February 1980 FORM: OM-1086

MODEL
CS-3

OWN ERS HilliER

MANUAL

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.
j

L1P ~_~ L~P L&P j~

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.

LIMITED WARRANTY-Subject to the terms and conditions As a matter of general policy only, Miller may honor claims
hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants submitted by the original user within the foregoing periods.
to its Distributor/Dealer that all new and unused Equipment

( furnished by Miller is free from defect in workmanship d
material as of the time and place of delivery by Miller. No war-
ranty is made by Miller with respect to engines, trade ac-
cessories or other items manufactured by others. Such
engines, trade accessories and other items are sold subject to
the warranties of their respective manufacturers, if any All
engines are warranted by their manufacturer for one year from
date of original purchase,
Except specified below, Millers warranty does not apply
as
to components having normal useful life of less than nile Ill
In the case of Millers breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedies
therefore shall be, at Millers option (1) repair or (2) replacement
or, where authorized in writing by Miller in appropriate cases, (3)
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 use) upon
return of the goods at Customers risk and expense. Upon receipt
of notice of apparent defect or failure, Miller shall instruct the clai- ~
mant on the warranty claim procedures to be followed.

year, such as spot welder tips, relay and contactor points, ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND

~ MILLERMATIC parts that come in contact with the welding ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA
wire including nozzles and nozzle insulators where failure does lION AS PERFORMANCE, AND ANY REMEDY FOR
TO
not result from defect in workmanship or material. BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION, ~
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
Miller shall be required to honor warranty claims on war- CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
ranted Equipment in the event of failure resulting from a defect ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF

~
within the following periods from the date of delivery of Equip- FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
( ment to the original user: ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX
CLUDED AND DISCLAIMED BY MILLER.
1. Arc welders, power sources and components . .
1 year
2. Original main power rectifiers 3 years EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN
(labor -
1 year only) WRITING, MILLER PRODUCTS ARE INTENDED FOR
3. All welding guns and feeder/guns 90 days ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL
4. All other Millermatic Feeders 1 year USERS AND FOR OPERATION BY PERSONS TRAINED AND
5. Replacement or repair parts, exclusive of labor .
60 days EXPERIENCED IN THE USE AND MAINTENANCE OF
6. Batteries 6 months WELDING EQUIPMENT AND NOT FOR CONSUMERS OR
CONSUMER USE. MILLER WARRANTIES DO NOT EXTEND
provided that Miller is notified in writing within thirty 130) days TO, AND NO RESELLER IS AUTHORIZED TO EXTEND
of the date of such failure. MILLERS WARRANTIES TO, ANY CONSUMER.

4~1

~, j ~ j~ j~
 ERRATA SHEET
After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to data appearing later in
this manual.

Effective With Style No. JA 19 F ~

RETUR~T~O~ ~
AMENDMENT TO SECTION 2 -
INSTALLATION & OPERATION ~ULDEp~
Amend Figure 2-1. Installation Of Control Unit

Spot Time

Time Range

Burnbeck Time Control

Spot-Continuous Switch

TB-047 181-A

Figure 2-1. Installation Of Control Unit

Item Or Dia. Part Replaced

Pg No Mkgs No. With Description Quantity
4 010 476 010 476 BUSHING (qtychg) 5
5 605 156 604 571 CORD,portableNo. 184C(orderbyft) 3 ft
9 605 156 604 571 CORD, portable No. 184C (order byft) 4 ft
14 048 726 045 483 CASE SECTION 1
23 RC1 048 283 048 283 RECEPTACLEW/PINS (description chg) 1
079 534 079 535 . TERMALE, male 1 pin 4
24 RC2 048 282 Deleted
Pg 2 079 535 Deleted
045 493 CORD, trigger (consisting of) 1
080 328 .
RECEPTACLE W/SOCKETS, free hanging (consisting of) 1
079 534 . TERMINAL, female 1 socket
.
4
079531 .CLAMP,cable29/64 1
604 571 .CORD, portable No. 184C(orderbyft) 3 ft

BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.

OM-1086 Page A
 SECTION 1 -
INTRODUCTION
1 -
1. GENERAL -
This manual has been prepared TINUOUS position, the control unit spot weld functions
especially for use in familiarizing personnel with the are shunted out of.the circuit thereby providing weld

design, installation, operation, maintenance, and control through the control/feeder and burnback
troubleshooting of this equipment. All information capability through the control unit. When in the SPOT
presented herein should be given careful consideration position, the control unit provides electronically timed
to assure optimum performance of this equipment. spot welding capability.
1 -
4. SAFETY -
Before the equipment is put into
1 2. RECEIVING-HANDLING
-
Prior to installing
-

this equipment, clean all packing material from around

operation, the safety section at the front of the welding
power source or welding generator manual should be
the unit and carefully inspect for any damage that may
read completely. This will help avoid possible injury due
have occurred during shipment. Any claims for loss or
to misuse or improper welding applications.
damage that may have occurred in transit must be filed
by the purchaser with the carrier. A copy of the bill of The following definitions apply to CAUTION, IMPOR
lading and freight bill will be furnished by the carrier on NOTE
TANT, and blocks found throughout this
request if occasion to file claim arises. manual:

When requesting information concerning this equip CAUTION Under

____________
this heading, installation,
ment, it is essential that Model Description and Serial operating, and maintenance procedures or practices will
(or Style) Number of the equipment be supplied. be found that if not carefully followed may create a

hazard to personnel.
1 3. DESCRIPTION
-
This control Unit iS designed
-

to add spot welding and burnback capability to the IMPORTANT Under this
heading, installation,
______________

SWINGARC DIGITAL -1 and -2, and 50 series con operating, procedures or practices will
and maintenance
trol/feeders. When installed, this unit will provide selec be found that if not carefully followed may result in
tion of either continuous or spot welding capability damage to equipment.
without having to change any interconnecting wiring
between the welding power source, control/feeder, t~iIi~ Under this heading, explanato,y statements
control unit, or gun. Mode change is accomplished via will be found that need special emphasis to obtain the
the SPOT-CONTINUOUS switch. When in the CON- most efficient operation of the equipment.

SECTION 2- INSTALLATION b OPERATION

2-1. INSTALLATION (Figure 2-1) 2. Connect the 6 prong male plug from the con
trol/feeder gas valve into the 6 pole female plug
CAUTION Prior to installing the unit, ensure that the PLG3.
___________

control/feeder and we/ding power source are both com

pletely disconnected from their respective power sup- 3. Connect the 6 prong male plug PLG4 from this
piles. unit to the 6 pole receptacle on the rear of the
IMPORTANT: If this unit is used with control/feeder.
a dual con

trol/feeder, only the Left gun can be used for spot 4. Connect the 4 pin male plug PLG2 from this unit
welding. Make all connections to the left portion of the to the TRIGGER receptacle on the front of the
dual control/feeder.
control/feeder.
1. Loosen the screws on top of the control. Set this 5. Connect the 4 pole female plug PLG1 from this
unit on top of the control and secure by tighten unit to the 115 Volt/Contactor receptacle on the
ing the screws.
rear of the control/feeder.

6 4
6. Connect the 115 VoIt/Contactor Control cable
(supplied with control/feeder) to receptacle RC1.
3
7. Connect the gun to the TRIGGER receptacle.

~ If this unit is used/n conjunction with

the DDSC control, the gun trigger plug must be con
nected to the DDSC control and the plug from the
DDSC control that normally goes to the TRIGGER
receptacle on the control/feeder must go the TRIGGER
Trigger this unit.
receptacle on
Receptacle4
Spot Time
2 2. SPOT-CONTINUOUS SWITCH (Figure
-

Control
2-1) When the SPOT-CONTINUOUS switch is in the
-

Time Range
Switch SPOT position, the control provides a timed welding
Burnback operation. When in the CONTINUOUS position, the
Time Control spot weld functions of the control unit are not available.
Spot-Continuous Switch TB-047 181
The control/feeder operates normally and a burnback
Figure 2-1. Installation Of Control Unit time, as set on the control unit, is available.
OM-1086 Page 1
 2 3. TIME RANGE SWITCH (Figure 2-1)
-
The
TIME RANGE switch provides two spot weld time
ranges. Placing the switch in the upper position pro
vides a time range of .2 to 2.5 seconds. Placing the
switch in the lower position provides a time range of 2.5
to 5 seconds.
-
vent the electrode wire from sticking to the workpiece
after the weld is complete. The control prevents this by
providing an adjustable time period (up to a maximum
of .25 seconds) that the electrode wire remains elec
trically hot after the wire has stopped feeding.

Rotating the BURNBACK time control clockwise in

2 4. SPOT TIME CONTROL (Figure 2-1)
-
The -

creases the burnback time.

SPOT TIME control provides the capability to select the
desired spot weld time within the range selected.
This control is calibrated in percentage and should not
be misconstrued as an actual time setting.
Rotating the SPOT TIME control clockwise increases
the spot weld time.
If the electrode wire sticks to the workpiece, the BURN-

This control is calibrated in percentage and should not BACK time control setting should be increased.
be misconstrued as an actual time setting.
If the electrode wire burns back into the contact tube,
2 5. BURNBACK TIME CONTROL (Figure
- the BURNBACK time control setting should be decreas
2-1) The BURNBACK time control is provided to pro-
- ed.

SECTION 3- SEQUENCE OF OPERATION

1. Ensure that proper connections have been made 7. Adjust SPOT TIME control.
as instructed in Section 2.
8. Set BURNBACK time control.
2. Turn on all associated equipment.
CAUTION Prior to we/ding, it is imperative that pro
___________

3. Place the SPOT-CONTINUOUS switch in the per protective clothing (welding coat and gloves) and
desired position. eye protection (glasses and welding helmet) be put on.
Failure to comply may result in serious or permanent
4. If in the CONTINUOUS position, set the BURN- bodily damage.
BACK time control and proceed as normal.
9. Position gun and commence spot welding.
5. If in the SPOT position proceed as outlined in the
I~IIIl~ Once the SPOT TIME control begins to time,
following steps.
the gun switch must not be re/eased until the comple
6. Position TIME RANGE switch to time tion of the spot weld cycle. If the gun switch is opened
range
desired. during the weld cycle the cycle will not finish.
SECTION 4- TROUBLESHOOTING
CAUTION: Hazardous voltages present on the in
are Use this chart in conjunction with the circuit diagram
_______

ternal circuit,y of this unit as long as power is con while performing troubleshooting procedures. If the
nected. Disconnect power before attempting any in trouble is not remedied after performing these pro
spection or work on the inside of the unit. cedures, the nearest Factory Authorized Service Sta
Troubleshooting of internal circuitry should be perform tion should be contacted. In all cases of equipment
ed by qualified personnel only. malfunction, the manufacturers recommendations
should be strictly followed.
The following chart is designed to diagnose and provide
remedies for some of the troubles that may develop in IMPORTANT Ensure that all connections at the
this unit. control/feeder and control unit are secure and that all
switches are in the proper position for the welding ap
It is assumed that proper installation has been made, ac plication before proceeding with troubleshooting.
cording to Section 2 of this manual, and that the unit
has been functioning properly until this trouble
developed.

Page 2
 TROUBLE PROBABLE CAUSE REMEDY

Gas (and water) valve will not Plug(s) not secure in receptacle(s). Ensure that plugs are secure in receptacle(s).
operate.

Control/feeder energizes but will Switch Control plug loose or a Secure switch control plug in receptacle on control unit.
not feed wire. loose lead in the switch control
plug. Secure loose lead in switch control plug.

Electrode. wire feeds but is not Plug from welding power source Secure plug in receptacle at control unit and welding power
electrically hot. Gas (and water) contactor control receptacle loose source.

valve operates. or loose lead(s) in the plug or

receptacle. Ensure the leads inside of receptacle and plug are secured to
theirrespective terminals.

Wire feeds when in Component defective in printed Replace printed circuit board.
CONTINUOUS positon but not in circuit board in control unit.
SPOT.
SPOT-CONT I NUOUS switch Check wiring of switch.
improperly wired.

- -

I-----

FROM GUN I

TRIGGERS 3

To

______J

To FEEDER
GAS/WATER 4~ EXIT FROM
RECEPTACLE P.C. S0ARD

2 3 324445501
TO FEEDER o 0 0 0 0 0 iT
ABC DEF

5-
TO
GAS/WATER a:
VALVES BAN
3> TO POWER SOURCE
8LK 1 I15VAC/CONTACTOF1
2>

1>
PLG3

Circuit Diagram No. B-048 835-B

Figure 4-1. Circuit Diagram

OM-1086 Page3
 February 1980 FORM: OM-1086

MODEL
CS-3

PARTS
LIST
 I
t

N
U,
I-
N
(0 I-

.9 eq
U.

C)
(4

TC.047 182
OM-1086 Page Figure ~
i Main
Assembly
Item Dia. Factory
No. Mkqs. Part No. Description Quantity

049 173 WRAPPER 1

2 048 907 CIRCUIT CARD ASSEMBLY, spot timer (See Fig. B Page 3) 1
3 081 738 TUBING, steel 5/16 OD x 17 ga 4
4 010 476 BUSHING, strain relief 5/8 x .570 4
5 605 156 CORD, portable No. 18 4C (order by ft.) 3 ft.
6 079531 CLAMP,cable 2
7 048 284 HOUSING PLUG & SOCKETS (consisting of) 1
079 534 .
TERMINAL, female 1 socket 4
8 079 878 HOUSING PLUG & PINS (consisting of) 1
079 535 .
TERMINAL, male 1 pin . 4
9 605 156 CORD, portable No. 18 4C (order by ft.) 4 ft.
10 056 265 CONNECTOR, male 6 contact 10 amp 1
11 048 842 CONNECTOR, female 6 socket w/cable clamps 1
12 052 246 CABLE. power 5C 3-20/2-18 (order by ft.) 3 ft.
13 052 246 CABLE. power 5C 3-20/2-18 (order by ft.) 2 ft.
14 048 726 CASE SECTION, front/bottom/back 1
15 iT 038 772 BLOCK, terminal 20 amp 6 pole ....
1
16 048 725 BRACKET, mounting relay - 1
17 080 148 SOCKET, relay 11 pin 1
18 CR53 080 388 RELAY, 24 volts ac 3PDT 1
19 048 848 SPRING, hoiddown relay - 1
20 S51 011 611 SWITCH, toggle DPDT 15 amp 125 volts 1
21 024 366 KNOB, pointer 2
22 NAMEPLATE (order by model and serial numbers) 1
23 RC 1 048 283 RECEPTACLE, 4 pin flanged size 11 (consisting of) 1
079 534 .
TERMINAL, female 1 socket 4
24 RC2 048 282 RECEPTACLE, 4 socket flanged size 11 (consisting of) 1
079 535 .
TERMINAL, male 1 pin 4

Attaching Hardware

F actory
Part No. Description

604 804 SCREW, sheet metal hex washer hd No. 8 x 3/8

-

602 070 SCREW, machine steel truss hd 6-32 x 3/8

-

602 143 SCREW, self tapping round hd 6-32 x 3/8

-

602 072 SCREW, machine steel truss hd 6-32 x 5/8

-

604 850 SCREW, machine steel round hd 6-32 x 3/4

.

602 198 WASHER, lock steel split No. 6

-

601 859 NUT, steel hex 6-32

-

BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.

OM-1 086 Page 2

 Dia. Factory
Mkgs. Part No. Description Quantity

Figure B 048 907 Circuit Card Assembly, S~,ot Timer (See Fig. A Page 2 Item 2)

C51,56 031 633 CAPACITOR,electrolytic80uf25voltsdc 2

C52,53 031 643 CAPACITOR, ceramic 0.01 uf 500 volts dc 2
C54 032 943 CAPACITOR, tantalum 4.7 uf 35 volts dc 1
C54 032 820 CAPACITOR, electrolylic 2.2 uf 35 volts dc 1
C55 032 943 CAPACITOR, tantalum 4.7 uf 35 volts dc 1
CR51 048 906 RELAY, enclosed 12 volts ac 3PFT 1
CR52 032945 RELAY,24voltsdcDPDT 1
032 946 SOCKET, relay 2
051,54 026 202 DIODE, 1 ampere 400 volts straight polarity 4
D55 037 243 DIODE, zener 18 volts I watt 1
Q51,52 022 135 THYRISTOR,4amp200volts 2
053,54 037 289 TRANSISTOR, unijunction 5OMA 35 volts 2
R51 030 055 RESISTOR, carbon 2 watt 10 ohm 1
R52,54,65 030 024 RESISTOR, carbon 0.5 watt 1000 ohm 3
R53 030 630 RESISTOR, WW fixed 11 watt 100 ohm 1
R55,57 030 937 RESISTOR, carbon 0.5 watt 10 ohm 2
R56 030 709 RESISTOR, carbon 1 watt 150 ohm 1
R58 030 004 RESISTOR, carbon 0.5 watt 10K ohm 1
R59 030 738 POTENTIOMETER, carbon 1 turn 2 watt 500K ohm 1
R60 .030 145 POTENTIOMETER, carbon 1 turn 0.25 watt 2000 ohm 1
R61,64 030 025 RESISTOR, carbon 0.5 watt 100 ohm 2
R62 030 131 POTENTIOMETER, carbon 1 turn 2 watt 50K ohm 1
R63 030 853 RESISTOR, carbon 0.5 watt 2200 ohm 1
R66 030 024 RESISTOR, carbon 0.5 watt 1000 ohm 1
R67,68 030 025 RESISTOR, carbon 0.5 watt 100 ohm 2
R69 032 819 RESISTOR, carbon 0.5 watt 390K ohm 1
S52 011 770 SWITCH, toggle SPDT 5 amp 125 volts 1

COMPONENTS TO BE REPLACED BY
QUALIFIED PERSONNEL ONLY.

TA-047 180

Figure B Circuit Card Assembly, S,iot Timer

BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.

Page 3