Miller Electric KC237900 Owner's Manual

TIG-RIG (Basic) Models And Models WithOptional Pulser And ElectroslopeProcessesDescriptionTIG (GTAW) WeldingEnables Welding Power Source toprovide TIG

OM-530 Page 63-5. FIELD INSTALLATION OF PULSERWARNING: ELECTRIC SHOCK can kill.• Do not touch live electrical parts.• Shut down welding power source,

OM-530 Page 7f. Cut off and discard existing connectors on Elec-troslope leads 58 and 59.CAUTION: SOLDER can damage unit.• Do not allow solder to fal

OM-530 Page 8to proper output terminals on welding power source;ensure that proper polarity is maintained.ELECTRIC SHOCK can kill.• Secure and insulat

OM-530 Page 9f. Connect lead 58 from preflow timer assembly toterminal 58 on 1T.ST-048 698-APre-FlowAssemblySpot TimeAssembly1/2 in.(12.7 mm) Dia.3/8

OM-530 Page 10l. Connect lead 58, originating at the preflow cir-cuit card, to the terminal on CR2 where lead 59was removed in Step j.m. Locate termin

OM-530 Page 11AJBKICLNHDMGEFRef. S-0004-AFigure 3-4. Front View Of REMOTE 14 ReceptacleWith Socket Locations3-11. GAS CONNECTIONS (Figure 4-1)GAS IN

OM-530 Page 12SECTION 4 – OPERATOR CONTROLSTB-059 588-AAmperageAdjustmentControlRemoteAmperageSwitchPolaritySwitch♦Meters ♦PulserPostflowControlGas/C

OM-530 Page 134-2. POLARITY SWITCH (Figure 4-1)+()ELECTRODEPOSTIVE()LECTRODENEGATIVEPOLARITY SWITCHDO NOT SWITCHWHILE WELDINGCAUTION: ARCING can dama

OM-530 Page 14condition resetting to Off is accomplished manually bypushing the switch once, provided that an arc has notbeen established. This contro

OM-530 Page 15Pulsing operations may be performed when the PO-LARITY SWITCH is in either the ELECTRODE NEGA-TIVE or ELECTRODE POSITIVE position.When r

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-530 Page 16ST-009 477-DST-007 648-G

OM-530 Page 17The scale surrounding the BACKGROUND control iscalibrated in percentage and does not indicate an am-perage or voltage value.IMPORTANT:

OM-530 Page 184-17. PERCENTAGE DOWNSLOPE RATE CON-TROL (Electroslope Models Only) (Figure 4-1)tPERCENTAGEDOWNSLOPERATE0.25-20 SEC.0.25-20sThe PERCENT

OM-530 Page 19soon as an arc is struck, the spot weld timer begins tim-ing out. The remote contactor control switch must re-main closed throughout the

OM-530 Page 20b. Select and obtain proper tungsten electrode(see Table 6-2).c. Prepare tungsten electrode according to Sec-tion 6-2, and insert into t

OM-530 Page 21Table 6-1. Maintenance ScheduleFrequency* MaintenanceEvery month. Units in heavy service environ-ments:Check labels, weld cables, cleani

OM-530 Page 22Table 6-2. Tungsten Size ChartElectrode DiameterPure Tungsten.010”.020”.040”1/16”3/32”1/8”5/32”3/16”1/4”2% Thorium Alloyed Tungsten.010”

OM-530 Page 23WARNING: ELECTRIC SHOCK can kill.• Do not touch live electrical parts.• Shut down welding power source, and dis-connect input power emp

OM-530 Page 24MOVING PARTS can cause serious injury.• Keep away from moving parts.HOT SURFACES can cause severe burns.• Allow cooling period before se

OM-530 Page 25SECTION 7 – ELECTRICAL DIAGRAMSCircuit Diagram No. SC-121 852-ADiagram 7-1. Circuit Diagram For TIG-Unit With Options

OM-530J - 5/93TABLE OF CONTENTSSECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS1-1. General Information And Safety 1. . . . . . . . . . . . . . . . . .

OM-530 Page 26Circuit Diagram No. SA-045 288-CDiagram 7-2. Circuit Diagram For Postflow TimerCircuit Diagram No. SB-088 800-ADiagram 7-3. Circuit Diag

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

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

OM-530 Page 29SECTION 8 – CERTIFICATION FOR HIGH FREQUENCY ARC WELDING EQUIPMENT8-1. GENERALThe following information is necessary to make a properins

OM-530 Page 30L. High FrequencyHigh frequency is radio frequency energy, either con-tinuous or pulsed, used to start or stabilize a welding arc.M. Hig

OM-530 Page 31S-0018High-FrequencyWelding Power SourceElectrode HolderPlace leads on floor or on boardsand keep 3/4 in. (19 mm)to 1 in. (25 mm) apart.

OM-530 Page 32connected so that good electrical contact is provided be-tween the shield and the high-frequency power source.S-0021Line Input50 ft. (15

OM-530 Page 33SECTION 9 – PARTS LISTDescriptionQuantityPartNo.Dia.Mkgs.Figure 9-1. Main AssemblyModelBasic W/PulserW/Electro-slopeW/Pulser &Electr

OM-530 Page 34DescriptionQuantityPartNo.Dia.Mkgs.Figure 9-1. Main Assembly (Continued)ModelBasic W/PulserW/Electro-slopeW/Pulser &ElectroslopeItem

OM-530 Page 35DescriptionQuantityPartNo.Dia.Mkgs.ModelBasic W/PulserW/ElectroslopeW/PulserElectroslopeItemNo.Figure 9-2. Panel, Control Rear w/Compone

SECTION 7 – ELECTRICAL DIAGRAMSDiagram 7-1. Circuit Diagram For TIG-Unit With Options 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-530 Page 36DescriptionPartNo.Dia.Mkgs.111 121ItemNo.Figure 9-3. HF Panel (Fig 9-1 Item 9)Quantity1 601 838 NUT, brs hex .375-16 jam hvy 4. . . . .

OM-530 Page 37DescriptionQuantityPartNo.Dia.Mkgs.ModelBasic W/PulserW/ElectroslopeW/PulserElectroslopeItemNo.Figure 9-4. Panel, Front w/Components(Fig

OM-530 Page 38DescriptionQuantityPartNo.Dia.Mkgs.ModelBasic W/PulserW/ElectroslopeW/PulserElectroslopeItemNo.Figure 9-4. Panel, Front w/Components(Fig

OM-530 Page 39DescriptionPartNo.011 974ItemNo.Figure 9-5. Switch, Polarity (300 & 400A Models) (Fig 9-4 Item 14)Quantity1 017 288 BRACKET, mtg swi

OM-530 Page 40DescriptionPartNo.Dia.Mkgs.041 213ItemNo.Figure 9-6. Pulser (Optional) (Fig 9-4 Item 38)Quantity1 R427 004 186 POTENTIOMETER, C std slot

OM-530 Page 41DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-7. Electroslope 9 (Optional) (Fig 9-4 Item 39)Quantity1 R92,94 009 398 POTENTIOMETER, C std s

OM-530 Page 42DescriptionPartNo.048 153ItemNo.Figure 9-8. Switch, Polarity (500 & 600A Models) (Fig 9-4 Item 14)Quantity1 011 080 SPACER, contact

OM-530 Page 43DescriptionQuantityPartNo.Dia.Mkgs.ModelItemNo.Figure 9-9. Panel, Control Front w/Components(Fig 9-1 Item 15)500 & 600Amp300 & 4

OM-530 Page 44DescriptionPartNo.Dia.Mkgs.QuantityOptional Equipment041 236 METER KIT AMP & VOLT DC 0-500 w/FILTER, (Fig 9-2 & 9-4) 1. . . . .

Notes

OM-530 Page 1SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS1-1. GENERAL INFORMATION AND SAFETY A . GeneralInformation presented in this manual and on

9/92OPTIONS AND ACCESSORIESTIG-RIG ACCESSORIESMETERS FOR TIG–RIGWith 300SS Power Source(#041 236 Factory)(#041 237 Field)With 400SS Power Source(#041

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 7/00Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-530 Page 2Table 2-1. SpecificationsModelRatedAmperesRatedDuty CycleWeightTIG-UnitTIG-Unit 5640060060%60%175 lbs.(79.4 kg)183 lbs.(83.9 kg)2-1. DESC

OM-530 Page 3ST-059 589-AInterconnectingCordPositiveOutputTerminalPositive Lead(No. 17)Negative Lead(No. 12)NegativeOutputTerminalFigure 3-1. Componen

OM-530 Page 4side 115 volts ac power supply. The second method (B)is to connect the TIG-Unit to 230 volts ac inside thewelding power source.A. Procedu

OM-530 Page 5placed on front of welding power source. Secure inplace with two sheet-metal screws, one on eitherside of lifting eye near center of cove