Miller Electric DWF3 manual

cover 5/94 PRINTED IN USA  1996 MILLER Electric Mfg. Co. Read and follow these instructions and all safety blocks carefully . Have only trained and qualified persons install, operate, or service this unit. Call your distributor if you do not understand the directions. Give this manual to the operator . For help, call your distributor or: MILLER [...]

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 near est distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW el[...]

sr1.1.1 2/94 ARC WELDING SAFETY PRECAUTIONS W ARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJUR Y OR DEA TH. KEEP CHILDREN A WA Y . P ACEMAKER WEARERS KEEP A W A Y UNTIL CONSUL TING YOUR DOCTOR. In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The safety information given belo[...]

sr1.1.1 2/94 WELDING can cause fire or explosion. W elding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating,[...]

! IMPORT ANT ! THIS MANUAL HAS BEEN DESIGNED FOR EXPERIENCED WELDING EQUIPMENT OPERA T ORS AND MUST BE READ COMPLETEL Y BEFORE USING THIS EQUIPMENT . IF YOU LACK EXPERIENCE OR ARE UNF AMILIAR WITH THE PRACTICES AND SAFE OPERA TION OF WELDING EQUIPMENT , PLEASE CONSUL T YOUR FOREMAN. DO NOT A TTEMPT TO INST ALL, OPERA TE, OR PERFORM MAINTENANCE ON T[...]

EMF INFORMA TION Th e following is a quotation from the General Conclusions Section of the U.S. Congress, Of fice of T echnology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields – Background Paper , OT A-BP-E-53 (W ashington, DC: U.S. Government Printing Office, May 1989): “ . . . there is now a very large volume[...]

SECTION 1 DESCRIPTION OM-179 078 1-1 1.1 INTRODUCTION Cold wire feed systems are designed for accurate application of filler wire into the weld or braze area. The DWF – 3 is designed to be used for GT AW and P AW processes. The Digital Wire Feeder System is made up of a positive feeding wire drive with a zero backlash 3 – axis wire manipulator [...]

SECTION 1 DESCRIPTION OM-179 078 1-2 Y ou may also order a combination of the wire guide mechanism, tip, conduit assembly , and conduit liner together as follows: .020 – .062 in dia. 179 165* *This includes all tips necessary for operation of .020 – .062 in dia. wire in one package. Figure 1.1, DIGIT AL WIRE FEED SYSTEM[...]

SECTION 2 INST ALLA TION OM-179 078 2-1 2.1 GENERAL SET – UP A standard DWF – 3 system is illustrated in Figure 2.1 with the necessary interconnections shown for a typical installation. The parts are listed below: DWF – 3 (.020 – .062) CONTROL UNIT 179 166 WIRE DRIVE UNIT 179 164 WIRE GUIDE ASSEMBL Y 179 165 2.2 CONTROL UNIT LOCA TION The c[...]

SECTION 2 INST ALLA TION OM-179 078 2-2 Figure 2.1, DIGIT AL WIRE FEED INST ALLA TION[...]

SECTION 2 INST ALLA TION OM-179 078 2-3 Figure 2.2, CONTROL UNIT OUTLINE[...]

SECTION 2 INST ALLA TION OM-179 078 2-4 Figure 2.3, DRIVE UNIT OUTLINE 2.4 WIRE GUIDE MOUNTING Th e guide mechanism portion of the wire guide assembly is made to accommodate a standard 1 – 3/8 in (34.9 mm) diameter machine torch barrel (see Figure 2.4). Guide tips are available for specific wire sizes from .020 in to .094 in diameter . The condui[...]

SECTION 2 INST ALLA TION OM-179 078 2-5 Figure 2.4, WIRE GUIDE ASSEMBL Y T ABLE 2.1 WIRE GUIDE ASSEMBL Y ITEM QTY P ART NMBR DESCRIPTION 11 – BODY MANIPULA TOR MACHINED 21 – PIVOT – WIRE MANIPULA TOR 31 – KNOB, VERT . ADJ – WIRE MANIPULA TOR 41 – CLAMP , WIRE MANIPULA TOR 51 – RACK – WIRE MANIPULA TOR 61 – CLAMP , T ORCH 71 – CO[...]

SECTION 2 INST ALLA TION OM-179 078 2-6 2.5 CONDUIT LENGTH ADJUSTMENT The conduit as supplied is an assembled unit 36 in (914 mm) long. If shorter lengths are desired, the conduit may be cut and reassembled according to the following steps. A) Disassemble existing fitting on one end. Save the fitting components. W rap hose with masking tape at cut [...]

SECTION 2 INST ALLA TION OM-179 078 2-7 C) Lubricate nipple and socket threads. For stainless steel fittings, use a molydisulfide base lubricant (e.g., Molykote T ype G); lubricants containing chloride are not recommended. Other material combinations use standard petroleum lubricants. Hold the nipple with hex in vise. Push hose over nipple with twi[...]

SECTION 2 INST ALLA TION OM-179 078 2-8 2.6 REMOTE CONTROLS A number of remote capabilities are available with the DWF – 3 system. On the rear panel of the control unit a connector is provided for remote operation. The remote connector , in addition to providing for the remote control connections, provides the user access to other wire feeder sig[...]

SECTION 3 OPERA TION OM-179 078 3-1 3.1 PRECAUTIONS V erify the following before connecting power to control unit. 1. Make certain the drive unit is grounded. 2. Check that all connections are secure and properly installed. All connections should be made to the torch and power supply before applying power to the control unit. 3. Should the cover of[...]

SECTION 3 OPERA TION OM-179 078 3-2 Figure 3.2, DWF – 3 REAR P ANEL ST ART DELA Y : Allows for a delay between the time a weld cycle is initiated and the time when wire feeding begins; ST ART DELA Y is presettable in 0.1 second increments, from 0.0 to 9.9 seconds. STOP DELA Y : Allows for a delay between the time when a weld cycle is terminated a[...]

SECTION 3 OPERA TION OM-179 078 3-3 indicated on the digital display; set the SPEED CONTROL selector switch to the ST ANDARD position. Positioning the MANUAL ST AR T/REMOTE ST ART switch to the MANUAL ST A RT position will now initiate a wire feed cycle. The digital display will blink during ST ART DELA Y time. At the end of ST ART DELA Y , wire wi[...]

SECTION 3 OPERA TION OM-179 078 3-4 Figure 3.3, REMOTE WIRING CABLE Th e remote start function requires a signal of +5 to 24 VDC. This signal is applied to pin C of J3. The common is from the DWF – 3 (this signal is optically isolated from the DWF – 3); therefore, the signal common need not be attached to the control unit ground. This signal wo[...]

SECTION 3 OPERA TION OM-179 078 3-5 Figure 3.5, INHIBIT FUNCTION WIRING[...]

SECTION 4 MAINTENANCE AND REP AIR OM-179 078 4-1 4.1 MAINTENANCE REQUIREMENTS The DWF – 3 wire feed system has no special scheduled maintenance requirements. However , periodic inspection of control and wire drive are helpful in preventing equipment failures. Replace any worn or broken parts found. Periodic dust and oil removal from both the cont[...]

SECTION 4 MAINTENANCE AND REP AIR OM-179 078 4-2 81 – CABLE ASSY , DWF – 3 DRIVE INTERFACE 91 – SWITCH, JOG FWD/REV OR 120/240 VOL T 10 1 179 140 CIRCUIT BREAKER ET A TYPE, 1 AMP 1 1 1 179 098 SWITCH, JOG FWD/REV 12 1 179 097 SWITCH, SPEED CONTROL ST AND/REMOTE 13 1 – POT 10K, 10 TURN SPEED CONTROL 14 1 – SWITCH, MOMENT ARY PRESS TO SET 1[...]

SECTION 4 MAINTENANCE AND REP AIR OM-179 078 4-3 4.4 DRIVE UNIT ASSEMBL Y Figure 4.2 shows an exploded view of the drive unit; user replaceable parts are listed in T able 4.2. 4.5 TROUBLESHOOTING W ARNING LINE VOL T AGE IS EXPOSED INSIDE THE CONTROL UNIT . T AKE PRECAUTION TO A VOID ELECTRIC SHOCK WHEN COVER IS REMOVED. The TROUBLESHOOTING section [...]

SECTION 4 MAINTENANCE AND REP AIR OM-179 078 4-4 TROUBLE INDICA TION REP AIR STEPS Incorrect wire feed speed. Check input signal (TP15 on Controller/Driver circuit board). Replace speed pot or circuit board if necessary . V erify that thumbscrew is fully seated. Exception: Back of f one full turn when using .020 in diameter wire. V erify that corre[...]

SECTION 4 MAINTENANCE AND REP AIR OM-179 078 4-5 18 A/R – TUBING SHRINK – BLACK 20 4 – SCREW SCH HEX 10 – 24 X .375 21 2 – SCREW CONE PT . 10 – 24 X .50 22 2 – SCREW P ANHD PHIL 6 – 32 X 3/8 23 2 – SP ACER, BEARING 0.020 THICK 24 2 – SP ACER, BEARING 0.032 THICK 25 8 – CABLE, 6 COND 22 A WG 29 1 – GUIDE, WIRE EXIT 30 1 – N[...]

SECTION 4 MAINTENANCE AND REP AIR OM-179 078 4-6 The standard setting for the DWF – 3 is 0.512 in. However , the following lengths may be obtained by inserting jumpers from P1, P2, P3, and P4 on the U12 IC Circuit to +12V and ground as shown: T ABLE 4.3 A V AILABLE RETRACT LENGTHS LENGTH DESIRED JUMPER CONNECTION TO +12 V AND GROUND FROM: INCHES [...]

SECTION 5 CIRCUIT DESCRIPTION OM-179 078 5-1 NOTE REFER TO FIGURE 5.1 ” SCHEMA TIC DIAGRAM OF DWF – 3 CONTROL UNIT ” . 5.1 SPEED CONTROL CIRCUITS There are two speed control circuits in the DWF – 3 control unit. One is for the Jog and Retract functions, and is a preset speed. The other is for wire feed during the weld cycle and this speed i[...]

SECTION 5 CIRCUIT DESCRIPTION OM-179 078 5-2 Figure 5.1, SCHEMA TIC DIAGRAM OF DWF – 3 CONTROL UNIT[...]

SECTION 5 CIRCUIT DESCRIPTION OM-179 078 5-3 Figure 5.1, SCHEMA TIC DIAGRAM OF DWF – 3 CONTROL UNIT (Continued)[...]

SECTION 5 CIRCUIT DESCRIPTION OM-179 078 5-4[...]

SECTION 5 CIRCUIT DESCRIPTION OM-179 078 5-5 Figure 5.1, SCHEMA TIC DIAGRAM OF DWF – 3 CONTROL UNIT (Continued)[...]

SECTION 5 CIRCUIT DESCRIPTION OM-179 078 5-6 1078 – 0012 Figure 5.2, DIGIT AL DISPLA Y AND DRIVER SCHEMA TIC[...]

OM-2218 Page 7 Notes[...]

Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expertise o[...]

PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Company 1635 West Spenc er St reet Applet on, W I 54914 USA International He adquarte rs – USA USA Phone: 920-735-4505 Aut o-A t t ended USA & C anada F AX: 9 20-735-4134 Int ernati onal F AX : 920-735-4125 European Headqua rters – Un[...]