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Miller Electric KC237900 Owner's Manual

Tig-rig (basic) models and models with optional pulser and electroslope
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TIG-RIG (Basic) Models And Models With
Shielded Metal Arc
(Stick) Welding
Automatic Welding
Optional Pulser And Electroslope
OM-530J
May 1993
Eff. w/Serial Number KC237900
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Enables Welding Power Source to
provide TIG as well as Stick capability

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Summary of Contents for Miller Electric KC237900

  • Page 1 TIG-RIG (Basic) Models And Models With Optional Pulser And Electroslope Shielded Metal Arc (Stick) Welding Automatic Welding OM-530J May 1993 Eff. w/Serial Number KC237900 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description Enables Welding Power Source to provide TIG as well as Stick capability...
  • Page 2 ISO 9001 Quality System Standard. service information for your particular model are also provided. 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS 1-1. General Information And Safety 1-2. Safety Alert Symbol And Signal Words SECTION 2 – SPECIFICATIONS 2-1. Description ..............SECTION 3 –...
  • Page 4 Diagram 7-1. Circuit Diagram For TIG-Unit With Options Diagram 7-2. Circuit Diagram For Postflow Timer Diagram 7-3. Circuit Diagram For Pulser (Optional) Diagram 7-4. Circuit Diagram For Electroslope (Optional) Diagram 7-5. Circuit Diagram For Preflow Timer (Optional) Diagram 7-6. Circuit Diagram For Spot Timer (Optional) SECTION 8 –...

  • Page 5: Section 1 - Safety Precautions And Signal Words

    SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS 1-1. GENERAL INFORMATION AND SAFETY A . General Information presented in this manual and on various la- bels, tags, and plates on the unit pertains to equipment design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed for the safe and effective use of this equipment.

  • Page 6: Description

    Table 2-1. Specifications Rated Rated Model Amperes Duty Cycle TIG-Unit TIG-Unit 56 SECTION 3 – INSTALLATION OR RELOCATION IMPORTANT: Read entire Section 8 on equipment that produces output in the radio frequency range, such as high-frequency starters, for site selection information and installation requirements before beginning the in- stallation procedures.

  • Page 7: Field Installation Of Tig-Unit

    Interconnecting Cord Positive Output Terminal Positive Lead (No. 17) 2. Attach plug from remote control cord (long cord, ap- proximately 28 ft. or 8.5 m) to amphenol receptacle on left side of TIG-Unit (under front access door); align keyway, insert plug, and rotate threaded collar clockwise.
  • Page 8 side 115 volts ac power supply. The second method (B) is to connect the TIG-Unit to 230 volts ac inside the welding power source. A. Procedure When Using An External 115 Volts AC Power Supply IMPORTANT: Read entire Section 8 on equipment that produces output in the radio frequency range, such as high-frequency starters, for site selection information and installation requirements before beginning the in-...
  • Page 9 placed on front of welding power source. Secure in place with two sheet-metal screws, one on either side of lifting eye near center of cover. Do not install the remaining sheet-metal screws (three on each end) until instructed to do so. 3.

  • Page 10: Field Installation Of Pulser

    3-5. FIELD INSTALLATION OF PULSER WARNING: ELECTRIC SHOCK can kill. Do not touch live electrical parts. Shut down welding power source, and dis- connect input power employing lockout/tagging procedure before beginning this installation. Lockout/tagging procedures consist of pad- locking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other discon- necting device.

  • Page 11: Procedure For Remote Tig-Unit Installation

    Cut off and discard existing connectors on Elec- troslope leads 58 and 59. CAUTION: SOLDER can damage unit. Do not allow solder to fall into unit. Cover exposed area of unit when soldering connections. Remove cover(s) and clean unit when fin- ished soldering.

  • Page 12: Field Installation Of Optional Preflow Timer

    to proper output terminals on welding power source; ensure that proper polarity is maintained. ELECTRIC SHOCK can kill. Secure and insulate with sleeving any ex- posed cable connections to prevent contact with personnel, equipment, etc. 12. If an Electroslope and/or Pulser is to be installed, see Section 3-5 and/or 3-6, and install the desired units at this point.
  • Page 13 Connect lead 58 from preflow timer assembly to terminal 58 on 1T. Figure 3-3. Front Panel Mounting Hole Layout g. Remove jumper link 7 from terminals 89 and 90 on 2T. h. Connect lead 89 from preflow timer assembly to terminal 89 on 2T.

  • Page 14: Field Installation Of Optional Spot Timer

    Connect lead 58, originating at the preflow cir- cuit card, to the terminal on CR2 where lead 59 was removed in Step j. m. Locate terminal JJ on electroslope circuit card. Route supplied lead 58, through the grommet in the electroslope box and connect it to terminal HH on the electroslope circuit card.

  • Page 15: Gas Connections

    Figure 3-4. Front View Of REMOTE 14 Receptacle With Socket Locations 3-11. GAS CONNECTIONS (Figure 4-1) GAS IN GAS OUT The GAS IN and GAS OUT fittings have 5/8-18 right- hand threads. Obtain proper size, type, and length hose, and make connections as follows: 1.

  • Page 16: Section 4 - Operator Controls

    SECTION 4 – OPERATOR CONTROLS Meters Electroslope Remote 14 Receptacle Interconnecting Cord Coolant Valve Inlet Coolant Valve Outlet Work Output Terminal 4-1. AMPERAGE ADJUSTMENT CONTROL AND REMOTE AMPERAGE SWITCH (Figure 4-1) AMPERAGE AMPERAGE ADJUSTMENT IMPORTANT: The AMPERAGE ADJUSTMENT con- trol may be adjusted while welding. A.

  • Page 17: Gas/Coolant Postflow Control

    4-2. POLARITY SWITCH (Figure 4-1) POLARITY SWITCH + ( ) LECTRODE NEGATIVE DO NOT SWITCH WHILE WELDING CAUTION: ARCING can damage switch contacts. Do not change POLARITY SWITCH position while welding or under load. The POLARITY switch provides a means of selecting ei- ther electrode negative or electrode positive weld output polarity without having to change the output cable con- nections.

  • Page 18: High Frequency Switch

    condition resetting to Off is accomplished manually by pushing the switch once, provided that an arc has not been established. This control is designed to be taped to the torch handle for convenient operation. 4-6. HIGH FREQUENCY SWITCH (Figure 4-1) HIGH FREQUENCY WARNING: USING HIGH FREQUENCY WITH...

  • Page 19: On Time" Control (Pulser Models Only)

    Pulsing operations may be performed when the PO- LARITY SWITCH is in either the ELECTRODE NEGA- TIVE or ELECTRODE POSITIVE position. When remote control of the output amperage is employed, only the peak amperage level is remotely controlled; the background amperage level is still estab- lished by the position of the BACKGROUND control.
  • Page 20 ST-009 477-D ST-007 648-G OM-530 Page 16...

  • Page 21: Electroslope (Electroslope Models Only)

    The scale surrounding the BACKGROUND control is calibrated in percentage and does not indicate an am- perage or voltage value. IMPORTANT: This control may be adjusted while welding. 4-13. ELECTROSLOPE (Electroslope Models Only) ELECTROSLOPE 9 The Electroslope in this unit allows the operator (by means of the momentary-contact switch, RMLS-14) to manually select the welding condition and the duration of that condition.

  • Page 22: Percentage Downslope Rate Control (Electroslope Models Only)

    4-17. PERCENTAGE DOWNSLOPE RATE CON- TROL (Electroslope Models Only) (Figure 4-1) PERCENTAGE DOWNSLOPE RATE 0.25-20 SEC. 0.25-20s The PERCENTAGE DOWNSLOPE RATE control is calibrated in percent and can be adjusted for a down- slope rate of approximately .25 (FAST) to 20 (SLOW) seconds.

  • Page 23: Section 5 - Sequence Of Operation

    soon as an arc is struck, the spot weld timer begins tim- ing out. The remote contactor control switch must re- main closed throughout the entire spot welding time in- terval. If the remote contactor control switch is released prior to the completion of the spot weld cycle, spot weld output ceases and the spot weld timer will reset for the next cycle.

  • Page 24: Shielded Metal Arc Welding With Tig-Unit

    b. Select and obtain proper tungsten electrode (see Table 6-2). c. Prepare tungsten electrode according to Sec- tion 6-2, and insert into torch). 13. Turn on shielding gas and coolant, if applicable. 14. Rotate the GAS/COOLANT POSTFLOW time con- trol to the desired coolant-gas postflow time (see Section 4-4).

  • Page 25: Tungsten Electrode

    Table 6-1. Maintenance Schedule Frequency* Maintenance Every month. Units in heavy service environ- ments: Check labels, weld cables, clean internal parts. Every 3 months. Check weld cables (see Section 6-1A). Every 6 months. Check all labels (see IMPORT- ANT block, Section 6-1). Clean internal parts (see Section 6-1B).

  • Page 26: Spark Gap Adjustment

    Electrode Diameter Pure Tungsten DC-Argon Electrode (Green Band) Negative/Straight Polarity .010” Up to 15 .020” 5-20 .040” 15-80 1/16” 70-150 3/32” 125-225 1/8” 225-360 5/32” 360-450 3/16” 450-720 1/4” 720-950 2% Thorium Alloyed Tungsten (Red Band) .010” Up to 25 .020”...

  • Page 27: Overload Protection

    WARNING: ELECTRIC SHOCK can kill. Do not touch live electrical parts. Shut down welding power source, and dis- connect input power employing lockout/tagging procedures before inspecting, maintaining, or servicing. Lockout/tagging procedures consist of pad- locking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other discon- necting device.
  • Page 28 MOVING PARTS can cause serious injury. Keep away from moving parts. HOT SURFACES can cause severe burns. Allow cooling period before servicing. Troubleshooting to be performed only by qualified persons. It is assumed that the unit was properly installed accord- ing to Section 3 of this manual, the operator is familiar with the function of controls, the unit was working prop- erly, and that the trouble is not related to the welding...

  • Page 29: Section 7 - Electrical Diagrams

    SECTION 7 – ELECTRICAL DIAGRAMS OM-530 Page 25...

  • Page 30: Diagram 7-2. Circuit Diagram For Postflow Timer

    Circuit Diagram No. SA-045 288-C Diagram 7-2. Circuit Diagram For Postflow Timer Circuit Diagram No. SB-088 800-A Diagram 7-3. Circuit Diagram For Pulser (Optional) OM-530 Page 26...
  • Page 31 OM-530 Page 27...

  • Page 32: Diagram 7-5. Circuit Diagram For Preflow Timer (Optional)

    Circuit Diagram No. SA-096 935-A Diagram 7-5. Circuit Diagram For Preflow Timer (Optional) Circuit Diagram No. SA-049 109-A Diagram 7-6. Circuit Diagram For Spot Timer (Optional) OM-530 Page 28...

  • Page 33: Section 8 - Certification For High Frequency Arc Welding Equipment

    SECTION 8 – CERTIFICATION FOR HIGH FREQUENCY ARC WELDING EQUIPMENT 8-1. GENERAL The following information is necessary to make a proper installation of the high-frequency arc welding equipment described in this instruction manual. In order to comply with Part 18 of the Rules and Regulations of the Federal Communications Commission (FCC), the certificate in the front of this manual must be filled in completely and signed after the unit has been correctly installed.

  • Page 34: High-Frequency Radiation

    L. High Frequency High frequency is radio frequency energy, either con- tinuous or pulsed, used to start or stabilize a welding arc. M. High-Frequency Assisted Arc Welding High-frequency assisted arc welding refers to any of the arc welding processes requiring high frequency. N.
  • Page 35 Place leads on floor or on boards High-Frequency and keep 3/4 in. (19 mm) Welding Power Source to 1 in. (25 mm) apart. Electrical Input Supply Ground Figure 8-2. General Rules For Welding Leads C. Grounding (Earthing) The Weld Cables Be sure that the enclosure of the high-frequency power source is firmly grounded to the WORK terminal.

  • Page 36: Guidelines For Installation Of High-Frequency Assisted Arc Welding Power Sources

    connected so that good electrical contact is provided be- tween the shield and the high-frequency power source. 50 ft. (15 m) Line Input Power Supply Solid Metallic Conduit Line Fuse And Switch Ground Figure 8-5. Installation Of High-Frequency Stabilized Arc Welding Power Source 8-6.

  • Page 37: Section 9 - Parts List

    Part Item Dia. Mkgs. Figure 9-1. Main Assembly ..000 527 BLANK, snap-in nyl .875mtg hole ... . . 010 116 GROMMET, rbr .375 ID x .500mtg hole .
  • Page 38 Part Item Dia. Mkgs. Figure 9-1. Main Assembly (Continued) . . . 009 062 CAPACITOR ..604 814 NUT, stl hex reg .750-10 ..604 813 WASHER, lock stl split .750 .

  • Page 39: Figure 9-2. Panel, Control Rear W/Components

    Part Item Dia. Mkgs. Figure 9-2. Panel, Control Rear w/Components (Fig 9-1 Item 5) 038 894 BLOCK, term 30A 4P ..008 269 PANEL, mtg components ..038 782 BLOCK, term 20A 10P .

  • Page 40: Figure 9-3. Hf Panel

    Part Item Dia. Mkgs. 111 121 Figure 9-3. HF Panel (Fig 9-1 Item 9) ... . . 601 838 NUT, brs hex .375-16 jam hvy ..033 373 COIL, coupling air HF .

  • Page 41: Figure 9-4. Panel, Front W/Components

    Part Item Dia. Mkgs. Figure 9-4. Panel, Front w/Components (Fig 9-1 Item 16) ..*025 604 . . . METER, volt dc 0-100 scale ..*025 608 .
  • Page 42 Part Item Dia. Mkgs. Figure 9-4. Panel, Front w/Components (Fig 9-1 Item 16) (Continued) . . . 028 294 . . . CAPACITOR, polye met film 1uf 250VDC ..011 974 . . . SWITCH, polarity (300 &...

  • Page 43: Figure 9-5. Switch, Polarity (300 & 400A Models)

    Part Item 011 974 Figure 9-5. Switch, Polarity (300 & 400A Models) (Fig 9-4 Item 14) ..017 288 BRACKET, mtg switch plrt ..103 634 MOUNTING BOARD, cmpnt plrt switch ..011 948 GUIDE, contact movable switch .

  • Page 44: Figure 9-6. Pulser (Optional)

    Part Item Dia. Mkgs. 041 213 Figure 9-6. Pulser (Optional) (Fig 9-4 Item 38) . . . R427 ..004 186 POTENTIOMETER, C std slot 1/T 2W 5K ohm . . . R429 ..035 897 POTENTIOMETER, C std slot 1/T 2W 1K ohm .

  • Page 45: Figure 9-7. Electroslope 9 (Optional)

    Part Item Dia. Mkgs. Figure 9-7. Electroslope 9 (Optional) (Fig 9-4 Item 39) R92,94 . . . 009 398 POTENTIOMETER, C std slot 1/T 2W 10K ohm R93,95 . . . 073 562 POTENTIOMETER, C std slot 1/T 2W 10K ohm .

  • Page 46: Figure 9-8. Switch, Polarity (500 & 600A Models)

    Part Item 048 153 Figure 9-8. Switch, Polarity (500 & 600A Models) (Fig 9-4 Item 14) ..011 080 SPACER, contact switch 1/8 in ..038 769 CONTACT BOARD ASSEMBLY, movable switch plrt (consisting of) .

  • Page 47: Figure 9-9. Panel, Control Front W/Components

    Part Item Dia. Mkgs. Figure 9-9. Panel, Control Front w/Components (Fig 9-1 Item 15) ..000 770 RELAY, encl 24VDC 3PDT ... . . 049 268 PANEL, mtg components .

  • Page 48: Optional Equipment

    Part Dia. Mkgs....041 236 ..... . 041 238 .
  • Page 49 Notes...

  • Page 50: Options And Accessories

    OPTIONS AND ACCESSORIES TIG-RIG ACCESSORIES METERS FOR TIG–RIG With 300SS Power Source (#041 236 Factory) (#041 237 Field) With 400SS Power Source (#041 238 Factory) (#041 908 Field) With 500SS and 600SS Power Sources (#041 240 Factory) (#041 909 Field) PC–SS PULSER (#041 213 Field) ELECTROSLOPE...
  • Page 51 Warranty Questions? Call LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold for your local after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.
  • Page 52 Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 2000 Miller Electric Mfg. Co. 6/00 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA &...

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