Instruction/ maintenance manual of the product OM-842 Miller Electric
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Processes Description TIG (GT A W ) W elding Stick (SMA W) W elding Programmable Precision Controller For W elding Power Source OM-842 162074B August 1997 Intellitig MPC Visit our website at www.
Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .
The following terms are used interchangeably throughout this manual: TIG = GT AW Stick = SMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . .
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OM-842 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message.
OM-842 Page 2 Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.
OM-842 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit.
OM-842 Page 4 1-5. EMF Information Considerations About Welding And The Ef fects Of Low Frequency Electric A n d M a g netic Fields W elding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields.
OM-842 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives.
OM-842 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage.
OM-842 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance Risque D ’ INCENDIE OU D ’ EXPLOSION. D Ne pas placer l ’ appareil sur , au-dessus ou à proxi- mit é de surfaces infllammables.
OM-842 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American W el- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.
OM-842 Page 9 SECTION 2 – INST ALLA TION 2-1. Connecting Remote Pendant Or Equivalent User-Wired Control A user-wired equivalent to the remote pendant may be connected to the control unit. However , connections must be made for a Stop push button even if it is not used in unit operation.
OM-842 Page 10 2-3. User Relay Contacts Ref. ST-162 477-A / ST -162 841 / Ref. SC-159 862 1 Access Door Access door is hinged at top, and held closed with industrial interlock strips.
OM-842 Page 1 1 2-4. Setting DIP Switch SW1 Ref. ST-800 194 / Ref. ST -162 477-A Set DIP switch SW1 rocker switch positions as follows: 1 Control Box Front Panel 2 Retaining Screw Location Loosen retaining screw , and open hinged front panel.
OM-842 Page 12 SECTION 3 – OPERA TION 3-1. Controls 1 V oltmeter 2 Ammeter 3 Digital Display 4 Left/Decrease Button 5 Right/Increase Button 6 Parameter Select Button 7 Purge Button 8 Mode Switch 9 Program/Run/Reset Keyed Switch 10 Remote Pendant Ref.
OM-842 Page 13 3-4. Ammeter And V oltmeter 1 Ammeter Meter displays weld amperage out- put of unit when welding. 2 V oltmeter V oltmeter displays voltage at the weld output terminals, but not nec- essarily the welding arc due to cable resistance, poor connec- tions, etc.
OM-842 Page 14 3-7. Program/Run/Reset Keyed Switch 1 Program/Run/Reset Keyed Switch Program Use to enter , change, and/or ex- ecute a program. Run Us e to execute a program only. Ke y can be removed to prevent unau- thorized access to program. Reset Us e before switching between Run/ Program positions when unit is On.
OM-842 Page 15 3-1 1. Purge Push Button 1 Purge Push Button Press switch to momentarily ener- gize gas valve and purge air from torch shielding gas line, and to allow shielding gas regulator to be ad- justed without energizing the weld- ing circuit. Switch is only active when the re- peating displays are shown.
OM-842 Page 16 SECTION 4 – INTRODUCTION T O PROGRAMMING 4-1. General Programs are created when parameters are defined in a series of displays. Up to four programs can be entered into each of the four modes of operation, for a total of sixteen programs.
OM-842 Page 17 4-4. Modes Of Operation The microprocessor control has four modes of operation: Automatic, Semi-Automatic, Manual GT AW , and SMA W . In abbreviated form, the modes function as follows: A. Automatic Mode Sequence Ref. SB-139 983 In this mode, the program controls each step of the weld sequence.
OM-842 Page 18 Ref. SB-139 983 In this mode, time values are not de- fined for initial current, weld/peak current, and final current. The micro- processor control operates in a mo - mentary-contact, single button for- mat.
OM-842 Page 19 In this mode, time values are not de- fined for initial current, initial slope, weld/peak current, and final slope. The operator uses the Start/In- crease and Decrease push buttons to vary the weld current level once initial current starts.
OM-842 Page 20 Ref. SB-139 983 In this mode, a single momentary closure of the Start/Increase push button starts the sequence. The pro- gram continues through the pro- grammed sequence of events until weld/peak current.
OM-842 Page 21 SECTION 5 – PROGRAMMING 5-1. General A. Displays The displays presented by the microprocessor control either provide information to the user , or allow the user to enter infor- mation needed for program execution. The displays vary from mode to mode.
OM-842 Page 22 Th e program number in a display can be increased by pressing Parameter Select while any of the repeating displays are shown. Thi s allows other programs to be accessed. NOTE 1. Th e first repeating display indicates the program num- ber and that the microprocessor control is ready for program execution.
OM-842 Page 23 1 1. If applicable, define the program number (see Section 5-1C). Define the shielding gas preflow time as desired. The range for preflow is 0.0 to 25.0 seconds, in incre- ments of 0.1 seconds. 12. Press Right/Increase, and the display shows: # 0 X ST ART L EVE L T I ME =.
OM-842 Page 24 5. Define the peak time and background time values as desired. Peak time is the length of time the pulse is at the peak level. Background time is the length of time the pulse is at the background level. The ranges for both peak and background times are 0.
OM-842 Page 25 7. Press Right/Increase, and the display shows: #0 X W I R E – F E ED S T ART D E L AY = XX . X SE C . 8. Define the wire feed start delay as desired. Wire feed start delay is the amount of time between the end of initial current and when the wire feed user relay (see Section 2-3) changes states.
OM-842 Page 26 If the Process Selector switch is in a dc output position, the choices are Start Only high frequency or Disabled high frequency . 10. When the desired choice is shown, press Right/In- crease to advance to the next display . The display shows: #0 X P R E FL O W TI M E = X X .
OM-842 Page 27 The ranges for both ApK and AbK are 2.0 to 400 am- peres, in increments of 1.0 ampere. 3. Press Right/Increase, and the display shows: # 0 X PEAK T I M E =X . X X B A C K T I M E = X .X X 4. Define the peak time and background time as desired.
OM-842 Page 28 5. Press Right/Increase, and the display shows: #0 X P O S T FL O W TI M E = X X . X 6. Define the shielding gas postflow time as desired. The range for postflow is 0.0 to 25.0 seconds, in incre- ments of 0.1 seconds. 7. Press Right/Increase, and the display shows: #0 X W I R E – F E ED S T ART D E L AY = XX .
OM-842 Page 29 8. Press Right/Increase. The microprocessor control will enter the Ready condition. 9. In the Ready condition the microprocessor control is ready to have another program entered or to execute a program. For information on executing a program, see Section 6.
OM-842 Page 30 #0 X W EL D A M PS =XXX . X b. Define the weld current as desired. Th e range for weld current varies from 2.0 to 400.0 amps, in increments of 1.0 amperes. c. Press Right/Increase, and go to Section 5-4D. B. Procedure With Pulse Mode On, Pulses Defined In Time V alues 1.
OM-842 Page 31 5-5. SMA W Mode If needed, see Section 5-1B f o r information o n selecting and defining a parameter. NOTE 1. Turn on welding power source, if applicable. 2. Place the Mode Selector switch in the SMA W position. 3. Place the Program/Run/Reset keyed switch in the Re- set position, and then in the Program position.
OM-842 Page 32 5-7. Dry Run Feature Th e Dry Run feature allows a program to be verified by execut- ing it without actually establishing an arc. All timing and contact closures are performed without gas, high frequency , or power source contactor being activated.
OM-842 Page 33 Reset follows Program Number 04. T o assign Reset to a Link position, select the function and press Right/In- crease repeatedly to go beyond Program Number 04. T o assign a number when Reset is displayed, select Reset and press Left/Decrease.
OM-842 Page 34 Right/Increase repeatedly to go beyond Program Number 04. T o assign a number when Reset is dis- played, select Reset and press Left/Decrease. If four program s are combined together , it is not necessary for the user to assign a reset.
OM-842 Page 35 10 . Wea r welding helmet with proper filter lens according t o ANSI Z49.1. 1 1. Be sure applicable remote control device is connected as follows: a. Semi-Automatic 1 Mode: Connect Remote Pendant to Remote 4 receptacle RC2. b. Semi-Automatic 2 Mode: Connect Remote Pendant to Remote 4 receptacle RC2.
OM-842 Page 36 control unit maintains the programmed initial current value. Program execution at this point varies according to whether pulsing is enabled or disabled. G o to Step 2 if pulsing is enabled, and Step 3 if pulsing is disabled. 2. When pulsing is enabled: a.
OM-842 Page 37 12. Enter th e R e a d y c o n d i tion (see Section 5-1F). The op- erator now has control of the welding power source contactor via the remote contactor control connected to the Remote 14 receptacle. 13. Start welding as follows: a. Be sure the desired program is active before ex- ecuting a program.
OM-842 Page 38 2. Turn of f welding power source. 3. Turn of f shielding gas supply at the source, if applica- ble. 6-8. Overheating Protection If the unit overheats, the weld sequence goes to postflow and the contactor is deenergized.
OM-842 Page 39 7-2. Diagnostics Program When the diagnostics program starts, the following series of in - formational displays is shown: * S Y NCRO W A V E 3 5 1 * DI A G N O S T I C P R O G R A M TH E FOL LO W I N G PR O G RA M W I L L CHECK YOUR UN I T T O V ER I F Y TH A T I T I S F UNC T I O N I NG PR O P ER L Y A.
OM-842 Page 40 6. If the Left/Decrease push button is not pressed in time, or if the push button is not working correctly , the follow- ing displays appear: ER R O R L E F T BU T TO N I S NO T W OR K .
OM-842 Page 41 position. I f this is done in time and the position is work- ing correctly , the display shows: RUN POS I T I ON IS W O R KIN G P R O P E R L Y If the Run position tests okay , go to Step 5.
OM-842 Page 42 4. I f the Mode Selector switch is not placed in the SMA W position in time, or if the position is not working correct- ly , the display shows: ER R O R ! ! S M A W – MA N U A L I S NO T W OR K I NG If the SMAW position is not working correctly , replace the Mode Selector switch.
OM-842 Page 43 is done in time and the push button is working correctly , the display shows: BUT T O N I S WO R K I N G P R O P E R L Y If the Purge push button tests okay , go to Step 5.
OM-842 Page 44 J. Background Relay T est This procedure tests the internal dc background current source. 1. When the repeating test displays are shown (see Sec- tion 7-2C), press Right/Increase or Left/Decrease until the display shows: B A C K GROU ND RE L A Y T E S T 2.
OM-842 Page 45 0 Ohms OL AB C Figure 7-1. T esting Energized User Relay 4. If the relay is working correctly , the VOM reads the re- sistances shown. In this case, go to Step 5. If the VOM does not read the resistances shown while the relay is energized, contact the nearest Factory Au- thorized Service Station/Service Distributor .
OM-842 Page 46 7. I f the Decrease push button is not pressed in time, or if the Decrease push button is not working correctly , the display shows: BUT T O N I S N O T WO R K I N G P R O P E R L Y If the Decrease push button is not working correctly , r e - place the push button.
OM-842 Page 47 3. When this display appears, the control unit waits three seconds for the specified contact closure. If this is done in time and the solid state contactor is working correct- ly , the display shows: I N P U T CON T A C T OR IS D E T E C T E D If the input contactor detection circuitry tests okay , g o t o Step 5.
OM-842 Page 48 SECTION 8 – ELECTRICAL DIAGRAMS SA-132 263 Figure 8-1. Circuit Diagram For Remote Pendant.
OM-842 Page 49 Figure 8-2. Wiring Diagram For MPC Module SC-161 093-B.
OM-842 Page 50 Figure 8-3. Circuit Diagram For Welding Power Source And MPC.
OM-842 Page 51 SC-182 947-B.
OM-842 Page 52 SECTION 9 – P ARTS LIST 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 9 23 24 25 27 28 29 30 32 35 33 34 36 38 39 13 31 17 Figure 9-1.
OM-842 Page 53 Quantity Description Part No. Dia. Mkgs. Item No. Figure 9-1. Main Assembly 1 NAMEPLA TE, (order by model and serial number) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 158 955 COVER, front electrical 1 .
OM-842 Page 54 Quantity Description Part No. Dia. Mkgs. 132 064 Item No. Figure 9-2. Pendant 1 079 725 GUARD, switch al knurled 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 NAMEPLA TE, (order by model and serial number) 1 .
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PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Com pany 1635 W est S pencer St reet Applet on, WI 54914 USA International He adquarters –.
An important point after buying a device Miller Electric OM-842 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric OM-842 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric OM-842 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric OM-842 you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric OM-842 will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric OM-842, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric OM-842.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric OM-842. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric OM-842 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
