Miller CS-4 Owner's manual

Miller
Brand
Miller
Model
CS-4
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Miller CS-4 adds run in speed and electronically timed pre-flow, spot welding, burnback and post-flow capabilities to the Swingarc and 50 Series single and dual wire feeders. The run in speed and burnback capabilities of the CS-4 are available for both spot and continuous welding.

Miller CS-4 adds run in speed and electronically timed pre-flow, spot welding, burnback and post-flow capabilities to the Swingarc and 50 Series single and dual wire feeders. The run in speed and burnback capabilities of the CS-4 are available for both spot and continuous welding.

January
1981
FORM:
OM-1
088
OWN
ERS
MANUAL
HilliER
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON
WI
54912
USA
Effective
With
Style
No.
JA-49
MODEL
CS-4
NWSA
CODE
NO.
4579
PRINTED
IN
U.S.A.
~.-
~
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.
Ii
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
and
In
the
case
of
Millers
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
Millers
option
(11
repair
or
(21
replacement
~
cessories
or
other
items
manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
13)
f~)
(
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
14)
payment
of
or
credit for
the
purchase
~
1
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
Iless
reasonable
depreciation
based
upon
actual
usel
upon
date
of
original
purchase,
return
of
the
goods
at
Customers
risk
and
expense.
Upon
receipt
~J
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
clai-
j7,~
Except
as
specified
below,
Millers
warranty
does
not
apply
mant
on
the
warranty
claim
procedures
to
be
followed.
to
components
having
normal
useful
life
of
less
than
one
(1)
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
TION
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
Ilabor
-
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
30)
days
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
?
of
the
date
of
such
failure.
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
,,,
...~,.
.,~.
~,
~
SECTION
1
-
INTRODUCTION
1-1.
GENERAL
INFORMATION
AND
SAFETY.
A.
General
Information
presented
in
this
manual
pertains
to
equip
ment
design,
installation,
operation,
maintenance,
and
troubleshooting
which
should
be
read,
understood,
and
followed
for
the
safe
and
effective
use
of
this
equip
ment.
B.
Safety
The
installation,
operation,
maintenance,
and
troubleshooting
of
arc
welding
equipment
requires
practices
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
all
ap
plicable
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source
in
the
welding
power
source
Owners
Manual.
Safet~
instructions
specifically
pertaining
to
this
unit
ap
pear
throughout
this
manual
highlighted
by
the
signal
word
IYAYI..~:li~hcI
which
identifies
the
level
of
hazard.
WARNING
statements
include
installation,
operating,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
serious
personal
injury
or
loss
of
life.
IMPORTANT
An
additional
signal
word,
_______________
highlights
instructions
which
need
special
emphasis
to
obtain
the
most
efficient
operation
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
)oss
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
-
The
CS-4
is
designed
to
add
run
in
speed
and
electronically
timed
pre-flow,
spot
welding,
burnback
and
post-flow
capabilities
to
the
Swingarc
and
50
Series
single
and
dual
wire
feeders.
The
run
in
speed
and
burnback
capabilities
of
the
CS-4
are
available
for
both
spot
and
continuous
welding.
SECTION
2
-
INSTALLATION
Figure
2-1.
CS-4
To
Gun
Switch
Plug
To
Gas
Control
Receptacle
On
Wire
Feeder
To
Plug
From
Gas
Valve
15-072
644
To
Trigger
Receptacle
On
Wire
Feeder
To
Remote
Control
Receptacle
On
Wire
Feeder
Pre-Flow
Time
Control
Speed
Control
Control
Post-Flow
Time
Control
OM-1088
Page
1
IMPORTANT
___________
All
directions,
such
as
left
or
right,
are
with
respect
to
the
operator
facing
the
front
panel.
2-1.
INSTALLATION
in
the
base
and
supplied
hardware.
Route
the
weld
output
cable
from
the
welding
power
source,
through
the
reed
relay,
to
the
weld
cable
terminal
on
the
wire
feeder.
side.
1.
Loosen
the
screws
along
the
top
of
the
wire
feeder
control.
Set
the
CS-4
on
top
of
the
con
trol
and
secure
by
tightening
the
screws.
2.
For
Swingarc
Wire
Feeders:
Attach
the
reed
relay
assembly
to
the
Swingarc
control
mounting
bracket
using
holes
provided
in
bracket
and
sup
plied
hardware.
Route
the
weld
output
cable
from
the
welding
power
~n,rce,
through
the
reed
relay,
to
the
weld
cable
terminal
on
the
wire
feeder.
For
50
Series
Wire
Feeders:
Attach
the
reed
relay
assembly
to
the
wire
feeder
base
in
line
with
the
wire
drive
housing
using
holes
provided
3.
Connect
the
plug
from
the
reed
relay
to
the
reed
relay
receptacle
in
the
center
portion
of
the
rear
panel
of
CS-4.
4.
Disconnect
the
gas
valve
plug
from
the
gas
con
trol
receptacle
on
the
rear
of
the
wire
feeder.
Reconnect
the
gas
valve
plug
to
the
6-contact
female
plug
from
the
CS-4.
5.
Connect
the
6-contact
male
plug
from
the
CS-4
to
the
gas
control
receptacle
on
the
wire
feeder.
6.
Connect
the
6-pin
plug
on
the
Remote
Control
Cord
to
the
Remote
Control
receptacle
on
the
wire
feeder.
I
Wi
l~1
~I
V
~
P/ace
the
wire
feeder
Remote
Control
switch
in
the
REMOTE
position.
7.
Connect
the
gun
switch
plug
to
the
4-pin
female
plug
on
the
CS-4.
8.
Connect
the
4-pin
male
plug
on
the
Trigger
Con
trol
interconnecting
cord
from
the
CS-4
to
the
TRIGGER
receptacle
on
the
front
of
the
wire
feeder.
WARNING
.
ELECTRIC
SHOCK
can
kill.
Shut
down
the
wire
feeder
and
the
we/ding
power
source
and
be
sure
that
neither
can
be
accidental
iy
energized
before
installing
the
control.
IMPORTANT
When
using
a
Dual
Wire
Feeder,
the
capabilities
of
the
CS-4
can
be
added
to
either
side.
All
control
connections
must
be
made
to
the
appropriate
Right
Gun
115
Volts/Contactor
control
Cord
Front
View
CS-4
Left
Gun
rri~ger
Control
Cord
Dual
Wire
Feeder
Rear
View
Figure
2-2.
Connection
Diagram
For
CS-4
Used
On
Dual
Wire
Feeder
A-071
072
Page
2
2-2.
TRIGGER
LOCK-OUT
CONNECTION
(Op
tional)
-
When
shipped
from
the
factory
the
CS-4
is
wired
to
complete
each
timed
weld
only
if
the
gun
switch
is
maintained
closed
throughout
the
spot
weld
cycle.
If
the
gun
switch
is
released
before
the
SPOT
TIME
control
times
out,
the
spot
weld
will
not
be
com
pleted.
Through
the
following
minor
modification,
the
CS-4
can
be
wired
to
complete
each
timed
weld
after
a
momentary
closure
of
the
gun
switch.
In
this
case,
the
spot
weld
cycle
ends
only
after
the
SPOT
TIME
control
times
out.
1.
Disconnect
input
power.
__________
ELECTRiC
SHOCK
can
kill.
Do
not
touch
five
electrical
parts.
Disconnect
unit
from
input
power
before
internal
ly
inspecting
or
servicing.
2.
Remove
the
wrapper.
3.
Locate
lead
No.
513
from
the
printed
circuit
board
on
the
bottom
left
side
of
the
unit.
4.
With
the
SPOT-CONTINUOUS
switch
S2
in
the
CONTINUOUS
position,
connect
the
friction
connector
on
lead
No.
513
to
the
normally-open
terminal
(the
only
unused
terminal)
on
S2.
5.
Replace
the
wrapper:
WARNING
SECTION
3-
FUNCTION
OF
CONTROLS
3i.
SPOT-CONTINUOUS
SWITCH
(Figure
2-1)
-
The
SPOT-CONTINUOUS
switch
provides
the
capability
of
selecting
either
a
continuous
weld
or
a
tim
ed
weld
operation.
Placing
the
SPOT-CONTINUOUS
switch
in
the
SPOT
position
provides
weld
current
for
the
time
period
set
by
the
TIME
RANGE
switch
and
SPOT
TIME
control.
The
SPOT
TIME
control
begins
to
time
out
upon
arc
initiation.
Placing
the
SPOT-CONTINUOUS
switch
in
the
CON
TINUOUS
position
provides
weld
current
for
as
long
as
the
gun
trigger
is
closed.
3-2.
TIME
RANGE
SWITCH
(Figure
2-1)
-
The
TIME
RANGE
switch
provides
selection
of
the
desired
spot
weld
time
range.
Placing
the
TIME
RANGE
switch
in
the
.2-2.5
SEC
position
provides
a
range
of
.2
to
2.5
seconds
of
weld
time.
Placing
the
TIME
RANGE
switch
in
the
2.5-5
SEC
position
provides
a
range
of
from
2.5
to
5
seconds
of
weld
time.
3-3.
SPOT
TIME
CONTROL
(Figure
2-1)
-
The
SPOT
TIME
control
provides
a
means
of
selecting
the
desired
spot
weld
time
within
the
time
range
selected.
The
scales
surrounding
the
SPOT
TIME
control
are
calibrated
in
seconds
and
correspond
with
the
ranges
of
the
TIME
RANGE
switch.
Rotating
the
SPOT
TIME
control
clockwise
increases
the
spot
weld
time.
3-4.
RUN
IN
SPEED
CONTROL
(Figure
2-1)
-
The
RUN
IN
speed
control
provides
a
means
of
selecting
the
rate
at
which
the
electrode
wire
feeds
from
the
moment
the
PRE-FLOW
TIME
control
times
out
until
arc
is
in
itiated.
Once
the
arc
is
initiated,
control
of
wire
feed
speed
is
transferred
from
the
RUN-IN
speed
control
to
the
WIRE
SPEED
control
on
the
wire
feeder.
The
scale
surrounding
the
RUN
IN
speed
control
is
calibrated
in
percent.
The
RUN
IN
speed
controls
variable
rate
is
the
same
as
the
rate
that
can
be
obtained
by
the
WIRE
SPEED
control
on
the
wire
feeder.
3-5.
PRE-FLOW
TIME
AND
POST-FLOW
TIME
CONTROLS
(Figure
2-1)
-
The
PRE-FLOW
TIME
and
POST-FLOW
TIME
controls
provide
a
means
of
selec
ting
the
period
of
time
shielding
gas
flows
at
the
beginn
ing
and
at
the
end
of
the
spot
weld
cycle.
Depressing
the
gun
trigger
initiates
pre-f
low
time.
Post-flow
time
begins
after
burnback
time
has
elapsed.
The
scales
surrounding
the
PRE-FLOW
TIME
and
POST-FLOW
TIME
controls
are
calibrated
in
in
crements
up
to
5
seconds.
3-6.
BURNBACK
TIME
CONTROL
(Figure
2-1)
-
The
BURNBACK
TIME
control
provides
a
means
of
varying
the
amount
of
time
that
weld
current
is
pre
sent
on
the
electrode
wire
after
the
wire
has
stopped
feeding.
By
keeping
weld
current
present
on
the
elec
trode
wire,
the
wire
burns
away
from
the
workpiece
and
toward
the
contact
tube.
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
decreased.
The
scale
surrounding
the
BURNBACK
TIME
control
is
calibrated
in
increments
up
to
.25
seconds.
OM-1088
Page
3
SECTION
4
-
SEQUENCE
OF
OPERATION
4-1.
GAS
METAL-ARC
WELDING
(GMAW)
1.
Ensure
that
proper
connections
have
been
made
as
instructed
in
Section
2.
2.
Energize
the
welding
power
source
and
the
wire
feeder.
Turn
on
shielding
gas
at
its
source.
IMPORTANT
Place
the
Contactor
Control
switch
on
the
welding
power
source
and
the
Remote
Control
switch
on
the
wire
feeder
in
the
REMOTE
position.
3.
Rotate
the
RUN
IN
speed
control
to
the
desired
setting.
4.
Rotate
the
BUANBACK
TIME
control
to
the
desired
setting.
WARNING
c.
Rotate
the
PRE-FLOW
TIME
and
POST-
FLOW
TIME
controls
to
the
desired
setting.
_________
ARC
RAYS,
SPARKS,
AND
HOT
SURFACES
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Wear
correct
eye,
ear,
and
body
protection.
See
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Sources
in
the
welding
power
source
Owners
Manual
for
basic
welding
safety
information.
7,
Depress
gun
trigger
and
commence
welding.
I
k~
I~s]
~
V..1~I
~
The
gun
trigger
must
be
held
closed
until
the
SPOT
TIME
control
has
timed
out
thereby
completing
the
spot
weld
unless
the
trigger
lockout
connection
has
been
made
(see
Section
2-2).
5.
Place
the
SPOT-CONTINUOUS
switch
in
the
desired
position.
6.
If
the
SPOT
mode
is
being
used:
a.
Position
the
TIME
RANGE
switch
to
time
range
desired.
b.
Rotate
the
SPOT
TIME
control
to
the
desired
setting.
4-2.
SHUTtiNG
DOWN
1.
Turn
off
shielding
gas
at
its
source.
2.
Shut
down
the
welding
power
source
and
wire
feeder.
WARNING
GASES
can
kill
or
seriously
harm
your
health.
0
Shut
off
gas
supply
at
source
when
not
in
use.
--
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
WARNING
__________
ELECTRIC
SHOCK
can
kill.
Do
not
touch
five
electrical
parts.
Disconnect
unit
from
input
power
before
internal
ly
inspecting
or
servicing.
Troubleshooting
of
internal
parts
to
be
performed
only
by
qualified
persons.
5-1.
INSPECTION
AND
UPKEEP
IMPORTANT
_______________
Periodically
inspect
the
labels
on
this
unit
for
legibility.
All
labels
must
be
maintained
in
a
clearly
readable
state
and
replaced
when
necessary.
See
the Parts
List
for
part
number
of
labels.
Periodically
inspect
all
interconnecting
cords
for
damage
to
or
breaks
in
the
insulation
jacket,
particularly
at
the
plug.
Repair
or
replace
the
cord(s)
as
necessary.
5-2.
TROUBLESHOOTING
IMPORTANT
Ensure
that
all
connections
at
the
wire
feeder
and
control
unit
are
secure
and
that
all
switches
are
in
the
proper
position
for
the
welding
application
before
proceeding
with
troubleshooting.
B.
Troubleshooting
Chart
The
following
chart
is
designed
to
diagnose
and
provide
remedies
for
some
of
the
troubles
that
may
develop
in
this
unit.
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
manufacturers
recommendations
should
be
strictly
followed.
A.
General
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.
Page
4
TROUBLE
PROBABLE
CAUSE
SUGGESTED
CHECK
AND/OR
REMEDY
Gas
(and
water)
valve
wilt
not
operate.
Plug
PLG3
and/or
PLG4
not
secure
in
receptacle(s),
Ensure
that
plugs
PLG3
and/or
PLG4
are
secure
in
receptacle(s).
Printed
circuit
board
defec-
tive.
Replace
printed
circuit
board
located
on
bottom
left
side
of
unit.
Wire
feeder
energizes
but
will
not
feed
wire.
Switch
control
plug
PLG5
loose
or
a
loose
lead
in
plug
PLG5.
,
Secure
plug
PLG5
in
receptace
on
control
unit.
Secure
loose
lead
in
plug
PLG5.
Gun
switch
defective.
Replace
gun
switch.
Remote
control
plug
PLG56
not
secure
in
receptacle.
Ensure
that
plug
PLG56
is
secure
in
receptacle.
Wiie
feeder
doOs
not
energize.
115
votts/contactor
control
plugs
PLG1
and/or
RC1
not
secure
in
receptacles.
Ensure
that
plugs
PLG1
and/or
RC1
are
secure
in
receptacle(s).
Electrode
wire
feeds
but
is
not
electrically
hot.
Gas
(and
water)
valve
operates.
~
Plug
in
welding
power
source
contactor
control
receptacle
loose
or
loose
lead(s)
in
the
plug
or
recep-
tacle.
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
does
not
feed
at
run-in
speed.
~
Reed
switch
plug
PLG9
not
secure
in
reed
switch
recep-
tacle
RC9.
Ensure
that
plug
PLG9
is
secure
in
receptacle
RC9.
Extremely
short
or
infinitely
long
pre-flow
and/or
post-
flow
time.
Printed
circuit
board
defec-
live,
Replace
printed
circuit
board
located
on
bottom
left
side
of
unit.
Extremely
short
or
infinitely
long
spot
and/or
burnback
time.
Printed
circuit
board
defec-
tive.
Replace
printed
circuit
board
located
on
bottom
right
side
of
unit.
OM-1088
Page
5
CR
575?
r~j
CR6
1
1516
CR
r
RC2
6
-
1W
173
CR50
-<
I
__________________________________________________
__
1~0
I
05
057
<
I
CR51
sI
75
D5o
:iiiii~1~
0
C~
<I.~J~
I
123
_
05
506
1502
1
503
C/i
CR3
~
l4~
059
CUSS
-
C25s
/5
/5
7~Uj~~
CI
i~
J.~SU5
15C
V
y
Tj
~
359
IF
05>E
Fl_C56
Circuit
Diagram.
No.
C-072
270-B
-v
RI
cC
0
C)
-
-
-T
556
:~1–~
0ji
0005/
053
___
iT
052
D5~
T
SC2rt.
~so
~~cso
F
ro
FEEDER
WilT
GUN
2<
~18
RECEPTACLE
06~0
CRI~I~CRS
~
IF~~B
528
R,5~DI4PR>C
REC/CG
CI
530
~
~
D
FEEDER
RE3~:os
!L~i.
Ysu
o_j~
150
IRLG5
FROM
GUN
7?
DOERS
REED
-~t
CO/i0
ITC
03
<
3
GAS/WATER
RED
VALVES
CR0
CR6
a
I
H0,
SPOT
rIME
578
579
~
22
Ia
3
a
Ii
_i_/6
20
C53
O0CIONAU
501
NECT
ID
N
~-
50
SEDER
GAS/WADES
RECEPTACLE
7
9
CR50
RURN
00CR
520
.525
3
75
78i1L~2
~eI.:55tHtJ1
I
T
~
CR50
CR57
-w
C56
059
056
~
Figure
5-1.
Circuit
Diagram
January
1981
FORM:
OM-1088
PARTS
LIST
Effective
With
Style
No.
JA-49
0
C
-v
0)
0
S
35
6
8
7
30
7
TD-072
642
2
Figure
A
-
Main
Assembly
Item
Dia.
Part
No.
Mkgs.
No.
Description
Quantity
Figure
A
Main
Assembly
1
049
173
WRAPPER
1
2
CR3,6
081
797
RELAY,
enclosed
24
volts
ac
4PDT
2
3
079
844
SPRING,
hold
down
-
relay
2
4
027811
CONNECTOR,l4pin
2
5
049
970
BRACKET,
mounting
-
relay
2
6
048
029
CLIP,
retaining
-
socket
relay
2
7
010476
BUSHING,strainrelief
5
8
079
121
CORD,
trigger
25
inch
(consisting
of)
1
9
604
571
.
CORD,
No.
184/c
(order
byft)
3
ft
10
079531
.CLAMP,cable
1
11
PLG5
080 328
.
RECEPTACLE
W/SOCKETS,
free
-
hanging
(consisting
of)
1
079
534
.
TERMINAL,
female
2
12
079
120
CORD,
trigger37
inch
(consisting
of)
1
13
604
571
CORD,
No.
184/c
(order
byft)
4
ft
14
079531
.CLAMP,cable
1
15
PLG2
079
878
.
HOUSING
PLUG
&
PINS
(consisting
of)
1
079
535
.
.
TERMINAL,
male
4
16
072
124
CABLE,
control-
remote
43
inch
(consisting
of)
1
17
PLG56
039 827
.
PLUG,
6
pin
MS-3106A-14S-6P
1
18
039
828
CLAMP,
cable
1
19
604
910
.
CABLE,
power
20
ga
5/c
(order
byft)
4
ft
20
Reed,
PLG9
057
053
RELAY,
current
1
21
071
759
CORD,
control
-
gas
&water28
inch
(consisting
of)
1
22
PLG4
056
265
.
CONNECTOR,
male6contact
10
amp
1
23
052
246
.
CABLE,
power
5/c
(order
by
ft)
3
ft
24
071
758
CORD,
control
-
gas
&
water
18
inch
(consisting
of)
1
25
PLG3
048
842
.
CONNECTOR,
female
6
socket
1
26
052
246
.
CABLE,
power
5/c
(order
by
ft)
2
ft
27
PLG6,7
079
798
HOUSING,
terminal
13
position
2
28
072
117
CIRCUITCARD,timer(FigBPg3)
2
29
010301
BUSHING,9/64IDx1/4ODx5/16
2
30
RC3,4
073
730
CONNECTOR,
edge
22
pin
2
31
031
251
BRACKET,
mounting
-
connector
4
32
1-3T
038 042
STRIP,
terminal4
pole
3
33
RC9
057
059
JACK,
3/c
1
34
072
128
CASE
SECTION,
front/bottom/back
1
35
NAMEPLATE
(order
by
model
&
style
numbers)
1
36
024 366
KNOB,
pointer
5
37
R3,9
16,22
028
770
POTENTIOMETER,
carbon
1
turn
2
watt
1
meg
ohm
4
38
Si
011
609
SWITCH,
toggle
SPDT
15
amp
125
volts
1
39
S2
011
611
SWITCH,
toggle
DPDT
15
amp
125
volts
1
40
R27
030
853
RESISTOR,
carbon
0.5
watt
2200
ohm
1
41
4T
038
785
STRIP,
terminal
3
pole
1
42
057
056
BRACKET,
mounting
-
terminal
strip
1
43
R28
030
854
RESISTOR,
carbon
0.5
watt
18K
ohm
1
44
Dl
026 202
DIODE,
rectifier
1
amp
400
volts
straight
polarity
1
45
R29
030
943
POTENTIOMETER,
carbon
1
turn
2
watt
15K
ohm
1
OM-1088
Page
2
Item
Dia.
Part
No.
Mkgs.
No.
Description
Quantity
Figure
A
Main
Assembly
(Contd.)
Attaching
Hardware
604
632
SCREW,
machine
-
round
hd
4-40
x
1/2
602
075
SCREW,
machine
-
round
hd
6-32
x
1
602
196
WASHER,
lock
-
internal
tooth
No.
4
602
199
WASHER,
lock
-
external
tooh
No.
6
601
858
NUT,
hex
4-40
601
859
NUT,
hex
6-32
I
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Page
3
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure
B
072
117
Circuit
Card,
Timer
(Fig
A
P9
2
Item
33)
A50
009
159
AMPLIFIER,
operational
32
voltsdc
1
C50
039
482
CAPACITOR,
electrolytic
100
uf
35
volts
dc
1
C51
,53
032
820
CAPACITOR,
tantalum
2.2
uf
35
volts
dc
2
C52
073
714
CAPACITOR,
tantalum
0.22
uf
35
volts
1
C54
072
113
CAPACITOR,
tantalum
4.7
uf35voltsdc
1
CR5O,51
027
810
RELAY,
enclosed
24
volts
dc4PDT
2
D50-55,
57-59
026
202
DIODE,
rectifier
1
amp
400
volts
straight
polarity
9
D56
037
449
DIODE,
zener
15
volts
1
watt
straight
polarity
1
050,51
037
200
TRANSISTOR,200MA4OvoItsNPN
2
R50
030 712
RESISTOR,
carbon
1
watt
1000
ohm
1
R51
605
918
RESISTOR,
carbon
0.25
watt
100
ohm
1
R52
078
433
RESISTOR,
carbon
0.25
watt
1
meg
ohm
1
R53,57
605
912
RESISTOR,
carbon
0.25
watt4700
ohm
2
R54,56,
59,60
605
911
RESISTOR,
carbon
0.25
watt
10K
ohm
4
R55,58
605 909
RESISTOR,
carbon
0.25
watt22K
ohm
2
079
843
SOCKET,
relay
2
079 844
SPRING,
hold
down
-
relay
2
079
795
TERMINAL,
header
13
pin
...
1
I
R56
I
I,
ri
r~
IR58
I
ri
LL~
050
~
0
5
Q059
R51
J
C53
J
0058
I
C54~
0054
ODso
0051
0052
0053
0
L
1D5T
CR5~
CR50
00
0
0
00
00
000
Cli
D55
o
___
I
COMPONENTS
TO
BE
REPLACED
BY
QUALIFIED
PERSONNEL
ONLY
Figure
B
-
Circuit
Card,
Timer
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
TA072
643
OM-1088
Page
4
  • Page 1 1
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  • Page 4 4
  • Page 5 5
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  • Page 14 14

Miller CS-4 Owner's manual

Miller
Brand
Miller
Model
CS-4
Category
Welding System
Type
Owner's manual
This manual is also suitable for

Miller CS-4 adds run in speed and electronically timed pre-flow, spot welding, burnback and post-flow capabilities to the Swingarc and 50 Series single and dual wire feeders. The run in speed and burnback capabilities of the CS-4 are available for both spot and continuous welding.

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