Miller KD480481 Owner's manual

Miller
Brand
Miller
Model
KD480481
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Millerfi
February
1995
Form:
OM-158
601
Effective
With
Serial
No.
KD480481
OWNERS
MANUAL
~GL~
_~c~r'
j~
Balancing/Paralleling
Control
Read
and
follow
these
instructions
and
all
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
Call
your
distributor
if
you
do
not
understand
the
directions.
Balances
Output
Of
Two
Paralleled
CV
Welding
Power
Sources
Varies
Welding
Power
Source
Output
By
–10%
Uses
115
Volts
AC,
60Hz
Input
Power
Welding
Power
Source
Must
Have
Full
Remote
14
Capability
Remote
Control
Connections
Through
Receptacle
Or
Terminal
Strip
Give
this
manual
to
the
operator.
For
help,
call
your
distributor
or:
MILLER
Electric
Mfg.
Co.,
P.O.
Box
1079,
Appleton,
WI
54912
414-734-9821
cover
5/94
-
ST-SOD
055
'
1995
MILLER
Electric
Mfg.
Co.
PRINTED
IN
USA
tax
I
MILLERS
TRUE
BLUETM
LIMITED
WARRANTY
Effective
January
1,
1995
(Equipment
with
a
serial
number
preface
of
KD
or
newer)
This
limited
wsrranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
Implied.
LIMITED
WARRANTY
Subject
to
the
terms
end
conditions
below,
MILLER
Electric
MIg.
Co.,
Appleton,
Wisconsin,
warrants
to
its
original
retail
purchaser
that
new
MILLER
equipment
sold
after
the
effective
date
ot
this
limited
warranty
is
tree
ot
de
tects
in
material
and
workmanship
at
the
time
it
is
shipped
by
MILLER.
THIS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
IMPLIED,
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FIT
NESS.
Within
the
warranty
periods
listed
below,
MILLER
will
repair
or
replace
any
war
ranted
parts
or
components
that
tail
due
to
such
detects
in
material
or
workmanship.
MILLER
must
be
notitied
in
writing
within
thirty
(30)
days
ot
such
detect
or
tailure,
at
which
time
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
tollowed.
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
event
ot
such
a
tailure
within
the
warranty
time
periods.
All
warranty
time
periods
start
on
the
date
that
the
equipment
was
delivered
to
the
original
retail
purchaser,
or
one
year
after
the
equipment
is
sent
to
a
North
American
distributor
or
eighteen
months
after
the
equipment
is
sent
to
an
International
distributor.
5
Yesrs
Parts
3
Years
Labor
Original
main
power
rectitiere
2.
3YesmPartssndLabor
Transtormer/Rectitier
Power
Sources
Plasma
Arc
Cutting
Power
Sources
Semi-Automatic
and
Automatic
Wire
Feeders
Robots
3.
2
Years
Paris
and
Labor
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
manutacturer.)
Air
Compressors
4.
1
Year
Parts
and
Labor
Motor
Driven
Guns
Process
Controllers
Water
Coolant
Systems
*
HF
Units
Grids
*
Spot
Welders
Load
Banks
SDX
Transtormers
Running
Gear/Trailers
Plasma
Cutting
Torches
(except
APT,
ZIPCUT
&
PLAZCUT
Models)
Tecumseh
Engines
*
Deutz
Engines
(outside
North
America)
Field
Options
(NOTE:
Field
options
are
covered
under
True
BlueTM
tor
the
remaining
warranty
period
ot
the
product
they
are
installed
in,
or
tor
a
minimurs
ot
one
year
whichever
is
greater.)
6
Months
Batteries
91)
Days
Parts
and
Labor
*
MIG
Guns/TIG
Torches
APT,
ZIPCUT
&
PLAZCUT
Model
Plasma
Cutting
Torches
Remote
Controls
Accessory
Kits
Replacement
Parts
MILLERS
True
BlueTM
Limited
Warranty
shall
not
apply
to:
1,
Items
turnished
by
MILLER,
but
manutactured
by
others,
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
msnutacturers
warranty,
it
any.
2.
Consumsble
components:
such
as
contact
tips,
cutting
nozzles,
contactors
and
relays
or
psrts
that
tail
due
to
normal
wear.
3.
Equipment
that
has
been
moditied
by
any
psrty
other
than
MILLER,
or
equip
ment
that
has
been
improperly
installed,
improperly
operated
or
misused
based
upon
industry
standards,
or
equipment
which
has
not
had
reasonable
end
necessary
maintenance,
or
equipment
which
has
been
used
tor
operation
outside
ot
the
speciticstions
tor
the
equipment.
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
COMMER
CIAL/INDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT.
In
the
event
ot
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
shsll
be,
et
MILLERS
option:
(1)
repair:
or
(2)
replacement:
or,
where
authorized
in
writing
by
MILLER
in
appropriste
cases,
(3)
the
ressonsbte
cost
ot
repair
or
replace-
mental
an
authorized
MILLER
service
station:
or
(4)
psymentot
orcredittor
the
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
retum
otthe
goods
at
customers
risk
end
expense.
MILLERS
option
ot
repair
or
reptscement
will
be
FOE.,
Factory
at
Appleton,
Wisconsin,
or
FOB.
ate
MILLER
authorized
ser
vice
tecility
as
determined
by
MILLER.
Theretore
no
compensation
or
reimburse
ment
tor
transportation
costs
ot
any
kind
will
be
allowed.
TO
THE
EXTENT
PERMITrED
BY
LAW,
THE
REMEDIES
PROVIDED
HEREIN
ARE
THE
SDLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENT
SHALL
MILLER
BE
LtABLE
FOR
DIRECT,
INDIRECT,
SPECIAL,
tNCIDENTAL
OR
CONSEQUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFtT),
WHETHER
BASED
ON
CON
TRACt
TORT
OR
ANY
OTHER
LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
GUARANTY
OR
REPRESENTATION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARtSE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALtNG,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
states
in
the
U.S.A.
do
not
allow
limitations
ot
how
long
en
implied
warranty
lssts,
or
the
exctusion
ot
incidental,
indirect,
specist
or
consequential
dsmsges,
so
the
above
limitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
spa
citic
legal
rights,
end
other
rights
mey
be
available,
but
may
very
trom
stste
to
state.
In
Canada,
legislation
in
some
provinces
provides
tor
certain
edditionel
warranties
or
remedies
other
then
as
stated
herein,
end
to
the
extent
that
they
mey
not
be
waived,
the
limitations
end
exclusions
set
out
above
may
not
apply.
This
Limited
Werranty
provides
specitic
legsl
rights,
end
other
rights
may
be
available,
but
may
vary
trom
province
to
province.
5.
6.
RECEIVING-HANDLING
Before
unpacking
eqUipment,
check
carton
for
any
damage
that
may
have
occurred
during
shipment.
File
any
claims
for
loss
or
damage
with
the
delivering
carrier.
Assistance
for
filing
or
settling
Claims
may
be
obtained
from
distributor
and/or
equipment
manufacturers
Transportation
Department.
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
unit.
The
information
is
located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No.
Date
of
Purchase
miller
1195
6
SECTION
1
SAFETY
IN
FORMATION
Read
all
safety
messages
throughout
this
manual.
U
Obey
all
safety
messages
to
avoid
injury.
U
Learn
the
meaning
of
WARNING
and
CAUTION.
a
WARNING
CAUTION
modl.1
2/93
I
Safety
Alert
Symbol
2
\
2
Signal
Word
WARNING
means
possible
death
or
serious
injury
can
happen.
MOVING
PARTS
can
injure.
~
Keep
away
from
moving
parts.
S
Keep
all
panels
and
covers
closed
I
when
operating.
I
injury
or
equipment
damage
can
CAUTION
means
possible
minor
happen.
3
Statement
Of
Hazard
And
Result
4
Safety
Instructions
To
Avoid
Hazard
-
READ
SAFETY
BLOCKS
at
start
of
Section
3-1
before
proceeding.
Turn
Off
switch
when
using
high
frequency.
5
Hazard
Symbol
(If
Available)
6
Safety
Banner
Read
safety
blocks
for
each
sym
bol
shown.
7
NOTE
Special
instructions
for
best
oper
ation
not
related
to
safety.
NOTE
~
Figure
1-1.
Safety
Information
SECTION
2INSTALLATION
N
OTE
Control
can
sit
on
flat
surface
close
to
welding
power
sources.
2-1.
Installing
Control
On
Welding
Power
Source
1
Welding
Power
Source
Remove
screws
as
shown.
2
Mounting
Bracket
Secure
to
welding
power
source
with
hooks
up.
3
Control
Align
slots
in
bottom
of
control
with
hooks
on
mounting
bracket.
Slide
control
onto
bracket
and
let
control
rest
on
hooks.
Control
can
be
mounted
on
other
side
of
welding
power
source.
Balancing
control
should
face
for.
ward
for
ease
of
adjustment.
Figure
2.1.
Installing
Control
ST-800
054
OM-158601
Page
1
2-2.
Connecting
Control
To
Welding
Power
Source
Figure
2-2.
Cord
Connections
m
a~
li-mm
m
mm
m
mm
~
Figure
2-3.
Connections
To
Terminal
Strip
1TB
(Disables
Remote
14
Receptacle)
OM-158
601
Page
2
I
I
14-Pin
Plug
PLG2
2
Master
Welding
Power
Source
3
Control
6
4
14-Pin
Plug
PLG3
5
Slave
Welding
Power
Source
6 115
Volts
AC
Plug
Make
connections
as
shown.
7
Remote
14
Receptacle
A
remote
control
device
must
be
used
to
control
the
welding
power
sources
contactor
and
output.
Connect
plug
from
remote
control
device
to
receptacle
as
follows:
align
keyway,
insert
plug,
and
tight
en
threaded
collar.
See
Figure
2-3
for
socket
informa
tion
if
remote
control
device
plug
does
not
match
receptacle.
ST-eGO
057
-4<4<44<44
~
1
Strain
Relief
2
Terminal
Strip
IT
3
Remote
14
Receptacle
When
using
iT,
remove
leads
at
2
1TB
that
come
from
Remote
14
_______/
/
receptacle.
Receptacle
is
disabled.
~
/
Route
leads
or
cord
from
remote
I
control
device
through
strain
relief
_______________________________
________________
to
1TB
terminals.
Make
connec
tions
according
to
the
following
in
_______________________________
formation:
Socket/Terminal
Information:
Remote
Contactor
A/1T5B
24voltsac.
B
/
1T4B
Contact
closure
to
pin
A
completes
_____________________
24
volts
ac
contactor
control
circuit.
I/
117B
115
volts
ac.
________________
J
/
1T6B
Contact
closure
to
pin
I
completes
115
volts
ac
contactor
control
circuit.
G
/
1T2B
Circuit
common
for
24
and
115
volts
ac
circuits.
____________________________________
Remote
Amperage/Voltage
Control
L
Cl
1T3B
Command
reference;
+10
volts
dc.
D
/
1T2B
Control
circuit
common
for
10
volts
dc
3
command
on
master
welding
power
source.
E/
1T1B
Input
command
signal
(potentiometer
wiper
or
0
to
+10
volts
dc).
K
/
1
T2B
Chassis
common.
The
remaining
sockets/terminals
are
not
used.
sb7.1
3/93
ST-800
058
2-3.
Welding
Power
Source
Connections
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Off
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.
Have
only
qualified
persons
install
unit.
Installation
must
meet
National
Electrical
Code
and
all
other
codes.
Do
not
use
different
polarities
at
the
same
time
on
a
common
workpiece
when
more
than
one
welding
power
source
is
used.
See
ANSI
Z49.1
and
OSHA
TITLE
29,
CHAPTER
XVII,
PART
1910,
Subpart
0.
Figure
2-4.
Paralleling
Welding
Power
Sources
swam3.1
2/93
1
Master
Welding
Power
Source
2
Control
3
Slave
Welding
Power
Source
4
Negative
Weld
Output
Cables
5
Paralleled
Negative
Weld
Output
Cable
3
6
Positive
Weld
Output
Cables
7
Paralleled
Positive
Weld
Output
Cable
Paralleled
weld
output
cables
need
to
be
sized
for
the
largest
amount
of
weld
output
available
from
the
paralleled
welding
power
sources.
See
Table
2-1.
Be
sure
paralleled
weld
cables
are
connected
postive-to-positve
and
negative-to-negative.
ST-800
053
N
OTE
~
Welding
power
source
input
power
circuit
grounding
conductors
must
be
tied
together
to
a
proper
ground.
2
OM-158
601
Page
3
1
Balancing
Control
Figure
3-1.
Front
View
Of
Control
-~
3
Months
-~
3
Months
-~
6
Months
:~:
Ujadable
Clean
And
Tighten
Weld
2-3
Connections
REMOTE
14
1
SL~!
010
INCREASE
MASTeR
1~\\l~VI/,
0
0
0
BA~NCECO~ROL
~T~E
PARA~ELING
FEEDER
V
BALANCING!
Eo:oo
~
o~rrptjT
(CONTACTORI
The
scale
around
the
control
is
for
reference
only.
The
control
is
ac
______________________________________________________________________________________
tually
varying
the
command
signal
to
the
slave
welding
power
source.
The
slave
output
is
varied
to
keep
total
output
of
the
two
welding
pow
er
sources
balanced.
\
5T-158
158/
Ref.
S0004-A
Figure
3-2.
Maintenance
Schedule
OM-158
601
Page
5
SECTION
4
ELECTRICAL
DIAGRAMS
O-IOVDC
E
COMMAND
COMMON
G
CHASSIS
K
GND
PLG2
O-IOVDC
E
COMMAND
MASTER
GND
0
POWER
SUPPLY
+IOVDC
C
B
A
J
I
C
ON
T
ACT
OR
CONTROL
I
15V
SLAVE
B
CONTACTOR
POWER
CONTROL
24V
SUPPLY
E
(O-IOVDC
COMMAND)
H5
VAC
PC
I
PC5/PLG5
I5VAC
CONT
ACTOR
CONTROL
I
15V
24VAC
CONTACTOR
CONTROL
24V
REMOTE
CONTROL
UNIT
D
(GND)
3
d
5
6
7
8
9
/0
0
0 0
0 0
0
0
0
3A
4A
5A
BA
7A
BA
9A
IOA
38
4B
58
68
78
88
98
I
08
Figure
4-1.
Circuit
Diagram
For
Control
SA-158
083
OM-158
601
Page
6
PLGI
PLG2
PLG3
PC
I
Figure
4-2.
Wiring
Diagram
For
Control
SC-156
130
OM-158
601
Page
7
SECTION
5-
PARTS
LIST
Dia.
Part
Mkgs.
No.
Description
Quantity
PCi
135400
PC2
158099
PLG1
023618
PLG2,3
141
162
134731
079 739
600
797
600342
PLG4
135558
079747
PLG5
135559
079
747
Al
009156
RC1
143976
079
534
Ti
035759
iT
098828
164263
127363
158098
158097
159
083
010
610
097
922
019
663
073
756
CIRCUIT
CARD,
power
supply
1
CIRCUIT
CARD,
interface
isolation
1
CORD
SET,
125V
5-15P
l6ga
3/c
lOft
1
CONNECTOR
&
PINS,
(consisting
of)
I
CONNECTOR,
circ
pin
push-in
14-l8ga
Amp
213603-1
14
CONNECTOR,
circ
clamp
str
nt
sz
17-20
Amp
206322-2
1
CABLE,
port
No.
16
8/c
(order
by
ft)
6ft
CABLE,
port
No.
16
4/c
(order
by
ft)
6ft
CONNECTOR
&
SOCKETS,
(consisting
of)
1
CONNECTOR,
rect
skt
24-l8ga
Amp
350980-1
7
CONNECTOR
&
SOCKETS,
(consisting
of)
1
CONNECTOR,
rect
skt
24-lBga
Amp
350980-1
12
POTENTIOMETER,
C
std
slot
l/T
2W
2.5K
ohm
1
CONNECTOR
w/SOCKETS,
(consisting
of)
1
CONNECTOR,
circ
skt
push-in
14-l8ga
Amp
66358-6
14
TRANSFORMER,
control
mintr
115/36VCT
1
BLOCK,
term
bA
lOP
1
BRACKET
SUPPORT,
terminal
strip
1
LABEL,
warning
electric
shock
can
kill
1
CASE
SECTION,
back/sides/end
1
COVER,
top
1
NAMEPLATE,
(order
by
model
and
serial
number)
1
PANEL,
mtg
control
1
CONNECTOR,
clamp
cable
.500
4
KNOB,
pointer
1
MOUNT,
nprn
15/16
OD
x
3/8rec
4
STAND-OFF,
6-32
x
.625
Ig
7
OM-158
601
Page
8
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Miller KD480481 Owner's manual

Miller
Brand
Miller
Model
KD480481
Category
Welding System
Type
Owner's manual
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