Miller HK49 Owner's manual

Miller
Brand
Miller
Model
HK49
Category
Welding System
Type
Owner's manual

This manual is also suitable for

December
1983
FORM:
OM-864
Effective
With
Style
No.
HK49
MODEL
PRC-2
OWN
ERS
MANUAL
fullER
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.
01
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
1
furnished
by
Miller
is
free
from
defect
in
workmanship
and
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
material
as
of
the
time
and
place
of
delivery
by
Miller.
No
war-
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
ranty
is
made
by
Miller
with
respect
to
engines,
trade
ac-
therefore
shall
be,
at
Millers
option
(1)
repair
or
12)
replacement
cessories
or
other
items
manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(31
engines,
trade
accessories
and
other
items
are
sold
sublect
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of
their
respective
manufacturers,
if
any
.
All
Miller
service
station
or
(4)
payment
of
or
credit
for
the
purchase
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
(less
reasonable
depreciation
based
upon
actual
usel
upon
date
of
original
purchase.
return
of
the
goods
at
Customers
risk
and
expense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
clai-
~
Except
as
specified
below,
Millers
warranty
does
not
apply
mant
on
the
warranty
claim
procedures
to
be
followed.
to
components
having
normal
useful
life
of
less
than
one
Ill
year,
such
as
spot
welder
tips,
relay
and
conlactor
points,
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
M!LLERMATIC
parts
that
come
in
contact
with
the
welding
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA-
?
wire
including
nozzles
and
nozzle
insulators
where
failure
does
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
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
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
onlyl
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
6months
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER
WARRANTIES
DO
NOT
EXTEND
provided
that
Miller
is
notified
in
writing
within
thirty
1301
days
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
~
:f
ti
:0f:hJ~
~
~
:LLE~:ARR:T:STIA:CO:U:ER~
1-2.
RECEIVING-HANDLING
-
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
will
be
furnished
by
the
manufacturer
on
re
quest
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
it
is
essential
that
Model
Description
and
Style
Number
of
the
equipment
be
supplied.
1-3.
DESCRIPTION
-
This
remote
control
provides
a
separate
polarity
on
each
of
two
electrode
wires
when
using
a
dual
digital
wire
feeder,
optional
dual
digital
voltage
control,
optional
digital
dual
schedule
control,
and
one
welding
power
source.
This
unit
is
equipped
with
contactors
to
provide
cold
wire
(electrically
deenergized)
conditions
on
the
inactive
gun
when
both
guns
are
connected
for
the
same
polar-
ity.
SECTION
2
-
2-1.
LOCATION
-
This
unit
can
be
mounted
on
the
boom
using
an
optional
mounting
bracket
or
on
the
Swingpac
base,
if
applicable.
If
the
unit
is
to
be
boom-mounted,
the
mounting
bracket
must
be
installed
to
the
boom
swivel
base.
Remove
the
hub
and
reel
support,
position
the
moun
ting
bracket,
replace
the
hub
and
reel
support,
and
secure.
Attach
the
unit
to
the
mounting
bracket.
If
the
unit
is
to
be
mounted
on
the
Swingpac
base,
posi
tion
the
unit
on
the
base
and
secure.
2-2.
WIRE
FEEDER
MODIFICATION
-
The
dual
digital
wire
feeder
is
shipped
from
the
factory
wired
for
use
with
one
welding
power
source.
In
order
for
the
polarity
reversing
control
to
function
properly,
the
dual
digital
wire
feeder
must
be
modified
to
operate
as
if
two
welding
power
sources
are
in
use.
IMPORTANT
_______________
Damage
to
equipment
will
result
if
the
dual
digital
wire
feeder
is
wired
for
use
with
one
we/ding
power
source
and
used
when
the
system
is
connected
with
one
gun
straight
polarity
and
the
other
gun
reverse
polarity.
Through
minor
modification,
the
contactor
control
cir
cuitry
of
the
wire
feeder
can
be
adapted
to
operate
two
welding
power
sources.
1.
Disconnect
power
from
wire
feeder.
This
remote
control
is
designed
specifically
for
use
with
dual
digital
controls
for
Gas
Metal-Arc
Welding
(GMAW)
and
Flux
Cored-Arc
Welding
(FCAW).
1-4.
NOMENCLATURE
-
The
terminals
and
recep
tacle
labeled
A
on
the
remote
control
correspond
to
the
Left
gun
and
associated
connections
and
controls
while
B
receptacle
and
terminals
correspond
to
the
Right
gun
and
associated
connections
and
controls.
1-5.
SAFETY
-
Before
the
equipment
is
put
into
operation,
the
safety
section
at
the
front
of
the
welding
power
source
manual
should
be
read
completely.
This
will
help
avoid
possible
injury
due
to
misuse
or
improper
welding
applications.
The
following
definitions
apply
to
CAUTION,
IMPOR
TANT
and
NOTE
blocks
found
throughout
this
manual:
~ULI~1~(
Under
this
heading,
installation,
operating,
and
maintenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
hazard
to
personnel.
I
I~
I
~i]
~I
f~
If
Under
this
heading,
installation,
operating,
and
maintenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
result
in
damage
to
equipment.
~
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
INSTALLATION
L~1UI
I
P/acing
the
POWER
switch
in
the
OFF
position
does
not
remove
power
from
all
of
the
wire
feeder
internal
circuitry.
Completely
terminate
all
elec
trical
power
to
the
wire
feeder
by
removing
the
115
volts
ac
plug
from
its
power
supply,
and
ensure
that
machinery
lockout
procedures
have
been
employed
on
the
welding
power
sources
input
line
(see
Instruc
tion
Manual
on
welding
power
source)
before
attemp
ting
any
inspection
or
work
inside
the
unit.
115
Volts
AC
Interconnecting
Cord
Left
Interconnecting
cord
Right
Interconnecting
Cord
SECTION
1
-
INTRODUCTION
1-1.
GENERAL
-
This
manual
has
been
prepared
especially
for
use
in
familiarizing
personnel
with
the
design,
installation,
operation,
maintenance,
and
troubleshooting
of
this
equipment.
All
information
presented
herein
and
on
various
labels,
tags,
and
plates
on
the
unit
should
be
given
careful
consideration
to
assure
optimum
performance
of
this
equipment.
Left
Secondary
Terminals
Right
Secondary
Terminals
Figure
2-1.
Component
Location
OM-864
Page
1
2.
Remove
the
wrapper
from
the
control
box
on
the
wire
feeder.
3.
Locate
terminal
strip
11
on
baffle
in
the
wire
feeder.
4.
Disconnect
lead
No.
39
from
terminal
K
on
ter
minal
strip
iT
and
reconnect
it
to
terminal
E.
5.
Replace
wrapper.
CAUTION:
_______
Before
making
any
connections
between
the
PRC
unit
and
any
other
controls,
ensure
that
all
equipment
is
deenergized.
Completely
terminate
all
electrical
power
to
the
wire
feeder
by
removing
the
115
volts
ac
plug
from
its
power
supply,
and
ensure
that
machinery
lockout
procedures
have
been
employed
on
the
welding
power
sources
input
lines.
2-3.
DVC
TO
PRC
CONNECTION
(Figures
2-1,
2-2,
2-3,
2-4)
-
The
Wire
Feed
Control
plug
from
the
DVC
unit
plugs
into
the
receptacle
on
the
end
of
the
115
VOLTS
AC
interconnecting
cord
from
the
PRC
unit.
Align
keyways,
insert
plug
into
receptacle
and
rotate
threaded
collar
clockwise.
2-4.
PRC
TO
CONTROL/FEEDER
CONNECTIONS
(Figures
2-1, 2-2,
2-3,
2-4)
-
The
LEFT
interconnec
ting
cord
from
the
PRC
unit
plugs
into
the
115
Volts/Left
Contactor
Control
receptacle
on
the
wire
feeder.
Align
keyways,
insert
plug
into
receptable,
and
rotate
threaded
collar
clockwise.
The
RIGHT
interconnecting
cord
from
the
PRC
unit
plugs
into
the
Right
Contactor
Control
receptacle
on
the
wire
feeder.
Align
keyways,
insert
plug
into
recep
tacle,
and
rotate
threaded
collar
clockwise.
2-5.
SECONDARY
CONNECTIONS
(Figures
2-1.
2-2,
2-3,
2-4)
-
The
LEFT
and
RIGHT
interconnecting
terminals
provide
a
connection
point
for
cables
carrying
weld
output
current.
Several
different
weld
conditions
are
available
when
us
ing
the
polarity
reversing
control
with
the
dual
digital
controls.
See
the
following
instructions
and
connection
diagrams
before
making
the
secondary
connections.
I~IsIH~
Interconnecting
weld
cables
are
supplied
with
boom
mounted
wire
feeders.
These
cables
extend
out
the
back
of
the
boom.
The
cable
connecting
the
Left
gun
is/abe/ed
LEFT;
the
cable
connecting
the
Right
gun
is
not
labeled.
All
bench
mounted
wire
feeders
require
customer
sup
plied
interconnecting
cables.
Refer
to
the
welding
power
source
Owners
Manual
for
proper
cable
sizes.
These
cables
must
be
connected
to
the
appropriate
gun
weld
cable
terminal
at
the
drive
assembly.
All
other
cable
carrying
weld
current
(such
as
jumper
cables
or
cab/es
from
the
we/ding
power
source)
must
be
of
adequate
current
carrying
capacity
for
the
an
ticipated
maximum
load.
1.
Both
Guns
Same
Polarity
(Figure
2-2)
IkITI~
This
connection
will
electrically
iso/ate
guns
so
that
only
one
electrode
wire
is
energized
at
any
time.
a.
For
Reverse
Polarity
(shown
in
Figure
2-2)
Connect
a
cable
from
the
welding
power
source
POSITIVE
(or
POSITIVE
WITH
SLOPE)
output
terminal
to
the
LEFT
ter
minal
on
the
PRC
unit.
Digital
Dual
lule
Control
Dual
Digital
Voltage
Control
Dual
Digital
Wire
Feeder
Gas
Output
To
Guns
TA-046
881-A
115
Volts/Contactor
Control
Cable
Wire
Drive
Motor
Left
Drive
Roll
Assembly
Right
Drive
Roll
Assembly
Trigger
Control
Cables
Voltage
Sensing
Leads
Current
Relay
Connections
-
DVC
MP
Models
Only
Indicates
Weld
Current
Path
Trigger
connections
when
DDSC
is
not
used
Figure
2-2.
Both
Guns
Same
Polarity
(Reverse
Polarity
Shown)
OM.864
Page
2
b.
Connect
a
jumper
cable
between
the
PRC
LEFT
and
RIGHT
terminals.
c.
Connect
the
Left
gun
weld
cable
to
the
re
maining
LEFT
terminal
on
the
PRC
unit.
d.
Connect
the
Right
gun
weld
cable
to
the
re
maining
RIGHT
terminal
on
the
PRC
unit.
e.
Connect
the
work
cable
to
the
welding
power
source
NEGATIVE
output
terminal.
IIs~I~
For
straight
polarity
(not
shown),
reverse
the
cab/es
at
the
we/ding
power
source
output
terminals.
2.
Both
Guns
Reverse
Polarity
Using
Two
Positive
Output
Terminals
(Figure
2-3)
a.
Connect
a
cable
from
the
welding
power
source
POSITIVE
output
terminal
to
the
LEFT
terminal
on
the
PRC
unit.
b.
Connect
a
cable
from
the
welding
power
source
POSITIVE
WITH
SLOPE
output
ter
minal
to
the
PRC
RIGHT
terminal.
c.
Connect
the
Left
gun
weld
cable
to
the
re
maining
LEFT
terminal
on
the
PRC
unit.
d.
Connect
the
RIGHT
gun
weld
cable
to
the
remaining
RIGHT
terminal
on
the
PRC
unit.
e.
Connect
the
work
cable
to
the
welding
power
source
NEGATIVE
output
terminal.
I~T~l~
The
positive
cables
oan
be
reversed
at
the
welding
power
source
to
provide
the
Left
gun
with
out
put
from
the
POSITIVE
WITH
SLOPE
output
terminal
and
the
Right
gun
with
output
from
the
POSITIVE
out
put
terminal.
The
voltage
sensing
lead
from
the
D
VC
unit
must
be
switched
from
the
RIGHT
terminal
on
the
PRC
unit
to
the
LEFT
terminal
on
the
PRC
unit.
3.
One
Gun
Straight
Polarity/One
Gun
Reverse
Polarity
(Figure
2-4)
I.1
Both
electrode
wires
will
be
electrically
energized
when
either
gun
trigger
is
depressed.
The
electrode
wire
in
the
Left
gun
is
positive
while
the
elec
trode
wire
in
the
Right
gun
is
negative.
I
IkA
I
~I]
l
f~
I
~
Ensure
that
the
dual
digital
wire
feeder
is
wired
for
use
with
two
welding
power
sources
(see
Section
2-2)
or
damage
to
equipment
will
result
when
the
system
is
connected
with
one
gun
straight
polarity
and
the
other
gun
reverse
polarity.
a.
Connect
a
cable
from
the
welding
power
source
POSITIVE
output
terminal
to
the
LEFT
terminal
on
the
PRC
unit.
b.
Connect
a
cable
from
the
welding
power
source
NEGATIVE
output
terminal
to
the
PRC
RIGHT
terminal.
c.
Connect
a
jumper
cable
between
the
remain
ing
LEFT
and
RIGHT
terminals
on
the
PRC
unit.
d.
Connect
the
work
cable
to
one
of
the
jumpered
terminals
on
the
PRC
unit.
115
Volts/Contactor
Control
Cable
Remote
Control
Cable
115
Volts
AC
Cable
Wire
Drive
Motor
Welding
Power
Sourcet
Left
Drive
Roll
Assembly
Right
Drive
Roll
Assembly
Trigger
Control
Cables
Digital
Dual
;chedule
Control
Positive
With
Slope
Output
Terminal
Dual
Digital
Wire
Feeder
Rear
View
Work
Voltage
Sensing
Leads
Front
View
Gas
Output
To
Guns
Current
Relay
Connections
-
DVC
MP
Models
Only
tMP
Model
Illustrated
Indicates
Weld
Current Path
Trigger
Connection
when
DDSC
is
not
used
115
Volts/Left
Contactor
Control
Cable
TA-046
879.A
Figure
2-3.
Both
Guns
Reverse
Polarity
Using
Two
Positive
Output
Terminals
OM-864
Page
3
13
7
3
Figure
A
-
Complete
Assembly
6
14-~
12
OM-864
Page
6
Item
Dia.
No.
Mkgs.
010 610
CONNECTOR,
clamp
-
cable
1/2
inch
038
639
BLOCK,
terminal
30
amp
6
pole
059 266
RELAY,
enclosed
120
voltsac
DPDTw/flange
032
618
BLADE,
fan60
Hz6inch4wing
007
678
MOTOR,
1/70
hp
115
volts
ac
1550
rpm
031
296
BRACKET,
mounting
-
motor
fan
047
497
LABEL,
general
precautionary
+047
328
CABINET
(consisting
of)
010
853
.
FASTENER,screw-slottedhdNo.2
010
855
.
RETAINER,
screw
No.
2
010 854
048
597
048
599
048 600
048
601
039
047
039 049
.
TERMINAL
BOARD,
red
039044
.BUSBAR
601
976
.SCREW,cap-hexhdl/2-13x1-1/2
601
880
.NUT,hexjaml/2-13
601
879
.NUT,hexfulll/2-13
048 475
GUARD,
stud
-
power
049
455
CORD,
No.18
2/c
(order
byft.)
079
531
CLAMP,
cable
079
878
HOUSING
PLUG
&
PINS
(consisting
of)
079
535
.
TERMINAL,
male
604
571
CORD,
portable
No.184/c
(order
byft.)
079
531
CLAMP,
cable
048
284
HOUSING
PLUG
&
SOCKETS
(consisting
of)
079 534
.
TERMINAL,
female
604
571
079
531
046
958
079
535
058
043
048
471
+
When
ordering
a
component
originally
displaying
a
precautionary
label,
the
label
should
also
be
ordered.
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Part
No.
Description
Quantity
Figure
A
Complete
Assen~bI~
2
3
4
5
6
7
8
9
10
11
12
13
14
3
1
2
1
1
1
iT
CR
1,2
FM
Wi
,2
RC2
RC3
RC1
NUT,
speed
No.
2
clip
-
on
CONTACTOR,
3P
110-120/208-240
volts
(consisting
of)
COIL,
contactor
115/230
volts
KIT,
points
LINK,
jumper
-
contactor
TERMINAL,
power
output
-
red
(consisting
of)
2
1
3
4
4
1
CORD,
No.18
4/c
(order
byft.)
CLAMP,
cable
RECEPTACLE
&
PINS
(consisting
of)
TERMINAL,
male
HOSE,1/2IDxll/16ODx4
TOOL,
extraction
-
pin
amp
(optional
equipment)
10
ft.
2
10
ft.
4
10
ft.
4
OM-864
Page
7
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10

Miller HK49 Owner's manual

Miller
Brand
Miller
Model
HK49
Category
Welding System
Type
Owner's manual
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