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Miller Electric WC-115A manual

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Table of contents for the manual

  • Page 1

    Processes Description MIG (GMAW) W elding W eld Control For Spoolmatic Gun OM-1078 142 862L March 2005 WC − 1 15A Visit our website at www.MillerWelds.com[...]

  • Page 2

    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 .MillerW eld[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-1078 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown i n the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means W arning! Watch Ou[...]

  • Page 6

    OM-1078 Page 2 Arc rays from the w elding 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 Z49.1 and Z[...]

  • Page 7

    OM-1078 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. F [...]

  • Page 8

    OM-1078 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American W elding Society , 550 N.W . LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www .aws.org). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Weld[...]

  • Page 9

    OM-1078 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE A V ANT UTILISA TION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Y Identifie un message de sécurité particulier . . Signifie « NOT[...]

  • Page 10

    OM-1078 Page 6 Le rayonnement de l’arc génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) suscep- tibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage. LES RA YONS DE L ’ARC peuvent cau- ser des brûlures oculaires et cuta- nées. D Porter un masque de soudage m[...]

  • Page 11

    OM-1078 Page 7 2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- SION D Ne pas placer l’appareil sur une surface inflam- mable, ni au − dessus ou à proximité d’elle. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surch[...]

  • Page 12

    OM-1078 Page 8 2-4. Principales normes de sécurité Safety in W elding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American W elding Society , 550 N.W . LeJeune Rd, Miami FL 33126 (téléphone : (305) 443 − 9353, site Web : www .aws.org). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Pip[...]

  • Page 13

    OM-1078 Page 9 SECTION 3 − INST ALLA TION 3-1. Specifications AC Input Power 1-Phase W elding Power Source T ype DC Output For Control Circuit W eld Circuit Rating Overall Dimensions W eight 1 15 V olts, 2 Amperes, 50/60 Or 100 Hz Constant Current (CC) Or Constant V oltage (CV) DC, With Or Without Contactor 30 V olts 100 V olts, 200 Amperes, 100%[...]

  • Page 14

    OM-1078 Page 10 3-4. Gun/Feeder Connections Ref. 149 966-C / Ref. 149 549-B / Ref. S-0621-C 1 Gun Control Receptacle 2 Weld Power Grommet 3 Regulator/Flowmeter 4 Gas Fitting T ools Needed: 5/8, 3/4 in Left Side W rapper Of f 1 4 2 2 3[...]

  • Page 15

    OM-1078 Page 1 1 3-5. Installing V oltage Sensing Lead And Motor Start Control Adjustment 150 035-B / Ref. 143 328-K / 149 920-B 1 Center Baffle 2 Circuit Board PC1 3 Jumper Plug 4 Receptacle RC3 Internal (INT) and external (EXT) are stamped on PC1 just above RC3. Unit is shipped with jumper plug in internal (INT) position. T o install voltage sens[...]

  • Page 16

    OM-1078 Page 12 3-6. W eld Cable Connections 149 920-A / 151 1 13 / 801 487-A / Ref. 139 439-B 1 Grommet 2 Positive (+) W eld Output T erminal On W elding Power Source 3 Reed Switch 4 W eld Cable (Customer Supplied) 5 Weld Cable T erminal 6 Weld Power Cable From Gun/Feeder 7 Weld Power Grommet Route weld cable and weld power cable as shown. Be sure[...]

  • Page 17

    OM-1078 Page 13 3-8. Optional Connections For Input Power From Welding Power Source Ref. 149 548-B / 150 078-A / Ref. S-0512 1 Input Power Cord And Plug PLG4 Cut plug off. 2 Individual Leads Strip a small amount of insulation from cord and from each of the three leads. 3 Pins (Part No. 134 731, Not Supplied) Crimp a supplied pin to each of the thre[...]

  • Page 18

    OM-1078 Page 14 3-9. Contact Closure Connections A. 14-Pin Plug Information For Standard Contact Closure Connections Pin* Pin Information A J B K I A Contact output signal. C L N H D M G E F B Input control to energize weld contactor . Contact closure to A completes 24 volts ac contactor control circuit. *The remaining pins are not used. B. Optiona[...]

  • Page 19

    OM-1078 Page 15 C. Optional Contact Closure Connections For Welding Power Sources Requiring Contact Closure 151 325 1 Contact Closure Interconnecting Cord 2 14-Pin Plug PLG5 Cut plug off. 3 T wistlock Plug (Part No. 039618 Or Hubbell 7102-CM4 Or Equivalent) Install customer-supplied twistlock plug onto contact closure interconnecting cord. Polarity[...]

  • Page 20

    OM-1078 Page 16 3-10. T ypical MIG Connections And Settings Using Weld Control And Spoolgun 802 750 / 200 017 . This section provides general guide- lines and may not suit all applications. 1 Weld Control 2 Spoolgun 3 Optional Contactor (Recommended) 4 Reed Switch 5 Weld Cable (Customer-Supplied) 6 Weld Control W eld T erminal 7 Weld Power Cable Fr[...]

  • Page 21

    OM-1078 Page 17 SECTION 4 − OPERA TION 4-1. 1 15 V olt Model Controls wfcontrols_1 1/96 / Ref. 144 451-D 1 Run-In Speed Control Use control to select welding wire speed before arc initiation. After arc initiation, the wire feed speed is controlled by the Wire Speed control on the gun/feeder . 2 Power Switch Use switch to turn unit On and Off. 1 2[...]

  • Page 22

    OM-1078 Page 18 5-1. Overload Protection Ref. 144 451-D / Ref. 800 185-A If fuse F1 opens, the weld control shuts down. T o check or change F1, proceed as follows: 1 Fuse Holder Cover 2 Fuse (See Parts List For Fuse Size) 1 2 Push And Turn Pull Out And Replace F1 Push And T ur n 5-2. T roubleshooting T rouble Remedy Pressing gun trigger does not en[...]

  • Page 23

    OM-1078 Page 19 SECTION 6 − ELECTRICAL DIAGRAM 207 834 Figure 6-1. Circuit Diagram[...]

  • Page 24

    OM-1078 Page 20 SECTION 7 − P ARTS LIST Figure 7-1. Complete Assembly Of WC-1 15A 2 3 4 5 6 7 8 9 10 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 29 30 29 33 34 38 143 328-K 11 13 28 31 32 35 . Hardware is common and not available unless listed. 37 1 36[...]

  • Page 25

    OM-1078 Page 21 Description Quantity Part No. Dia. Mkgs. Item No. Figure 7-1. Complete Assembly Of WC-1 15A 1 126 415 Clamp, Saddle 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 126 416 Handle 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 26

    OM-1078 Page 22 Notes[...]

  • Page 27

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 1/05 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[...]

  • Page 28

    PRINTED IN USA © 2005 Miller Electric Mfg. Co. 1/05 Miller Elect ric Mfg. Co. An Illinois T ool Wor k s Comp any 1635 W es t Spencer St reet Applet on, WI 5 4914 USA International He adquarters − US A USA Phone: 920-735-4505 Aut o-Att ended USA & Canada F AX : 920-735-4134 Int ernational F A X: 920-735-4125 European Headqua rters − United [...]