Miller | HK49 | Owner Manual | Miller PRC-2 User manual

Miller PRC-2 User manual
December 1983
FORM: OM-864
Effective With Style No. HK49
01
MODEL
PRC-2
OWN ERS
MANUAL
fullER
MILLER ELECTRIC MFG. CO.
718 S. BOUNDS ST. P.O. Box 1079
APPLETON, WI 54912 USA
ADDITIONAL COPY PRICE 25 CENTS
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.
1
LIMITED WARRANTY-Subject to the terms and conditions
hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants
to its Distributor/Dealer that all new and unused Equipment
furnished by Miller is free from defect in workmanship and
material as of the time and place of delivery by Miller. No warranty is made by Miller with respect to engines, trade accessories or other items manufactured by others. Such
engines, trade accessories and other items are sold sublect to
All
the warranties of their respective manufacturers, if any
engines are warranted by their manufacturer for one year from
date of original purchase.
As
In the
Equipment
required
to
within the
ment to
honor warranty claims
resulting from
on
in the event of failure
following periods
the original user:
from the date of
delivery
of Millers
case
within the
user
may
honor claims
foregoing periods.
breach of warranty or any other duty
any goods, the exclusive remedies
quality of
option (1) repair or 12) replacement
Miller in appropriate cases, (31
the reasonable cost of repair or replacement at an authorized
Miller service station or (4) payment of or credit for the purchase
price (less reasonable depreciation based upon actual usel upon
risk and expense. Upon receipt
return of the goods at Customers
of notice of apparent defect or failure, Miller shall instruct the claimant on the warranty claim procedures to be followed.
therefore shall be,
as
Miller shall be
original
at
Millers
or, where authorized in
specified below, Millers warranty does not apply
to components having normal useful life of less than one Ill
year, such as spot welder tips, relay and conlactor points,
M!LLERMATIC parts that come in contact with the welding
wire including nozzles and nozzle insulators where failure does
not result from defect in workmanship or material.
ranted
general policy only, Miller
of
matter
with respect to the
.
Except
a
submitted by the
writing by
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
GUARANTY OR REPRESENTA-
ANY IMPLIED WARRANTY,
2.
war-
AS
TO
a
defect
ANY
of
Equip-
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
IMPLIED WARRANTY OF MERCHANTABILITY OR
OF
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX
Arc welders, power sources and components
Original main power rectifiers
(labor
3.
-
1 year
.
.
3 years
EXCEPT
WRITING,
All
welding guns and feeder/guns
All other Millermatic Feeders
5.
Replacement
6.
Batteries
90 days
ULTIMATE
1 year
repair parts, exclusive of labor
.
AS
EXPRESSLY
MILLER
BY
PURCHASE
notified in
writing
within
ARE
BY
MILLER
INTENDED
60 days
EXPERIENCED
WELDING
thirty 1301 days
TO,
~ :f ti :0f:hJ~
COMMERCIAL/INDUSTRIAL
IN
USE
THE
EQUIPMENT
AND
AND
NO
RESELLER
AND
NOT
MAINTENANCE
FOR
CONSUMERS
~
OF
OR
WARRANTIES DO NOT EXTEND
IS
AUTHORIZED
TO
:LLE~:ARR:T:STIA:CO:U:ER~
~
IN
FOR
USERS AND FOR OPERATION BY PERSONS TRAINED AND
6months
is
PROVIDED
PRODUCTS
CONSUMER USE. MILLER
provided that Miller
1
1 year
onlyl
4.
or
?
PERFORMANCE, AND ANY REMEDY FOR
BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION.
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
TION
CLUDED AND DISCLAIMED BY MILLER.
1.
~
EXTEND
SECTION 1
GENERAL
1-1.
-
This
has
manual
been
INTRODUCTION
-
prepared
especially for use in familiarizing personnel with the
design, installation, operation, maintenance, and
troubleshooting of this equipment. All information
presented herein and on various labels, tags, and plates
on the unit should be given careful consideration to
assure optimum performance of this equipment.
RECEIVING-HANDLING
1-2.
-
Prior
to
installing
equipment, clean all packing material from around
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
this
the unit and
to file
quest if occasion
This remote control is
digital
controls
for
NOMENCLATURE
1-4.
tacle labeled A
on
The terminals
-
the remote control
concerning this equip
is essential that Model Description and Style
of the equipment be supplied.
requesting
ment, it
Number
1-5.
SAFETY
operation,
-
Before
the
safety section
the
equipment
-
This remote control
provides
a
polarity on each of two electrode wires when
using a dual digital wire feeder, optional dual digital
voltage control, optional digital dual schedule control,
and one welding power source.
separate
is
put
at the front of the
the
into
welding
welding applications.
following definitions apply
~ULI~1~(
operating,
hazard
to
CAUTION, IMPOR
this
heading,
and maintenance
procedures
Under
carefully
or
this manual:
installation,
practices will
followed may create
a
personnel.
I I~ I ~i] ~I f~ If Under
operating,
to
this
and maintenance
be found that if not
damage
to
throughout
information
DESCRIPTION
to
power source manual should be read completely. This
will help avoid possible injury due to misuse or improper
be found that if not
1-3.
recep
and associated connections and controls.
TANT and NOTE blocks found
When
and
correspond
Left gun and associated connections and controls while
B receptacle and terminals correspond to the Right gun
The
claim arises.
designed specifically
for use with
Gas Metal-Arc Welding
(GMAW) and Flux Cored-Arc Welding (FCAW).
dual
heading,
procedures
carefully
or
installation,
practices will
followed may result
in
equipment.
equipped with contactors to provide cold
~ Under this heading, explanatory statements
(electrically deenergized) conditions on the inactive
will be found that need special emphasis to obtain the
gun when both guns are connected for the same polarmost efficient operation of the equipment.
ity.
SECTION 2
INSTALLATION
This unit is
wire
-
LOCATION
2-1.
-
This unit
can
be mounted
using an optional mounting bracket
Swingpac base, if applicable.
boom
or
on
on
the
the
Attach the unit to the
If the unit is to be mounted
tion the unit
on
on
the base and
mounting
the
position
P/acing
does not
the POWER switch in the OFF
remove
power from all of the wire
circuitry. Completely terminate all elec
trical power to the wire feeder by removing the 115
volts ac plug from its power supply, and ensure that
machinery lockout procedures have been employed
on the welding power sources
input line (see Instruc
tion Manual on welding power source) before attemp
ting any inspection or work inside the unit.
feeder internal
If the unit is to be boom-mounted, the mounting
bracket must be installed to the boom swivel base.
Remove the hub and reel support, position the moun
ting bracket, replace the hub and reel support, and
secure.
L~1UI I
bracket.
Swingpac base, posi
secure.
115 Volts AC
2-2.
WIRE
digital
FEEDER
MODIFICATION
-
The
dual
Interconnecting
Cord
wire feeder is
shipped from the factory wired for
use with one welding power source. In order for the
polarity reversing control to function properly, the dual
digital wire feeder must be modified to operate as if two
welding power sources are in use.
Left
Interconnecting
cord
Right
Interconnecting
Cord
IMPORTANT
Damage
to
equipment
will result if the
_______________
dual
digital
power
with
wire feeder is wired for
use
with
one
we/ding
and used when the system is connected
gun straight polarity and the other gun reverse
source
one
Left
polarity.
Secondary
Terminals
Through minor modification,
cuitry of the wire feeder
welding power sources.
1.
can
the contactor control cir
be adapted to operate two
Disconnect power from wire feeder.
Right Secondary
Figure
2-1.
Terminals
Component
Location
OM-864
Page
1
Remove the wrapper from the control box
2.
on
the
2-5.
SECONDARY
2-2, 2-3, 2-4)
wire feeder.
-
terminals provide
3.
Locate terminal
strip
11
on
baffle in the wire
CONNECTIONS
(Figures 2-1.
interconnecting
point for cables carrying
The LEFT and RIGHT
a
connection
weld output current.
feeder.
Several different weld conditions
Disconnect lead No. 39 from terminal K
4.
minal
5.
strip
Replace
on
ter
iT and reconnect it to terminal E.
are
available when
us
ing the polarity reversing control with the dual digital
controls. See the following instructions and connection
diagrams before making the secondary connections.
wrapper.
I~IsIH~
making any connections between
the PRC unit and any other controls, ensure that all
equipment is deenergized. Completely terminate all
CAUTION: Before
Interconnecting
weld cables
boom mounted wire feeders.
are
supplied with
These cables extend out
_______
electrical power to the wire feeder by removing the 115
volts ac plug from its power supply, and ensure that
lockout procedures have been employed
power sources input lines.
machinery
on
the
welding
the back of the boom.
DVC TO PRC CONNECTION (Figures 2-1, 2-2,
The Wire Feed Control plug from the DVC
unit plugs into the receptacle on the end of the 115
VOLTS AC interconnecting cord from the PRC unit.
2-3, 2-4)
-
Align keyways, insert plug into
threaded collar clockwise.
receptacle and
rotate
connecting the Left
connecting the Right gun
All bench mounted wire feeders
plied interconnecting cables.
require
Refer
customer sup
to
the
welding
Owners
Manual for proper cable sizes.
These cables must be connected to the appropriate gun
weld cable terminal at the drive assembly.
power
2-3.
The cable
gun is/abe/ed LEFT; the cable
is not labeled.
source
All other cable
cables
or
weld current (such
carrying
be of
adequate current
ticipated maximum load.
PRC TO CONTROL/FEEDER CONNECTIONS
(Figures 2-1, 2-2, 2-3, 2-4) The LEFT interconnec
ting cord from the PRC unit plugs into the 115
as
jumper
cab/es from the
we/ding power source) must
carrying capacity for the an
2-4.
1.
-
Volts/Left Contactor Control receptacle on the wire
feeder. Align keyways, insert plug into receptable, and
rotate threaded collar clockwise.
Both Guns Same
IkITI~
so
plugs into
interconnecting cord from the PRC unit
the Right Contactor Control receptacle on
the wire feeder.
tacle, and
Align keyways,
rotate
insert
plug
This connection will
that only
a.
The RIGHT
into recep
threaded collar clockwise.
Polarity (Figure 2-2)
one
electrically iso/ate guns
energized at any time.
electrode wire is
For Reverse
Connect
a
Polarity (shown in Figure 2-2)
welding power
cable from the
POSITIVE (or POSITIVE WITH
SLOPE) output terminal to the LEFT ter
minal on the PRC unit.
source
Wire Drive Motor
Left Drive Roll
115 Volts/Contactor Control Cable
Right
Assembly
Drive Roll
Trigger
Assembly
Control Cables
Digital
Dual
lule Control
Dual
Digital Voltage
Control
Dual
Digital
Wire Feeder
Gas
Output To Guns
Voltage Sensing Leads
Current
Indicates
Trigger
Relay
Connections
-
DVC MP Models
Only
Weld Current Path
connections when DDSC is not used
Figure 2-2. Both Guns Same Polarity (Reverse Polarity Shown)
OM.864
Page
2
TA-046 881-A
b.
Connect
a
cable between the PRC
jumper
LEFT and RIGHT terminals.
I~T~l~
The
welding
power
positive cables oan be reversed at the
source to provide the Left gun with out
put from the POSITIVE WITH SLOPE output terminal
c.
Connect the Left gun weld cable to the
maining LEFT terminal on the PRC unit.
re
Connect the
e.
Connect
source
power
work
cable
to
the
gun with output from the POSITIVE out
The voltage sensing lead from the D VC
PRC unit to the LEFT terminal
3.
the
Right
unit must be switched from the RIGHT terminal
Right gun weld cable to the re
maining RIGHT terminal on the PRC unit.
d.
and the
put terminal.
welding
on
cab/es at the
Gun Straight Polarity/One Gun Reverse
Polarity (Figure 2-4)
NEGATIVE output terminal.
(not shown),
straight polarity
we/ding power source output
Both Guns Reverse Polarity Using
Output Terminals (Figure 2-3)
2.
a.
Connect
a
cable from the
POSITIVE
source
LEFT terminal
b.
Connect
a
on
reverse
terminals.
d.
trode wire in the
welding
power
the
to
welding
a.
power
the
source
use
Connect
source
negative.
that
the
dual
a
with two
cable from the
POSITIVE
LEFT terminal
b.
re
Connect
a
on
welding
power
output terminal
to
cable from the
welding
power
the
NEGATIVE output terminal
PRC RIGHT terminal.
c.
Connect
a
the
the PRC unit.
to
source
Connect the RIGHT gun weld cable to the
remaining RIGHT terminal on the PRC unit.
power
gun is
digital wire
welding power sources
(see Section 2-2) or damage to equipment will result
when the system is connected with one gun straight
polarity and the other gun reverse polarity.
feeder is wired for
Connect the Left gun weld cable to the
maining LEFT terminal on the PRC unit.
Connect
Right
I IkA I ~I] l f~ I ~ Ensure
ing
e.
electrically
when either gun trigger is depressed. The
electrode wire in the Left gun is positive while the elec
energized
Two Positive
output terminal
the PRC unit.
cable from the
the
source POSITIVE WITH SLOPE output ter
minal to the PRC RIGHT terminal.
c.
the
One
I.1 Both electrode wires will be
IIs~I~ For
on
the PRC unit.
jumper cable between the remain
LEFT and RIGHT terminals
the PRC
on
unit.
the
work cable to
welding
NEGATIVE output terminal.
d.
Connect
the
work
jumpered terminals
cable
to
of
one
the
the PRC unit.
on
Wire Drive Motor
115 Volts/Contactor
Control Cable
Left Drive Roll
Assembly
Remote Control Cable
Right
Drive Roll
Assembly
115 Volts AC Cable
Trigger Control
Cables
Digital
Dual
;chedule Control
Welding
Power
Dual
Sourcet
Digital
Wire Feeder
Positive
With Slope
Output
Terminal
Gas
Rear View
Output
To Guns
Front View
115 Volts/Left Contactor
Voltage
Sensing
Leads
Work
Current
Relay
Connections
-
Control Cable
DVC MP Models
Only
TA-046 879.A
tMP Model Illustrated
Indicates
Weld Current Path
Trigger Connection
when DDSC is not used
Figure 2-3. Both Guns
Reverse
Polarity Using Two Positive Output Terminals
OM-864 Page 3
The cables
I~I)1~
welding
be reversed at the
can
power source output terminals to obtain straight polari
ty on the Right gun and reverse polarity on the Left gun.
Wire Drive Motor
115 Volts/Contactor
Left Drive Roll
Control Cable
Assembly
Remote Control Cable
Right Drive
Roll
Assembly
115 Volts AC Cable
Trigger Control Cables
Dual
Digital
Wire Feeder
Welding
Power
Polarity
Reversing
Source
Control
Gas
Gas Output To Guns
Control Cable
Front View
Rear View
115 Volts/Left Contactor
Control Cable
TA-046 880-A
Work
Current Relay Connections
DVC MP Models Only
Indicates Weld Current Path
-
Trigger
Connection when DDSC is not used
Figure 2-4. One Gun Straight Polarity/One Gun Reverse Polarity
SECTION 3
SEQUENCE OF OPERATION
-
CAUTION Never, under any circumstances, operate
3.
Turn
the
on
shielding
supply.
gas
___________
the remote control with the outer enclosure removed. In
addition
to a
safety hazard, improper cooling
may result
4.
the remote control components. Warranty
is void if the remote control is operated with the outer
in
damage
enclosure open
I ~I~ I ~
legibility.
3-2.
removed.
or
Periodically inspect
the labels
on
this unit for
All labels must be maintained in
a
the welding
Begin welding.
Energize
feeder.
to
power
source
and
wire
SHUTTING DOWN
1.
Stop welding.
2.
Allow the
clearly
readable state and
replaced when necessary. See the
Parts List for part number of labels.
welding
minutes with
power
load
no
source
applied
to
to
idle for 3
permit
proper
cooling.
GAS METAL-ARC WELDING (GMAW} AND
FLUX CORED-ARC WELDING (FCAW)
3-1.
3.
Place the
welding
in the OFF
Make
1.
necessary
welding
connections
between
the
control
power source, wire
trol, any
feeder, voltage con
other controls, the gun, and the polarity
reversing
control.
See
respective
derives
welding
power
source
POWER switch
position. Since the polarity reversing
its
operating
power from
the
the
polarity reversing
control will also be deenergized when the
welding power source is deenergized.
Owners
power
source,
Manual.
4.
2.
Adjust all
each units
controls
necessary
Owners
as
instructed
Manual.
r~tuiiis]i~r If
E~..1UI I Es] ~ Prior to
eye
welding, it/s imperative that pro
protective clothing (welding coat and gloves) and
protection (glasses and welding helmet) be put on.
Failure to
nent
OM-864
comply may result
bodily damage.
Page
4
shielding
gas.
performed in a confined
shielding gas supply could
result in a buildup of gas fumes, thereby endangering
personnel reentering the welding area.
area,
per
Turn off the
in
in serious and/or perma
we/ding
is
failure to turn off the
1
ii
CR1
I
CR2
T
2~-T
,q~-D
71
115 V.
7
3
4
<
0
4
0
A
B
77495556
0
0
0
O1T
C
D
E
F
___
41
WHT
~
____
RC 1
H
8LK
1>
RED
2>
A
~
>T
4
A
_O
1~~~OA
LEFT
_________
______________
PLGi
1<
2~(
BL K
56
1
(Ei~\
3<
,
B
RIGHT
W2
WH T
B
PL G 2
Circuit
Diagram No. A-047 249-B
Figure 3-1. Circuit Diagram
OM-864
Page
5
7
3
14-~
13
12
6
Figure
OM-864
Page
6
A
-
Complete Assembly
1
Item
Dia.
Part
No.
Mkgs.
No.
Complete
Figure A
010 610
2
iT
038 639
3
CR 1,2
059 266
FM
032 618
007 678
4
5
031 296
047 497
6
+047 328
7
010 853
010 855
8
9
Description
010 854
Wi ,2
048 597
048 599
048 600
048 601
039 047
10
039 049
039044
601 976
601 880
Quantity
Assen~bI~
CONNECTOR, clamp cable 1/2 inch
BLOCK, terminal 30 amp 6 pole
RELAY, enclosed 120 voltsac DPDTw/flange
BLADE, fan60 Hz6inch4wing
MOTOR, 1/70 hp 115 volts ac 1550 rpm
BRACKET, mounting motor fan
LABEL, general precautionary
CABINET (consisting of)
FASTENER,screw-slottedhdNo.2
RETAINER, screw No. 2
NUT, speed No. 2 clip on
CONTACTOR, 3P 110-120/208-240 volts (consisting of)
COIL, contactor 115/230 volts
KIT, points
LINK, jumper contactor
TERMINAL, power output red (consisting of)
TERMINAL BOARD, red
3
-
1
2
1
1
-
.
1
.
-
2
1
3
4
-
4
-
.
.BUSBAR
.SCREW,cap-hexhdl/2-13x1-1/2
.NUT,hexjaml/2-13
601 879 .NUT,hexfulll/2-13
11
048 475
GUARD, stud
12
049 455
079 531
CORD, No.18 2/c (order byft.)
CLAMP, cable
079 878
079 535
HOUSING PLUG & PINS (consisting of)
RC2
604 571
13
RC3
14
RC1
+
When
ordering
079 531
048 284
079 534
604 571
079 531
046 958
079 535
058 043
048 471
a
-
power
10 ft.
TERMINAL, male
CORD, portable No.184/c (order byft.)
CLAMP, cable
2
.
10 ft.
HOUSING PLUG & SOCKETS (consisting of)
TERMINAL, female
4
.
CORD, No.18 4/c (order byft.)
CLAMP, cable
RECEPTACLE & PINS
10 ft.
(consisting of)
TERMINAL, male
HOSE,1/2IDxll/16ODx4
TOOL, extraction pin amp (optional equipment)
4
-
component originally displaying
a
precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND STYLE NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-864 Page 7
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