Miller INTELLIMATE DW Owner's manual

Miller
Brand
Miller
Model
INTELLIMATE DW
Category
Welding System
Type
Owner's manual

This manual is also suitable for

June
1985
FORM:
OM-875
MODEL
INTELLIMATETM
DW
OWN
ERS
MANUAL
hullER
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST,
P.O.
Box
1079
APPLETON,
WI
54912
USA
IMPORTANT
Read
and
understand
the
entire
contents
of
both
this
manual
and
the
power
source
manual
used
with
this
unit,
with
special
emphasis
on
the
safety
material
throughout
both
manuals,
before
installing,
operating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equipment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
Effective
With
Style
No.
JF-22
PRINTED
IN
U.S.A.
LIMITED
WARRANTY
EFFECTIVE:
FEBRUARY
25.
1985
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
condi-
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
tions
hereof,
Miller Electric
Mfg.
Co.,
Appleton,
Wisconsin
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
~
warrants
to
its
Distributor/Dealer
that
all
new
and unused
therefore
shall
be,
at
Millers
option
(1)
repair
or
(2)
replacement
Equipment
furnished
by
Miller
is
free
from
defect
in
workman-
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
ship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
)
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
Miller
service
station
or
(4)
payment
of
or
credit
for
the
purchase
~
accessories
or
other items
manufactured
by
others.
Such
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
~
engines,
trade
accessories
and
other
items
are
sold
subject
to
retum
of
the
goods
at
Customers
risk
and
expense.
MILLERs
the
warranties
of
their
respective
manufacturers,
if
any
.
A)l
option
of
repair
or
replacement
will
be
F.O.B.,
Factory,
at
engines
are
warranted
by
their
manufacturer
for
one
year
from
Appleton,
Weconsin,
or
F.O.B.,
at
a
MILLER
authorized
service
~4
~
date
of
original
purchase,
except
Tecumseh
engines
which
facility,
therefore,
no
compensation
for
transportation
costs
of
have
a
two
year
warranty.
any
kind
will
be
allowed.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
claimant
on
the
warranty
4/
Except
as
specified
below,
Millers
warranty
does
not
apply
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,
MILLERMATIC
parts
that
come
in
contact
with
the
welding
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
,~)
wire
including
nozzles
and
nozzle
insulators
where
failure
does
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA-
r,
not
result
from
defect
in
workmanship
or
material.
TION
AS TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
Miller
shall
be
required
to
honor
warranty
claims
on
war-
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
.~
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
~
within
the
following
periods
from
the
date
of
delivery
of
Equip-
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
~
ment
to
the
original
user:
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EX
~
~:
Arl
components.
.
.
.ly:ar
CLUDED
AND
DISCLAIMED
BY
MILLER.
3.
Al
welding
guns,
feeder/guns
and
plasma
torches...
90
days
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
~
4.
All
other
Millermatic
Feeders
1
year
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
5.
Replacement
or
repair
parts,
exclusive
of
labor..
60
days
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
6.
Batteries
6
months
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE USE
AND
MAINTENANCE
OF
provided
that
Miller
is
notified
in
writing
within
thirty
(30)
days
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
of
the
date
of
such
failure.
CONSUMER
USE.
MILLERS
WARRANTIES
DO
NOT
EXTEND
submthed
by
the
onginal
user
withui
the
foregomg
periods.
MILLERS
WAR
RANTI
ES
TO,
ANY
CONSUMER.
EXTEND
,~,
~
~ ~
J~
~,
.%r I,
.~t,
J1
~.
~
,,1.
:?~,
jr
i~,
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
AMENDMENT
TO
SECTION
2
-
INSTALLATION
Amend
DIP
switch
placement
portion
of
Figure
2
-
1.
DIP
Switch
Location
And
Placement
Motor
Flash
Error
Disable
Volts
Correction
I
ntellimate
Dual
RPS-4
Switch
Trigger
Dual
Schedule
Trigger
Latch
Timed
Abort
Error
Shutdown
Amps
Display
Meters
Cycles
Arc
Hourse
Reset
Flash
Error
Enable
No
Volts
Correction
Intelliweld
DSS-9M
Switch
No
Trigger
Dual
Schedule
No
Trigger
Latch
No
Timed
Abort
Error
Blink
Only
No
Amp
Display
Inches
Seconds
No
Arc
Hours
Reset
_~!_~_~j~i
J
Low
Speed
ii
~
1
J
High
Speed
TB-107 899
Figure
2
-
1.
DIP
Switch
Placement
RLE
COPY
RETURN
IC)
~OU~
~
November
7,
1985
FORM:
OM-875
I
OJI
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I
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IQJ
16
I
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F
~Ii
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
-
INTRODUCTION
1
-
1.
General
Information
And
Safety
1
1
-
2.
Receiving-Handling
2
1
-
3.
Description
2
SECTION
2
-
INSTALLATION
2
-
1.
Changing
Dip
Switch
Positions
Inside
Intellimatic
Wire
Feeder
2
2
-
2.
Installation
Of
Interface
Control
3
2
-
3.
Interface
Cable
Connections
3
2
-
4.
115
Volts
AC
Connections
3
2
-
5.
Voltage
And
Contactor
Control
Connections
4
2
-
6.
Current
Relay
(Reed
Switch)
Connections
And
Installation
4
SECTION
3
-
OPERATION
3
-
1.
Pilot
Light
4
3
-
2.
Operation
4
3
-
3.
Shutting
Down
5
SECTION
4
-
MAINTENANCE
&
TROUBLESHOOTING
4
-
1.
Maintenance
5
4
-
2.
Overload
Protection
5
4
-
3.
Troubleshooting
5
A.
General
SECTION
1
-
INTRODUCTION
Information
presented
in
this
manual
and
on
various
labels,
tags,
and
plates
on
the
unit
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
Arc
Welding
Power
Source
in
the
welding
power
source
Owners
Manual.
Safety
instructions
specifically
pertaining
to
this
unit
ap
pear
throughout
this
manual
highlighted
by
the
signal
and
___________
which
identify
ITATL~
:
kilel
statements
include
installation,
operating,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
serious
personal
injury
or
loss
of
life.
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
CAUTION
_________
statements
include
installation,
operating,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
A
third
signal
word,
_______________
highlights
instruc
tions
which
need
special
emphasis
to
obtain
the
most
efficient
operation
of
this
equipment.
Input
Power
Weight
Net
Ship
115
Volts
AC
50/60
Hz
3
Amperes
11.38
lbs.
(5.16
kg)
12
lbs.
(5.44
kg)
Figure
1
-
1.
Specifications
1
-
1.
GENERAL
INFORMATION
AND
SAFETY
Figure
1
-
2.
Dimensions
TC-099 816
WARNING
words
different
levels
of
hazard.
CAUTION
OM-875
Page
1
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
will
be
furnished
by
the
manufacturer
on
re
quest
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
unit
is
an
interface
con
trol
that
allows
an
INTELLIMATIC
S52M
or
S54M
wire
feeder
or
INTELLIMATIC
SS-12M
or
16M
Swingarc
to
be
used
with
a
DELTAWELD
series
welding
power
source.
SECTION
2
-
INSTALLATION
2
-
1.
CHANGING
DIP
SWITCH
POSITIONS
IN
SIDE
INTELLIMATIC
WIRE
FEEDER
(Figure
2-1)
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
wire
feeder
and
welding
power
source
and
disconnect
welding
power
source
from
line
power
employing
lockout/tagging
procedures
before
internally
inspecting
or
servicing.
Lockout/tagging
procedures
consist
of
padlock-
ing
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
It
is
necessary
to
change
some
DIP
switch
posi
tions
inside
INTELLIMATIC
wire
feeder before
in
stalling
the
interface
control
so
that
proper
opera
tion
will
occur.
To
change
switch
positions,
pro
ceed
as
follows:
S
.
DIP
Switch
Locatione
On
PC3-_.~~
Motor
Place
Switches
2
And
3
To
Loft
Side
(Away
From
Board)....1~
Opposite
Of
the
Shown
Positions
RPS-4
Switch
Trigger
Dual
Schedule
Trigger
Latch
Timed
Abort
Error
Shutdown
Amps
Display
Meters
Cycles
Arc
Hours
Reset
IDJ
I
I
cni
I
ml
I~I
ImI
L~
~
I~l
I
ml
Si
Front
Of
Wire
Feeder
Standard
~
}
Low
Speed
High
Speed
Rese~ed
For
Future
Options
DSS-9M
Switch
No
Trigger
Dual
Schedule
No
Trigger
Latch
No
Timed
Abort
Error
Blink
Only
No
Amp
Display
Inches
Seconds
TB-097
552
No
Arc
Hours
Reset
I
OJI
I
ml
I
coi
IoJ
I
I
EDI
I
OJI
F
ml
I
ml
I
ml
Figure
2
-
1.
DIP
Switch
Location
And
Placement
OM-875Page2
1.
Remove
wrapper
from
wire
feeder.
4.
Tighten
wire feeder
wrapper
screws.
2.
Locate
DIP
switches
on
rear
left
side
of
interface
circuit
board
PC3
(see
Figure
2-1).
3.
Place
switches
2
and
3
on
DIP
switch
S2
to
posi
tions
away
from
circuit
board.
4.
Reinstall
wrapper
onto
wire
feeder
but
do
not
secure
top
four
screws
at
this
time.
2
-2.
INSTALLATION
OF
INTERFACE
CONTROL
(Figure
2-2)
-
This
interface
control
mounts
on
top
of
the
INTELLIMATIC
wire
feeders.
To
install
the
interface
control,
proceed
as
follows:
1.
Place
interface
control
on
top
of
wire
feeder
with
front
panels
facing
same
direction.
2.
Postion
control
so
that
the
wrapper
slots
corres
pond
to
feeder
screws
(4).
2
-
3.
INTERFACE
CABLE
CONNECTIONS
(Figure
2-2)
-
Connect
large
26-socket
amphenol
plug
from
rear
of interface
control
to
corresponding
receptacle
on
rear
of
wire
feeder,
and
rotate
threaded
collar
clockwise.
2
-
4.
115
VOLTS
AC
CONNECTIONS
(Figure
2-2)
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
The
control
will
be
electrically
hot
internally
and
ready
to
operate
as
soon
as
the
115
volts
power
plug
is
con
nected
to
the
115
volts
ac
source
and
the
welding
power
source
is
energized.
1.
Locate
supplied
10
ft.
(3.1
m)
long
interconnec
ting
coard
with
4-pin
Amp
plug
on
one
end and
3-prong,
twistlock
plug
on
other
end.
3.
Slide
control
down
onto
screws.
Figure
2
-
2.
Interface
Connections
TC-099
817
Current
Relay
(Reed
Switch);
Installs
Onto
Feeder
Base
Or
Swingarc
Control
Box
Bracket
Voltage
And
Contactor
Control
Cord
And
Plug
To
Welding
Power
Source
Interface
Cable
Connector
(26-Socket
Amphenol
Plug)
To
Wire
Feeder
Receptacle
OM-875Pege3
2.
Connect
4-pin
Amp
plug
to
corresponding
receptacle
on
rear
of
interface
control
directly
to
right
of
interface
cable
(see
Figure
2-2),
and
rotate
threaded
collar
clockwise.
3.
Route
and
connect
remaining
end
of
cord
with
3-prong,
twistlock
plug
attached
to
115
volts
ac
twistlock
receptacle
on
welding
power
source,
and
rotate
plug
clockwise.
2
-5.
VOLTAGE
AND
CONTACTOR
CONTROL
CONNECTIONS
(Figure
2-2)
1.
Locate
supplied
10
ft.
(3.1
m)
long
interconnec
ting
cord
with
6-pin
amphenol
plug
on
one
end
and
5-pin
amphenol
plug
on
other
end.
2.
Connect
6-pin
amphenol
plug
to
receptacle
on
rear
of
interface
control
directly
to
left
of
inter
face
cable
(see
Figure
2-2),
and
rotate
threaded
collar
clockwise.
3.
Route
and
connect
remaining
end
of
cord with
5-pin
amphenol
plug
attached
to
REMOTE
VOLTAGE/CONTACTOR
control
receptacle
on
front
of
welding
power
source,
and
rotate
threaded
collar
clockwise.
4.
Place
welding
power
source
REMOTE
VOLTAGE
and
REMOTE
CONTACTOR
switches
in
the
ON
positions.
2
-6.
CURRENT
RELAY
(REED
SWITCH)
CON
NECTIONS
AND
INSTALLATION
(FIgure
2-2)
1.
Locate
the
supplied
22
in.
(559
mm)
long
cord
with
current
relay
on
one
end
and
4-pin
Amp
plug
on
other
end
(see
Figure
2-2).
2.
Install
current
relay
as
follows:
a.
For
INTELLIMATIC
S52M
or
S54M
wire
feeders:
Install
current
relay
onto
feeder
base
at
provided
location
approximately
4
in.
(102
mm)
directly
to
rear
of
drive
roll
hous
ing
so
that
relay
cord
points
toward
opposite
side of
base
(toward
control
box),
and
secure
relay
with
supplied
10-32
x
3/4
in.
screws,
lock
washers,
and
nuts.
b.
For
INTELLIMATIC
SS-12M
or
16M
Sw
ingarcs:
Install
current
relay
onto
provided
location
on
control
box
bracket
between
box
and
boom
so
that
relay
cord
points
toward
control
box,
and
secure
relay
with
supplied
10-32
x
3/4
in.
screws,
lock
washers,
and
nuts.
3.
Route
and
connect
remaining
end
of
cord
with
4-pin
Amp
plug
attached
to
far
left
receptacle
on
rear
of
interface
control
(see
Figure
2-2),
and
rotate
threaded
collar
clockwise.
I~YIi~:hII~e~
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
we/ding
power
source
and
disconnect
from
line
power
employing
lockout/tagging
pro
cedures
before
routing
and
connecting
weld
cable.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
4.
Route
weld
cable
through
current
relay,
and
con
nect
cable
to
proper
terminal
on
drive
roll
hous
ing
(see
wire
feeder
Owners
Manual
for
location
of
terminal).
If
weld
cable
is
already
connected
to
feeder,
disconnect
cable,
route
through
current
relay,
and
reconnect
to
drive
roll
housing
ter
minal.
SECTION
3
-
OPERATION
WARNING
_________
ELECTRIC
SHOCK
can
kill;
MOVING
PARTS
can
cause
serious
injury.
Do
not
touch
live
electrical
parts.
Keep
clear
of
moving
parts.
The
welding
wire
and
all
metal
parts
in
contact
with
it
are
energized
while
welding.
ARC
RAYS,
SPARKS,
AND
HOT
SURFACES
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Wear
correct
eye,
ear,
and
body
protection.
FUMES
AND
GASES
can
seriously
harm
your
health.
Use
enough
ventilation
to
keep
fumes
and
gases
from
the
breathing
zone.
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.
necessaty.
See
the
Parts
List
for
part
number
of
precau
tionary
labels.
3
-
1.
PILOT
LIGHT
-
The
pilot
light
on
the
interface
control
front
panel
turns
on
and
off
as
the
welding
power
source
is
energized
and
deenergized
and
therefore
indicates
the
condition
of
the
welding
power
source
(on
or
off).
It
DOES
NOT
indicate
the
on
or
off
status
of
the
wire
feeder.
3
-2.
OPERATION
1.
Install
and
connect
unit
according
to
Section
2
of
this
manual.
2.
Turn
on
shielding
gas
at
the
source,
if
applicable.
IMPORTANT
______________
Periodically
inspect
the
labels
on
this
unit
for
legibility.
All
precautionary
labels
must
be
main
tained
in
a
clearly
readable
state
and
replaced
when
3.
Energize
welding
power
source
and
wire
feeder.
4.
Begin
welding.
OM-875
Page
4
3
-3.
SHUTTING
DOWN
2.
Turn
off
shielding
gas
supply
at
the
source.
1.
Shut
down
welding
power
source
and
wire
feeder.
L~~U~E
HIGH
CONCENTRATION
OF
SHIELDING
GASES
can
harm
health
or
kill.
Shut
off
gas
supply
when
not
in
use.
SECTION
4
-
MAINTENANCE
&
TROUBLESHOOTING
WARNING
_________
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
wire
feeder
and
welding
power
source
and
disconnect
we/ding
power
source
from
line
power
employing
lockout/tagging
procedures
be
fore
internally
inspecting
or
servicing.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
MOVING
PARTS
can
cause
serious
injury.
Keep
clear
of
moving
parts.
HOT
SURFACES
can
cause
severe
burns.
Allow
cooling
period
before
servicing.
Troubleshooting
of
internal
parts
to
be
performed
only
by
qualified
persons.
4
-
1.
MAINTENANCE
-
Usage
and
shop
conditions
will
determine
the
frequency
and
type
of
maintenance.
Inspect
equipment
as
follows:
1.
Periodically
inspect
all
interconnecting
cords
for
damage
to
or
breaks
in
the
insulation
jacket,
par
ticularly
at
the
plugs.
Repair
or
replace
the
cord(s)
as
necessary.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
This
unit
is
equipped
with
a
fuse
Fl
located
inside
the
unit
for
overload
protection
(see
Parts
List
view
for
loca
tion).
If
this
fuse
should
open,
the
unit
would
be
com
pletely
inoperative.
To
check
and
replace
the
fuse,
it
is
necessary
to
remove
the
wrapper
from
the
unit.
4
-3.
TROUBLESHOOTING
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
trouble
developed.
IMPORTANT
______________
Check
large
26-socket
interface
plug
PL
G55
connection
from
rear
of
unit
to
wire
feeder
and
be
sure
it
is
secure
in
feeder
receptacle
before
beginning
troublehsooting
procedures.
B.
Troubleshooting
Chart
2.
Remove
grease
and
grime
from
components;
moisture
from
electrical
parts
and
cable.
4
-2.
OVERLOAD
PROTECTION
The
following
chart
is
designed
to
diagnose
and
provide
remedies
for
some
of
the
troubles
that
may
develop
in
this
unit.
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
wire
feeder
and
welding
power
source
and
disconnect
welding
power
source
from
line
power
employing
lockout/tagging
procedures
before
internally
inspecting
or
servicing.
WARNING
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.
OM-875
Page
5
TROUBLE
PROBABLE
CAUSE
REMEDY
Completely
inoperative.
Fuse
Fl.
Check
and
replace
Fl
if
necessary
(see
Section
35)
*
11
5vac
plug
PLG52
not
secure
in
rear
receptacle
RC52.
Secure
PLG52
in
RC52
(see
Section
2-4).
ll5vac
cord
and/or
power
source.
Check
and
correct
ll5vac
cord/supply
problem(s).
Wire
feeder
remains
in
Run-
In
and
will
not
advance
to
the
weld
sequence.
Current
(reed)
relay
cord
not
secure
in
rear
recep
tacle
RC54.
Secure
relay
cord
to
RC54.
Weld
cable
not
routed
through
reed
relay.
Check
and
reroute
weld
cable
(see
Section
2-6).
Using
less
than
50
amperes
of
welding
current.
Increase
welding
current
to
above
50
amperes
if
possible
(50
amperes
flowing
in
weld
circuit
re
quired
for
proper
reed
relay
operation).
Voltage
and/or
contactor
control
operation
incorrect
or
erratic.
.
Voltage/contactor
control
cord
not
secure
in
rear
receptacle
RC53.
Secure
cord
to
RC53
(see
Section
2-5).
Welding
power
source
REMOTE
VOLTAGE
and
REMOTE
CONTACTOR
switches
not
in
ON
posi
tions.
Place
REMOTE
VOLTAGE
and
CONTACTOR
switches
on
welding
power
source
in
the
ON
posi
tions.
*Be
sure
replacement
fuse
is
same
size,
type,
and
rating.
OM-875
Page
6
Figure
4
-
1.
Circuit
Diagram
Circuit
Diagram
No.
B-098
425
PLG
~5
T2
70
4
2
SRI
1
1
IC,
~
I
OM-875
Page
7
PARTS
LIST
June
1985
FORM:
OM-875
Effective
With
Style
No.
JF-22
0
-J
01
-v
a,
0
CD
43
37
36
23
31
34
3332
FiJA1
TD-099
818
Figure
A
-
Main
Assembly
Item
Dia.
No.
Mkgs.
Description
Quantity
Figure
A
Main
Assembly
+098
486
1
070
634
1
Fl
*012
633
1
4
012571
1
5
SRi
035
704
1
6
098531
1
7
PLG52
048 284
1
079
534
4
8
079531
1
9
007826
lOft
10
039687
1
11
010610
1
12
098513
1
13
098578
2ft
14
082726
ift
15
091
100
1
16
PLG55
091
099
1
17
098565
1
18
073
507
1
19
073331
2
20
604910
lOft
21
039
685
1
22
039 273
1
23
049 260
1
24
057
087
1
25
010487
1
26
047
365
1
27
079
531
1
28
079
878
1
079
535
4
29
RC54
048 282
1
079
534
4
iT
038782
1
RC53
073
505
1
073
756
4
098319
1
PLG51
094
449
1
PLG5O
072
669
1
098
487
1
074
188
1
048
283
1
079 535
4
601
375
1
048
504
1
098510
1
084
199
1
*Recommended
Spare
Parts
+
When
ordering
a
component
originally
displaying
a
precautionary
label
the
label
should
also
be
ordered.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Part
No.
2
3
WRAPPER
LABEL,
warning
electric
shock
can
kill
etc
FUSE,
miniature-glass
sb
blo
3
amp
HOLDER,
fuse
RECTIFIER,
integrated
30
amp
600
volts
CORD,
power
(consisting
of)
HOUSING
PLUG
&
SOCKETS
(consisting
of)
TERMINAL,
female
CLAMP,
cable
CORD,
No.
183/c
(order
byft)
CAP,
twistlock-grounded
2P3W
15
amp
277
volts
CONNECTOR,
clamp-cable
1/2
inch
CORD,
interconnecting
(consisting
of)
CABLE,
power
18
gal5/c
300
volts
(order
byft)
.TUBING,
No.11
(orderbyft)
CLAMP,
cable
PLUG,
26
socket
MS-3108B-28-12S
CORD,
voltage/contactor
control
(consisting
of)
PLUG,
6
socket
MS-3106A-18-12S
CLAMP,
cable
CABLE,
power
20
ga
5/c
(order
by
ft)
CLAMP,
cable
PLUG,
5
pin
MS-3106A-16S
8P
RELAY,
current
(consisting
of)
CORE,
relay-current
FITTING,
brass-compression
union
1/4
TBG
SWITCH,
reed
(consisting
of)
CLAMP,
cable
HOUSING
PLUG
&
PINS
(consisting
of)
TERMINAL,
male
RECEPTACLE
W/SOCKETS
(consisting
of)
TERMINAL,
female
BLOCK,
terminal
20
amp
10
pole
RECEPTACLE,
6
pin
MS-3102A-18-12P
STAND-OFF,
No.
6-32
x
5/8
CIRCUIT
CARD,
interface
(Fig
Al
Pg
4)
HOUSING,
terminal
header
5
socket
HOUSING,
terminal
header
9
pin
CASE
SECTION,
front/bottom/rear
NAMEPLATE
(order
by
model
&
serial
number)
LIGHT,
neon-red
lens
RECEPTACLE
W/
PINS
(consisting
of)
TERMINAL,
male
CLAMP,
capacitor
1-3/8
CAPACITOR,
electrolyte
5000
uf
50
volts
TRANSFORMER,
control
TRANSFORMER,
signal
16VCT
3.5
amp
30
31
32
33
34
35
36
37
38
39
PL1
RC52
Cl
40
41
42
43
OM-875
Page2
COMPONENTS
TO
BE
REPLACED
BY
QUALIFIED
PERSONNEL
ONLY
Figure
Al
-
Circuit
Card,
Interface
_(V)N~
Q
RI~
I,
I
R16-
C8
C3
____1C15
A
B
C
D
E
F
G
H
J
0
If)
U
0
(0
U
RC5I
VRI
R17
0
R4
I
I
____
.
R31__
RI
1
1
Q3
QI
L1I~R2
~
1
ASSY
098319
Ret:
B-098
321
OM-875
Page
3
Part
No.
Description
CORD,
voltage/contactor
control
(consisting
of)
.
PLUG,5pinMS-3106A-16S-1P
RECEPTACLE,
5
socket
MS-3101A-16S-8S
CLAMP,
cable
CABLE,
power
20
ga
5/c
(order
by
ft)
25
FT
EXTENSION
CABLE
(consisting
of)
RECEPTACLE
W/PINS
(consisting
of)
TERMINAL,
male
CLAMP,
cable
29/64
CORD,
No.
184/c
(order
byft)
HOUSING
PLUG
&
SOCKETS
(consisting
of)
TERMINAL,
female
TOOL,
extraction
pin
Quantity
2
25ft
4
2
25ft
1
4
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Dia.
Mkgs.
Description
Quantity
Figure
Al
098 319
Circuit
Card,
Interface
(Fig
A
Pg
2
Item
33)
C2,3
000
339
CAPACITOR,
electrolyte
220
uf
50
volts
dc
2
C5,6,9,10,15
073
739
CAPACITOR,
ceramic0.1
uf50voltsdc
5
C7
089 025
CAPACITOR,
ceramic
470
pf
100
volts
dc
1
C8
053
992
CAPACITOR,
ceramic
0.001
uf
1000
volts
1
C11,12,14
000
340
CAPACITOR,ceramic0.0i
uf
50
volts
3
C13
000 348
CAPACITOR,
tantalum
0.47
uf
35
volts
1
Dl
-4
026 202
DIODE,
1
amp
400
volts
SP
4
D5
028
351
DIODE,
signal
0.020
amp
75
volts
SP
1
OC1
047
034
IC,
interface
4N26
1
OC2
000
041
IC,
interface
4N32
1
Q1-3
037
200
TRANSISTOR,200MA4OvoItsNPN
3
Ri
039
331
RESISTOR,
carbon
film
0.25
watt
4.7K
ohm
1
R2
035 888
RESISTOR,
carbon
film
0.25
watt
2.2K
ohm
1
R3
081
833
RESISTOR,
carbon
film
2.7
meg
ohm
1
R4
078
431
RESISTOR,
carbon
0.25
watt
330
ohm
1
AS
009
173
POTENTIOMETER,
cermet20
turn
0.5
watt
5K
ohm
1
R6 044
789
RESISTOR,
carbon
film
0.25
watt
lOOK
ohm
1
R7
089
173
RESISTOR,
metal
film
0.25
watt
4.99K
ohm
1
R8,12
035
827
RESISTOR,
carbon
film
0.25
watt
10K
ohm
2
R9
035
885
RESISTOR,
carbon
film
0.25
watt
68K
ohm
1
RiO
035
824
RESISTOR,
carbon
film
0.25
watt
270
ohm
1
Ru
089
172
RESISTOR,
metalfilm0.25watt6.8lKohm
1
R13,15
035 825
RESISTOR,
carbon
film
0.25
watt
1K
ohm
2
R14
035
820
RESISTOR,
carbon
film
0.50
watt
470
ohm
1
R16
039
334
RESISTOR,carbonfilm0.2Swatt27Kohm
2
R17
003
272
RESISTOR,
carbon
film
0.25
watt
1
meg
ohm
1
RC5O
072 670
TERMINAL,
header
9
pin
1
RC51
093
707
TERMINAL,
header
5
pin
1
Ui
089
068
IC,
interface
331
1
VR1
081
832
IC,linear78Ml5
1
Optional
Equipment
Part
No.
099
308
039
273
052
654
039
685
604 910
047
813
046
958
079
535
079
531
604
571
048 284
079
534
048
471
OM-875
Page
4
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Miller INTELLIMATE DW Owner's manual

Miller
Brand
Miller
Model
INTELLIMATE DW
Category
Welding System
Type
Owner's manual
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