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Miller Electric KC237900 manual

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Table of contents for the manual

  • Page 1

    TIG-RIG (Basic) Models And Models W ith Optional Pulser And Electroslope Processes Descrip tio n TIG (GT A W) W elding Enables Welding Power Source to provide TIG as well as Stick capability OM -530J May 1993 Eff. w/Serial Number KC237900 Stick (SMA W) W elding  Shielded Metal Arc (Stick) W elding Automatic W elding[...]

  • 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

    OM-530J - 5/93 T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS 1-1. General Information And Safety 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Safety Alert Symbol And Signal Words 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 4

    SECTION 7 – ELECTRICAL DIAGRAMS Diagram 7-1. Circuit Diagram For TIG-Unit With Options 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 7-2. Circuit Diagram For Postflow T imer 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 7-3. Circuit Diagram For Pulser (Optional) 25 . [...]

  • Page 5

    OM-530 Page 1 SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS 1-1. GENERAL INFORMA TION 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 saf[...]

  • Page 6

    OM-530 Page 2 T able 2-1. Specifications Model Rated Amperes Rated Duty Cycle Weight TIG-Unit TIG-Unit 56 400 600 60% 60% 175 lbs. (79.4 kg) 183 lbs. (83.9 kg) 2-1. DESCRIPTION The TIG-Unit is an accessory package which enables the solid-state welding power source to provide Gas T ungsten Arc (GT A W) as well as Shielded Metal Arc Welding (SMA W) c[...]

  • Page 7

    OM-530 Page 3 ST-059 589-A Interconnecting Cord Positive Output T erminal Positive Lead (No. 17) Negative Lead (No. 12) Negative Output T erminal Figure 3-1. Component Installation 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 ke[...]

  • Page 8

    OM-530 Page 4 side 1 15 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 V olts 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 s[...]

  • Page 9

    OM-530 Page 5 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. Remove blank snap-in from access hole toward rear of cover installed on welding power source. I[...]

  • Page 10

    OM-530 Page 6 3-5. FIELD INST ALLA TION OF PULSER W ARNING: 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 positi[...]

  • Page 11

    OM-530 Page 7 f. Cu t of f 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. g. Splice and solder Electroslope lead 59 to lead 59. (Make[...]

  • Page 12

    OM-530 Page 8 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 instal[...]

  • Page 13

    OM-530 Page 9 f. Connect lead 58 from preflow timer assembly to terminal 58 on 1T . ST-048 698-A Pre-Flow Assembly Spot Time Assembly 1/2 in. (12.7 mm) Dia. 3/8 in. (9.5 mm) Dia. 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

    OM-530 Page 10 l. 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. Connect re- maining end of l[...]

  • Page 15

    OM-530 Page 1 1 AJ B K I C L NH D M G E F Ref. S-0004-A Figure 3-4. Front V iew Of REMOTE 14 Receptacle With Socket Locations 3-1 1. 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. Connect hose from shielding g[...]

  • Page 16

    OM-530 Page 12 SECTION 4 – OPERA TOR CONTROLS TB-059 588-A Amperage Adjustment Control Remote Amperage Switch Polarity Switch ♦ Meters ♦ Pulser Postflow Control Gas/Coolant Switch High Frequency Control High Frequency Switch Circuit Breaker (See Section 6-4) 1 15 V olts AC Duplex Receptacle Gas V alve Outlet Gas V alve Inlet Electrode Output [...]

  • Page 17

    OM-530 Page 13 4-2. POLARITY SWITCH (Figure 4-1) + () ELECTRODE POSTIVE () LECTRODE NEGA TIVE POLARITY SWITCH DO NOT SWITCH WHILE WELDING CAUTION: ARCING can damage switch contacts. • Do not change POLARITY SWITCH position while welding or under load. Th e POLARITY switch provides a means of selecting ei- ther electrode negative or electrode posi[...]

  • Page 18

    OM-530 Page 14 condition resetting to Of f 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 ON OFF W ARNING: USING HIGH FREQUENCY WITH THE SHIELDED MET AL ARC WE[...]

  • Page 19

    OM-530 Page 15 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 contro[...]

  • Page 20

    OM-530 Page 16 ST-009 477-D ST-007 648-G[...]

  • Page 21

    OM-530 Page 17 The scale surrounding the BACKGROUND control is calibrated in percentage and does not indicate an am- perage or voltage value. IMPORT ANT : 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 switc[...]

  • Page 22

    OM-530 Page 18 4-17. PERCENT AGE DOWNSLOPE RA TE CON- TROL (Electroslope Models Only) (Figure 4-1) t PERCENT AGE DOWNSLOPE RA TE 0.25-20 SEC. 0.25-20s The PERCENT AGE DOWNSLOPE RA TE control is calibrated in percent and can be adjusted for a down- slope rate of approximately .25 (F AST) to 20 (SLOW) seconds. The settings of this control are compara[...]

  • Page 23

    OM-530 Page 19 soon as a n 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 [...]

  • Page 24

    OM-530 Page 20 b. Select and obtain proper tungsten electrode (see T able 6-2). c. Prepare tungsten electrode according to Sec- tion 6-2, and insert into torch). 13. T urn 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). 15. Depress the POWER [...]

  • Page 25

    OM-530 Page 21 T able 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). *Frequency [...]

  • Page 26

    OM-530 Page 22 T able 6-2. T ungsten Size Chart Electrode Diameter Pure T ungsten .010 ” .020 ” .040 ” 1/16 ” 3/32 ” 1/8 ” 5/32 ” 3/16 ” 1/4 ” 2% Thorium Alloyed T ungsten .010 ” .020 ” .040 ” 1/16 ” 3/32 ” 1/8 ” 5/32 ” 3/16 ” 1/4 ” Zirconium Alloyed T ungsten .010 ” .020 ” .040 ” 1/16 ” 3/32 ” 1/8 ” [...]

  • Page 27

    OM-530 Page 23 W ARNING: 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 [...]

  • Page 28

    OM-530 Page 24 MOVING P ARTS can cause serious injury . • Keep away from moving parts. HOT SURF ACES can cause severe burns. • Allow cooling period before servicing. T roubleshooting 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 wit[...]

  • Page 29

    OM-530 Page 25 SECTION 7 – ELECTRICAL DIAGRAMS Circuit Diagram No. SC-121 852-A Diagram 7-1. Circuit Diagram For TIG-Unit With Options[...]

  • Page 30

    OM-530 Page 26 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)[...]

  • Page 31

    OM-530 Page 27 Circuit Diagram No. SC-080 063-E Diagram 7-4. Circuit Diagram For Electroslope (Optional)[...]

  • Page 32

    OM-530 Page 28 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)[...]

  • Page 33

    OM-530 Page 29 SECTION 8 – CERTIFICA TION FOR HIGH FREQUENCY ARC WELDING EQUIPMENT 8-1. GENERAL Th e 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 Commissio[...]

  • Page 34

    OM-530 Page 30 L. High Frequency High frequency is radio frequency energy , either con- tinuous o r 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. Interference Interference is the unwanted and proble[...]

  • Page 35

    OM-530 Page 31 S-0018 High-Frequency W elding Power Source Electrode Holder Place leads on floor or on boards and keep 3/4 in. (19 mm) to 1 in. (25 mm) apart. Electrical Input Supply Ground W ork Clamp 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[...]

  • Page 36

    OM-530 Page 32 connected so that good electrical contact is provided be- tween the shield and the high-frequency power source. S-0021 Line Input 50 ft. (15 m) Power Supply Solid Metallic Conduit Line Fuse And Switch Ground High-Frequency W elding Power Source Box Figure 8-5. Installation Of High-Frequency Stabilized Arc Welding Power Source 8-6. GU[...]

  • Page 37

    OM-530 Page 33 SECTION 9 – P ARTS LIST Description Quantity Part No. Dia. Mkgs. Figure 9-1. Main Assembly Model Basic W/Pulser W/Electro- slope W/Pulser & Electroslope Item No. 1 000 527 BLANK, snap-in nyl .875mtg hole 1 1 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 010 1 16 GROMMET , rbr .375 ID [...]

  • Page 38

    OM-530 Page 34 Description Quantity Part No. Dia. Mkgs. Figure 9-1. Main Assembly (Continued) Model Basic W/Pulser W/Electro- slope W/Pulser & Electroslope Item No. 10 C8 009 062 CAP ACITOR 1 1 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 604 814 NUT , stl hex reg .750-1[...]

  • Page 39

    OM-530 Page 35 Description Quantity Part No. Dia. Mkgs. Model Basic W/Pulser W/Electro slope W/Pulser Electroslope Item No. Figure 9-2. Panel, Control Rear w/Components (Fig 9-1 Item 5) 1 TE1 038 894 BLOCK, term 30A 4P 1 1 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 008 269 P ANEL, mtg compo[...]

  • Page 40

    OM-530 Page 36 Description Part No. Dia. Mkgs. 1 1 1 121 Item No. Figure 9-3. HF Panel (Fig 9-1 Item 9) Quantity 1 601 838 NUT , brs hex .375-16 jam hvy 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 T3 033 373 COIL, coupling air HF 1 . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 41

    OM-530 Page 37 Description Quantity Part No. Dia. Mkgs. Model Basic W/Pulser W/Electro slope W/Pulser Electroslope Item No. Figure 9-4. Panel, Front w/Components (Fig 9-1 Item 16) 1 V *025 604 METER, volt dc 0-100 scale 1 1 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 A *025 608 METER, amp dc 0-500[...]

  • Page 42

    OM-530 Page 38 Description Quantity Part No. Dia. Mkgs. Model Basic W/Pulser W/Electro slope W/Pulser Electroslope Item No. Figure 9-4. Panel, Front w/Components (Fig 9-1 Item 16) (Continued) 13 C19 028 294 CAP ACITOR, polye met film 1uf 250VDC 1 1 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 S3 01 1 974 SWITCH, polarity (30[...]

  • Page 43

    OM-530 Page 39 Description Part No. 01 1 974 Item No. Figure 9-5. Switch, Polarity (300 & 400A Models) (Fig 9-4 Item 14) Quantity 1 017 288 BRACKET , mtg switch plrt 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 103 634 MOUNTING BOARD, cmpnt plrt switch 1 . . . . . . . [...]

  • Page 44

    OM-530 Page 40 Description Part No. Dia. Mkgs. 041 213 Item No. Figure 9-6. Pulser (Optional) (Fig 9-4 Item 38) Quantity 1 R427 004 186 POTENTIOMETER, C std slot 1/T 2W 5K ohm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 R429 035 897 POTENTIOMETER, C std slot 1/T 2W 1K ohm 1 . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 45

    OM-530 Page 41 Description Part No. Dia. Mkgs. Item No. Figure 9-7. Electroslope 9 (Optional) (Fig 9-4 Item 39) Quantity 1 R92,94 009 398 POTENTIOMETER, C std slot 1/T 2W 10K ohm 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 R93,95 073 562 POTENTIOMETER, C std slot 1/T 2W 10K ohm 2 . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 46

    OM-530 Page 42 Description Part No. 048 153 Item No. Figure 9-8. Switch, Polarity (500 & 600A Models) (Fig 9-4 Item 14) Quantity 1 01 1 080 SP ACER, contact switch 1/8 in 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 038 769 CONT ACT BOARD ASSEMBL Y , movable switch plrt (consi[...]

  • Page 47

    OM-530 Page 43 Description Quantity Part No. Dia. Mkgs. Model Item No. Figure 9-9. Panel, Control Front w/Components (Fig 9-1 Item 15) 500 & 600 Amp 300 & 400 Amp 1 CR2 000 770 RELA Y , encl 24VDC 3PDT 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 049 268 P ANEL, mtg components 1 1[...]

  • Page 48

    OM-530 Page 44 Description Part No. Dia. Mkgs. Quantity Optional Equipment 041 236 METER KIT AMP & VOL T DC 0-500 w/FIL TER, (Fig 9-2 & 9-4) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 041 238 METER KIT AMP & VOL T DC 0-600 w/FIL TER, (Fig 9-2 & 9-4) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 041[...]

  • Page 49

    Notes[...]

  • Page 50

    9/92 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  9 (#041 212 Field ) GAS PREFL[...]

  • Page 51

    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[...]

  • Page 52

    PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Com pany 1635 West S pencer Street Applet on, WI 5 4914 US A International He adquarters – US A USA Phone: 920-735-4505 Auto-A t t ended USA & Canada FAX: 920-735-4134 Int ernati onal F AX : 920-735-4125 European Headquart ers – Unite[...]