Miller KK001686 Owner's manual

Brand: Miller

Model: KK001686

Category: Welding System

Type: Owner's manual

This manual is also suitable for

Visit our website at

www.MillerWelds.com

CP/CC-1500P

Processes

Description

Air Carbon Arc (CAC-A)

Cutting and Gouging

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Arc Welding Power Source

OMĆ271 049 517G

April 1999

Submerged (SAW) Welding

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. To locate your nearest

distributor or service agency call 1-800-4-A-Miller,

or visit us at www.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Now

you can get the job done and get it done right. We know

you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc

welders in 1929, he made sure his products offered

long-lasting value and superior quality. Like you, his

customers couldn’t afford anything less. Miller products

had to be more than the best they could be. They had to

be the best you could buy.

Today, the people that build and sell Miller products continue the

tradition. They’re just as committed to providing equipment and service

that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety precautions. They will

help you protect yourself against potential hazards on the worksite. We’ve

made installation and operation quick and easy.

With Miller you can count on years of reliable

service with proper maintenance. And if for

some reason the unit needs repair, there’s a

Troubleshooting section that will help you

figure out what the problem is. The parts list

will then help you to decide which exact part

you may need to fix the problem. Warranty and

service information for your particular model

are also provided.

Miller is the first welding

equipment manufacturer in

the U.S.A. to be registered to

the ISO 9001 Quality System

Standard.

Working as hard as you do

– every power source from

Miller is backed by the most

hassle-free warranty in the

business.

From Miller to You

Miller offers a Technical

Manual which provides

more detailed service and

parts information for your

unit. To obtain a Technical

Manual, contact your local

distributor. Your distributor

can also supply you with

Welding Process Manuals

such as SMAW, GTAW,

GMAW, and GMAW-P.

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols for Installation, Operation, and Maintenance 3. . . . . . . . . . . . . . . . . . . . . .

1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . .

1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Dangers relatifs au soudage à l’arc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Information sur les champs électromagnétiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – INSTALLATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Duty Cycle 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Volt-Ampere Curves 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Selecting A Location And Moving The Welding Power Source 10. . . . . . . . . . . . . . . . . . . . . . . .

2-5. Overall Dimensions And Base Mounting Hole Layout 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Selecting And Preparing Weld Output Cables 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Weld Cable Size 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8. Connecting To Weld Output Terminals 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-9. Remote Contactor Control Connections, 115 Volts AC Twistlock Receptacle, And

115 Volts AC Duplex Receptacle 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-10. Remote Amperage/Voltage Control Information And Connections 13. . . . . . . . . . . . . . . . . . . . .

2-11. Adapter Cord Installation 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-12. Start Control Selection And Low Input Voltage Adjustment 14. . . . . . . . . . . . . . . . . . . . . . . . . . .

2-13. Contactor Interlock Connections 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-14. Positioning Jumper Links 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-15. Connecting Input Power 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-16. Electrical Service Guide 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – OPERATION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Controls 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Work Clamp 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Ammeter And Voltmeter (Optional) 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Start Amperage Control 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. CV/CC Switch 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Weld Amperage/Voltage Control 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Output (Contactor) Control Switch 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Remote Amperage/Voltage Switch 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Power Switch And Pilot Light 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Sequence Of Flux Cored Arc Welding (FCAW) 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11. Sequence Of Submerged Arc Welding (SAW) 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-12. Sequence Of Air Carbon Arc Cutting And Gouging (CAC-A) 21. . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – MAINTENANCE & TROUBLESHOOTING 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Routine Maintenance 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Output Overload Circuit Breaker CB1 And Control Overload Circuit Breaker CB2 22. . . . . . . .

4-3. Fuses F1, F2, F3, F4, And F5 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Troubleshooting 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – ELECTRICAL DIAGRAMS 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – PARTS LIST 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES

WARRANTY

WARNING

This product, when used

for welding or cutting,

produces fumes or

gases which contain

chemicals known to the

State of California to

cause birth defects and,

in some cases, cancer.

(California Health &

Safety Code Section

25249.5 et seq.)

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OM-271 Page 1

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

som _nd_5/97

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in

the adjoining symbols.

Y Marks a special safety message.

. Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions

to avoid the hazards.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see

the symbol, watch out, and follow the related instructions to

avoid the hazard. The safety information given below is only

a summary of the more complete safety information found in

the Safety Standards listed in Section 1-4. Read and follow all

Safety Standards.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks

or severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic wire welding, the

wire, wire reel, drive roll housing, and all metal parts touching the

welding wire are electrically live. Incorrectly installed or improperly

grounded equipment is a hazard.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.

D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D Use AC output ONLY if required for the welding process.

D If AC output is required, use remote output control if present on

unit.

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

D Always verify the supply ground – check and be sure that input

power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first – double-check connections.

D Frequently inspect input power cord for damage or bare wiring –

replace cord immediately if damaged – bare wiring can kill.

D Turn off all equipment when not in use.

D Do not use worn, damaged, undersized, or poorly spliced cables.

D Do not drape cables over your body.

D If earth grounding of the workpiece is required, ground it directly

with a separate cable – do not use work clamp or work cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.

D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal of

input power on inverters.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section

before touching any parts.

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

FUMES AND GASES can be hazardous.

D Keep your head out of the fumes. Do not breathe the fumes.

D If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases.

D If ventilation is poor, use an approved air-supplied respirator.

D Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings,

cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form

highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld

area, the area is well ventilated, and if necessary, while wearing an

air-supplied respirator. The coatings and any metals containing

these elements can give off toxic fumes if welded.

OM-271 Page 2

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays

that can burn eyes and skin. Sparks fly off from the

weld.

ARC RAYS can burn eyes and skin.

D Wear a welding helmet fitted with a proper shade of filter to protect

your face and eyes when welding or watching (see ANSI Z49.1

and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash and

glare; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant mate-

rial (leather and wool) and foot protection.

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up. Sparks

can fly off from the welding arc. The flying sparks, hot

workpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can cause

sparks, explosion, overheating, or fire. Check and be sure the area is

safe before doing any welding.

WELDING can cause fire or explosion.

D Protect yourself and others from flying sparks and hot metal.

D Do not weld where flying sparks can strike flammable material.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.

D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly

unknown paths and causing electric shock and fire hazards.

D Do not use welder to thaw frozen pipes.

D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.

D Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.

D Allow cooling period before working on gun or

torch.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.

D Wearers should consult their doctor before

going near arc welding, gouging, or spot

welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

D Wear approved ear protection if noise level is

high.

Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode. Since

gas cylinders are normally part of the welding

process, be sure to treat them carefully.

CYLINDERS can explode if damaged.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.

D Never drape a welding torch over a gas cylinder.

D Never allow a welding electrode to touch any cylinder.

D Never weld on a pressurized cylinder – explosion will result.

D Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and

associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.

D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety

Standards.

OM-271 Page 3

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near

combustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring – be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of

unit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.

D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

D Keep away from moving parts.

D Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading

welding wire.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guards

closed and securely in place.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa-

tion.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained.

D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment

such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American

Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-

dent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cut-

ting of Containers That Have Held Hazardous Substances, American

Welding Society Standard AWS F4.1, from American Welding Society,

550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face

Protection, ANSI Standard Z87.1, from American National Standards

Institute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-271 Page 4

1-5. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined. Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from opera-

tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-

ble.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor,

then following the above procedures is recommended.

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OM-271 Page 8

1-4. Principales normes de sécurité

Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel-

ding Society, 550 N.W. Lejeune Rd, Miami FL 33126

Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent

of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practice for the Preparation for Welding and Cut-

ting of Containers That Have Held Hazardous Substances, norme AWS

F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL

33126

National Electrical Code, NFPA Standard 70, de la National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

de la Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

Règles de sécurité en soudage, coupage et procédés connexes, norme

CSA W117.2, de l’Association canadienne de normalisation, vente de

normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protec-

tion, norme ANSI Z87.1, de l’American National Standards Institute,

1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme NFPA 51B, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5. Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les effets, pour l’organisme,

des champs magnétiques basse fréquence

Le courant de soudage, pendant son passage dans les câbles de sou-

dage, causera des champs électromagnétiques. Il y a eu et il y a encore

un certain souci à propos de tels champs. Cependant, après avoir ex-

aminé plus de 500 études qui ont été faites pendant une période de

recherche de 17 ans, un comité spécial ruban bleu du National Re-

search Council a conclu: “L’accumulation de preuves, suivant le

jugement du comité, n’a pas démontré que l’exposition aux champs

magnétiques et champs électriques à haute fréquence représente un

risque à la santé humaine”. Toutefois, des études sont toujours en cours

et les preuves continuent à être examinées. En attendant que les con-

clusions finales de la recherche soient établies, il vous serait

souhaitable de réduire votre exposition aux champs électromagnéti-

ques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques dans l’environnement

de travail, respecter les consignes suivantes :

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif.

2 Mettre tous les câbles du côté opposé de l’opérateur.

3 Ne pas courber pas et ne pas entourer pas les câbles autour de

votre corps.

4 Garder le poste de soudage et les câbles le plus loin possible de

vous.

5 Relier la pince de masse le plus près possible de la zone de

soudure.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout

consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est

alors recommandé de respecter les consignes ci–dessus.

OM-271 Page 9

SECTION 2 – INSTALLATION

2-1. Specifications

Amperage Voltage Maximum

Amperes Input at Rated Load

Output, Three-Phase

Rated Welding

Output

Range In CC

Mode

Range In

CV Mode

Open-Circuit

Voltage DC

230 V

60 HZ

380 V

50 HZ

460 V

60 HZ

575 V

60 HZ

KVA KW

1500 A @ 44 Volts

DC, 100% Duty

Cycle

115–1820 A

25–60 Volts

80 274 A 166 A 137 A 110 A 109 80

Continuous Welding

2-2. Duty Cycle

Duty Cycle is percentage of 10 min-

utes that unit can weld at rated load

without overheating.

If unit overheats, thermostat(s)

opens, output stops, and cooling

fan runs. Wait fifteen minutes for

unit to cool. Reduce amperage or

voltage, or duty cycle before

welding.

Y Exceeding duty cycle can

damage unit and void war-

ranty.

sduty1 5/95 / ST-007 972-B

100% Duty Cycle

ssb1.1 10/91 – ST-049 581-B

The volt-ampere curves show the

minimum and maximum voltage

and amperage output capabilities of

the welding power source. Curves

of other settings fall between the

curves shown.

2-3. Volt-Ampere Curves

OM-271 Page 10

Ref. ST-159 482-C

1 18 in (460 mm) Open Space

On Front And Rear For Good

Airflow

2 Lifting Eye

Use lifting eye to move unit.

3 Lifting Forks

If using lifting forks, extend forks out

opposite side of unit.

4 Rating Label

Locate unit near correct input pow-

er supply.

Front

Rear

2-4. Selecting A Location And Moving The Welding Power Source

OM-271 Page 11

ST-159 484

2-5. Overall Dimensions And Base Mounting Hole Layout

Weight: 1870 lb (848 kg)

Inches Millimeters

A 59-3/4 1518

B 27-1/4 696

C 46 1168

D 1-5/8 41

E 42-3/4 1086

F 15/16 24

G 25-3/8 644

H 21/32 17

Ref. S-0752

2-6. Selecting And Preparing Weld Output Cables

1 Weld Output Cable

Determine total cable length in weld

circuit and maximum welding am-

peres. Use Section 2-7 to select

proper cable size.

Use shortest cables possible.

Do not use damaged cables.

2 Terminal Lug

Use lugs of proper amperage

capacity and hole size for connect-

ing to weld output terminals.

3 Weld Cable Ends

Install connectors onto cable ends

necessary to connect cables to

welding system equipment.

10 ft (3 m)

Total Cable

Length In Weld

Circuit = 20 ft (6 m)

10 ft (3 m)

For Example,

Tools Needed:

S-0008-B

OM-271 Page 12

2-7. Weld Cable Size

Total Cable (Copper) Length In Weld Circuit Not Exceeding*

50 ft Or Less

(15m)

100 ft

(30m)

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

Welding

Amperes

10 Thru 100% Duty Cycle

100 4 4 4 3 2 1 1/0 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 2 2 1 1/0 2/0 3/0 4/0 4/0

250 1 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1/0 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

350 2/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0

400 2/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

500 4/0 4/0 4/0 2-2/0 2-3/0 2-4/0 1000 1000

600 4/0 4/0 2-2/0 2-3/0 2-4/0 1000 1000 2-750

700 4/0 2-2/0 2-3/0 2-4/0 1000 1000 2-750 2-750

800 2-2/0 2-2/0 2-3/0 2-4/0 1000 2-750 2-750 2-1000

900 2-3/0 2-3/0 2-4/0 1000 1000 2-750 2-1000 2-1000

1000 2-3/0 2-3/0 2-4/0 1000 2-7500 2-750 2-1000 2-1000

1250 2-4/0 2-4/0 750 2-750 2-750 2-1000 2-1000

1500 500 750 1000 2-750 2-1000 2-1000

1750 750 1000 2-750 2-1000 2-1000

2000 750 1000 2-750 2-1000

*Weld cable size (AWG and MCM) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

Ref. ST-048 680-C

2-8. Connecting To Weld Output Terminals

1 Door

Open door.

2 Positive (+) Weld Output

Terminal

3 Negative (–) Weld Output Ter-

minal

For Electrode Positive (DCEP),

connect work cable to negative (–)

terminal and welding system equip-

ment cable to positive (+) terminal.

For Electrode Negative (DCEN),

reverse cable connections.

Close door.

Tools Needed:

7/8 in

OM-271 Page 13

Ref. ST-048 680-C

2-9. 115 Volts AC Duplex Receptacle

1 115 Volts AC Duplex

Receptacle

A total of 15 amperes of 115 volts ac

power is shared between the du-

plex receptacle and Remote 14 re-

ceptacle pin I (see Section 2-11).

Circuit breaker CB3 (see Section

4-2) protects the duplex receptacle

and the 115 volts portion of the Re-

mote 14 receptacle from overload.

2-10. Connecting Remote Control

Ref. ST-193 901 / Ref. S-0005-A / S-0750

1 Remote Amperage/Voltage

Control Receptacle

2 Keyway

3 Plug

4 Threaded Collar

To connect to this receptacle, align

keyway, insert plug, and tighten

threaded collar.

5 Remote Amperage/Voltage

Switch (See Section 3-8)

For Socket information, see Sec-

tion 2-11.

OM-271 Page 14

2-11. Remote 14 Receptacle RC4 Information

Socket

on RC4

Information

A 24 volts, 15 amperes, 60 Hz ac. Protected by circuit breaker CB4.

24 VOLTS AC

B Contact closure to A completes 24 volts ac contactor control circuit.

C Command reference; +10 volts dc.

REMOTE OUTPUT CONTROL

D Remote control circuit common.

E 0 to +10 volts dc input command signal from remote control.

I 115 volts, 15 amperes, 60 Hz ac. Protected by circuit breaker CB3.

115 VOLTS AC

J Contact closure to I completes 115 volts ac contactor control circuit.

GND

Chassis common.

Circuit common for 24 and 115 volts ac circuits.

A/V AMPERAGE

F Current feedback; +1 volt dc per 200 amperes (or, +1 volt dc per 100

amperes, see Section 2-12).

VOLTAGE

H Voltage feedback; +1 volt dc per 10 output terminal volts.

2-12. Start Control Selection, Low Input Voltage Adjustment, And Current Feedback

Scaling

Ref. ST-159 572-A / Ref. SB-193 713

1 Front Panel Circuit Board Ac-

cess Door

2 Circuit Board PC1

3 DIP Switch S1

S1 switch functions:

1 Low primary– On (Down) for

low primary compensation

2 Not Used

3 Current Signal Scaling – On

(Down) for 1 volt dc/100 amps

4 Not Used

5 Start control disable – On

(Down) to disable start control

This unit is shipped so that start

control works in the CC mode. To

turn Off start control in the CC

mode, place switch S1-5 in the On

(Down) position. NOTE: Start con-

trol is automatically disabled in the

CV mode.

If input voltage is usually low, place

S1-1 in the On (Down) position.

NOTE: Low primary voltage com-

pensation only works in the CV

mode. While in the CC mode, the

position of S1-1 has no affect on

output.

This unit is shipped so that current

feedback scaling from pin F of the

Remote 14 receptacle is 1 volt dc

per 200 amperes. To change scal-

ing to 1 volt dc per 100 amperes,

place S1-3 in On (Down) position.

Close and secure access door.

Do not operate unit in the low input voltage position

if input voltage is normal, otherwise output control

becomes more sensitive and difficult to adjust.

Tools Needed:

OM-271 Page 15

2-13. Contactor Interlock Connections

Ref. ST-159 483

A set of normally-open contacts is

provided on the contactor interlock

for connecting equipment that re-

quires a contact closure for opera-

tion. To make connections, proceed

as follows:

Remove top and right side panel.

1 Strain Relief Connector

2 Equipment Cord

Insert cord from equipment through

strain relief.

3 Contactor Terminal NO

4 Contactor Terminal C

Connect equipment cord to termi-

nals NO and C. Use lugs of proper

amperage capacity and correct

hole size.

Tighten strain relief.

Reinstall top and side panel, or go

to Section 2-14 or 2-15 as

applicable.

Tools Needed:

3/8 in

Right Side

OM-271 Page 16

2-14. Positioning Jumper Links

Single voltage 50 Hz models do not have an input terminal board and jumper links.

Check the unit data label for input voltage requirements.

NOTE

Ref. ST-159 481-B

Jumper links allow operation on dif-

ferent input voltages and are facto-

ry set for the highest input voltage.

Check input voltage available at

site.

Remove right side panel to check

jumper links.

1 Input Voltage Label – Only

One Is On Unit

Look at jumper links and compare

link position with unit label.

2 Input Voltage Jumper Links

3 Bus Bars

Move bars and links to match input

voltage. For example, use 230 volts

position when 230 volts input power

is available.

Reinstall side panel or go on to Sec-

tion 2-15.

Tools Needed:

11/16 in

3/8 in

460 VOLTS 575 VOLTS

S-158 866

230 VOLTS 460 VOLTS

S-158 867

OM-271 Page 17

2-15. Connecting Input Power

Have only qualified persons make

this installation.

Remove right side panel.

1 Line Disconnect Device Of

Proper Rating

2 Strain Relief Connector

3 Input Conductors

4 Grounding Conductor

Select size and length using Sec-

tion 2-16. Conductor insulation

must comply with national, state,

and local electrical codes. Use lug

with correct hole size for grounding

conductor.

5 Contactor

6 Line Terminals

7 Ground Terminal

Insert conductors through strain

relief.

Connect input conductors into line

terminals on contactor as shown,

and connect grounding conductor

to ground terminal.

Install and connect input conduc-

tors and grounding conductor in

conduit or equivalent to deener-

gized line disconnect switch.

Be sure grounding conductor goes

to an earth ground.

Reinstall side panel.

8 Overcurrent Protection

Select type and size using Section

2-16. Install into deenergized line

disconnect device (fused discon-

nect switch shown).

ssb2.4* 8/92 – ST-159 816

Tools Needed:

7/16 in

3/8 in

1/4 in

3/4 in (19 mm)

Strip Insulation

Tighten And

Secure

2-16. Electrical Service Guide

Input Voltage

230 380 460 575

Input Amperes At Rated Output

274 166 137 110

Max Recommended Standard Fuse Or Circuit Breaker Rating In

Amperes

400 250 200 175

Min Input Conductor Size In AWG/Kcmil

3/0 2/0 1/0 2

Max Recommended Input Conductor Length In Feet (Meters)

186 (57) 450 (137) 402 (123) 425 (129)

Min Grounding Conductor Size In AWG/Kcmil

3 4 6 6

Reference: 1996 National Electrical Code (NEC). S-0092J

OM-271 Page 18

SECTION 3 – OPERATION

3-1. Controls

Ref. ST-048 680-C

1 Voltmeter

2 Ammeter

3 Pilot Light

4 Power Switch

5 Start Amperage Control

6 Weld Amperage/Voltage

Control

7 Remote Amperage/Voltage

Switch

8 Constant Voltage (CV)/Con-

stant Current (CC) Switch

9 Output (Contactor) Switch

10 24 VAC Overload Circuit

Breaker (See Section 4-2)

11 Control Overload Circuit

Breaker (See Section 4-2)

12 115 VAC Overload Circuit

Breaker (See Section 4-2)

13 Output Overload Circuit

Breaker (See Section 4-2)

23 4 56

3-2. Work Clamp

1 Work Clamp

Use wire brush or sandpaper to

clean metal at weld joint area. Use

chipping hammer to remove slag

after welding.

Connect work clamp to a clean,

paint-free location on workpiece, as

close to weld area as possible.

sb4.1 5/92

Tools Needed:

OM-271 Page 19

3-3. Ammeter And Voltmeter (Optional)

Ref. ST-049 187-E

1 Voltmeter

Voltmeter displays voltage at the

weld output terminals, but not nec-

essarily the welding arc due to

cable resistance, poor connec-

tions, etc.

2 Ammeter

Ammeter displays weld amperage

output of unit.

3-4. Start Amperage Control

1 Start Amperage Control

Use control to help start an arc in

the CC mode.

Set Start Amperage control higher

than Weld Amperage control to as-

sist arc starting in CC mode.

Select setting best suited for appli-

cation. Numbers around control are

for reference only.

This control has no affect in CV

mode.

This control can be adjusted while

welding.

Ref. ST-193 901

3-5. CV/CC Switch

1 CV/CC Switch

In the CV position, the unit provides

weld output characteristics specifi-

cally designed for wire feeding

applications.

In the CC position, the unit provides

output for welding applications re-

quiring constant current weld out-

put characteristics.

OM-271 Page 20

3-6. Weld Amperage/Voltage Control

1 Weld Amperage/Voltage

Control

Use control as a means of selecting

weld output (weld amperage for CC

mode, weld voltage for CV mode).

This control can be adjusted while

welding.

Numbers around control are for ref-

erence only.

3-7. Output (Contactor) Control Switch

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Do not touch weld output terminals when contactor is energized.

• Do not touch electrode and work clamp at the same time.

swarn7.1 10/91

1 Output (Contactor) Switch

Use switch to select way of control-

ling unit output.

For front panel control, place switch

in On position.

For remote control, place switch in

Remote position.

Weld output terminals are

energized when switch is

On and Power is On.

Ref. ST-193 899

3-8. Remote Amperage/Voltage Switch

1 Remote Amperage/Voltage

Switch

For remote control of output, place

switch in Remote position.

For front panel control of output,

place switch in Panel position.

2 Remote 14 Receptacle (see

Sections 2-10 and 2-11)

Ref. ST-193 901

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Miller KK001686 Owner's manual

Brand: Miller

Model: KK001686

Category: Welding System

Type: Owner's manual

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