1,17
073
738
CAPACITOR,
ceramic
0.68
uf
50
volts
4
Ci0,13,19
073
732
CAPACITOR,
electrolytic
10
uf
50
volts
dc
3
C16
073
737
CAPACITOR,
electrolytic
25
uf
50
volts
dc
1
C20
073
547
CAPACITOR,
mylar
0.33
uf
200
volts
1
01,4,9,11,13,15
073
533
TRANSISTOR,
unijunction
6
amp
200
volts
6
Q2,3,10
073
790
DIODE,
10
amp
14
volts
straight
polarity
3
05,7,8,12,14
037
289
TRANSISTOR,
unijunction
5OMA
35
volts
5
06
073
535
TRANSISTOR,
100MA
30
volts
1
Q16
073710
THYRISTOR,6amp200volts
1
Ri
078
426
RESISTOR,
carbon
0.12
watt
2200K
ohm
1
R2
605
909
RESISTOR,
carbon
0.25
watt
22K
ohm
1
R3,20
605
910
RESISTOR,
carbon
0.25
watt
15K
ohm
2
R4
605
915
RESISTOR,
carbon
0.25
watt
2.2K
ohm
1
R5,21
605
916
RESISTOR,
carbon
0.25
watt
1K
ohm
2
R6
078
434
RESISTOR,
carbon
0.25
watt
18K
ohm
1
R
7,
14,
17,
24,27,29
605
918
RESISTOR,
carbon
0.25
watt
100
ohm
6
R8
605
919
RESISTOR,
carbon
0.25
watt
47
ohm
1
R9
074
026
RESISTOR,
carbon
0.25
watt
150
ohm
1
Ri0,12,19,25
605
908
RESISTOR,
carbon
0.25
watt
33K
ohm
4
Ri
1
078
430
RESISTOR,
carbon
0.12
watt
82
ohm
1
R13,16,28
605
911
RESISTOR,
carbon
0.25
watt
10K
ohm
3
R15
078429
RESISTOR,
carbon
0.25
watt
lOOK
ohm
1
R18,26
078
428
RESISTOR,
carbon
0.25
watt
220
ohm
2
R22
078
431
RESISTOR,
carbon
0.25
watt
330
ohm
1
R23
030
091
RESISTOR,
carbon
0.25
watt
1500
ohm
1
R30
078
433
RESISTOR,
carbon
0.25
watt
1
meg
ohm
1
*
REC2,3
073
540
074453
DIODE,
150
MA
75
volts
reverse
polarity
RECTIFIER,
integrated
lamp
600voIts
27
2
REC19
074
242
DIODE,
zener
16
volts
1
watt
1
T1-6
073
682
TRANSFORMER,
pulse
6
c20
IREC7
R29
I
__
ft6
c3
C21
~R11
015
REC17~
J
REC2
J
R
EC8
~
002
~REc1
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Miller HE787389 Owner's manual

Miller
Brand
Miller
Model
HE787389
Category
Welding System
Type
Owner's manual
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