Miller KD27 Owner's manual
- Category
- Welding System
- Type
- Owner's manual
This manual is also suitable for
cover 1/94 − Ref. ST-141 294-A PRINTED IN USA
© 1994 MILLER Electric Mfg. Co.
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.
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
OWNER’S
MANUAL
March 1994 Form: OM-826H
Effective With Style No. KD27
Remote Foot Controls
For Remote Amperage, Voltage, And Output (Contactor) Control
For SMAW And GTAW Welding
20 ft (6 m) Interconnecting Cord
RFC-14, RFC-23A, RFC-23AG,
RFCS-23, And RFC-23GD25A
OM-826H − 3/94
EMF INFORMATION
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields −
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): “. . . there is now a very large
volume of scientific findings based on experiments at the cellular
level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
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 the body.
4. Keep welding power source and cables as far away as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.
Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields
NOTE
mod10.1 4/93
TABLE OF CONTENTS
SECTION 1 − SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INSTALLATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATION
4-1. Adjusting Amperage Or Voltage Without Output (Contactor) Control 4. . . . . . . . . . . . . . . . . .
4-2. Adjusting Amperage Or Voltage With Output (Contactor) Control 5. . . . . . . . . . . . . . . . . . . . .
SECTION 5 − MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Troubleshooting 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − ELECTRICAL DIAGRAMS 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − PARTS LIST
Figure 7-1. Complete Assembly 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-826 Page 1
SECTION 1 − SAFETY INFORMATION
mod1.1 2/93
Read all safety messages throughout this manual.
Obey all safety messages to avoid injury.
Learn the meaning of WARNING and CAUTION.
1 Safety Alert Symbol
2 Signal Word
WARNING means possible death
or serious injury can happen.
CAUTION means possible minor
injury or equipment damage can
happen.
3 Statement Of Hazard And Re-
sult
4 Safety Instructions To Avoid
Hazard
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.
2
NOTE
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Disconnect input power before
installing or servicing.
WARNING
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
WARNING
5
4
6
7
1 2
CAUTION
MOVING PARTS can injure.
• Keep away from moving parts.
• Keep all panels and covers closed
when operating.
3
Turn Off switch when using high frequency.
Figure 1-1. Safety Information
SECTION 2 − SPECIFICATIONS
Table 2-1. Remote Foot Control
Specification Description
Model Description RFC: Remote Foot Control
Interconnecting Cord 20 ft ( 6 m)
Overall Dimensions See Figure 3-1
OM-826 Page 2
SECTION 3 − INSTALLATION
Ref ST-141 294-A
Inches Millimeters
A 7-1/2 190
B 6-1/4 159
C 11 279
A
B
C
Figure 3-1. Overall Dimensions
ST-800 096
Turn Off welding power source, or
stop engine on welding generator.
1 Welding Power Source Or
Generator
2 Remote Foot Control
3 Interconnecting Cord(s)
Units are equipped with a 20 ft (6
m) multiconductor cord(s) (unless
otherwise specified). If a longer
cord is required, see Table 3-1.
4 14- Or 5-Pin Amphenol Plug
Insert plug into matching receptacle
on welding power source or welding
generator, and tighten threaded col-
lar.
5 Twistlock Plugs
Insert plugs into matching recep-
tacles on welding power source or
welding generator, and tighten cap
clockwise as far as it will go.
OR
1
2
3
5
1
2
3
4
Figure 3-2. Interconnections
OM-826 Page 3
Table 3-1. Interconnecting Cord Conductor Length And Size
Amperage Or Voltage Control Contactor Control
Cord Length Conductor Size* Cord Length Conductor Size*
Up to 20 ft (6 m) No. 16
Up to 20 ft (6 m) (GD Models) No. 14
21 to 100 ft (6 to 30 m) (GD Models) No. 12
21 to 50 ft (6 to 15 m) No. 14 Up to 200 ft (61 m) No. 16
51 to 100 ft (16 to 31 m) No. 12
101 to 200 ft (31 to 61 m) No. 10
*AWG − American Wire Gauge
SECTION 4 − OPERATION
WARNING
ELECTRIC SHOCK can kill.
• Always wear dry insulating gloves.
• Insulate yourself from work and ground.
• Do not touch live electrical parts.
• Keep all panels and covers securely in place.
FUMES AND GASES can be hazardous
to your health.
• Keep your head out of the fumes.
• Ventilate area, or use breathing device.
• Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.
WELDING can cause fire or explosion.
• Do not weld near flammable material.
• Watch for fire; keep extinguisher nearby.
• Do not locate unit over combustible surfaces.
• Do not weld on closed containers.
• Allow work and equipment to cool before handling.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
• Wear welding helmet with correct shade of filter.
• Wear correct eye, ear, and body protection.
MAGNETIC FIELDS FROM HIGH CUR-
RENTS can affect pacemaker operation.
• Pacemaker wearers keep away.
• Wearers should consult their doctor before going
near arc welding, gouging, or spot welding opera-
tions.
See Safety Precautions at beginning of welding power
source or welding generator manual for basic welding
safety information.
swarn6.1* 10/91
See welding power source or welding generator Owner’s Manual to determine if
Remote Foot Control will act as a fine Amperage or Voltage control, or as a full
range Amperage or Voltage control.
NOTE
OM-826 Page 4
4-1. Adjusting Amperage Or Voltage Without Output (Contactor) Control
Ref. ST-122 023-A / Ref. ST-141 127-A / ST-039 411-D
EXAMPLE Of Fine Remote Amperage Control Without Output (Contactor) Control
Set Switch Set Desired Max. Amperage Press Control To Adjust Amperage
Or
EXAMPLE Of Full Remote Amperage Control Without Output (Contactor) Control
Min
(40 A)
(Control
Setting,
Set Switch
Control Setting
Press Control To Adjust Amperage
Min
(40 A)
Unit
Maximum
Does Not Matter
For Application
200 A)
(375 A)
Max
In Example: Min = 40 A In Range B
Max = 200 A In Range B (Control Setting)
In Example: Min = 40 A In Range B
Max = 375 A In Range B
Figure 4-1. Examples Of Amperage Or Voltage Adjustment Without Output (Contactor) Control
OM-826 Page 5
4-2. Adjusting Amperage Or Voltage With Output (Contactor) Control
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
Ref. ST-159 059
Set Switches Set Control
EXAMPLE Of Fine Remote Amperage/Voltage Control With Output (Contactor) Control
Press control to turn weld output On.
Release control to turn weld output Off.
Or
EXAMPLE Of Full Remote Amperage/Voltage Control With Output (Contactor) Control
Press control to turn weld output On.
Release control to turn weld output Off.
On
Unit
Minimum
Control
Setting
Off
On
Unit
Minimum
Unit
Maximum
Off
(200 A or
24 V)
(375 A or
36 V)
Set Switches Control Setting
Does Not Matter
Figure 4-2. Examples Of Amperage Or Voltage Adjustment With Output (Contactor) Control
OM-826 Page 6
SECTION 5 − MAINTENANCE & TROUBLESHOOTING
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off welding power source, and disconnect
remote control before inspecting, maintaining, or
servicing. Stop engine on welding generator.
HOT PARTS can cause severe burns.
• Allow cooling period before maintaining or servicing.
Maintenance to be performed only by qualified persons.
swarn8.1* 2/93
5-1. Routine Maintenance
Turn Off all power before
maintaining.
3 Months
Replace
Unreadable
Labels
Everyday
14-Pin Cord
Replace
Cracked
Parts
Move Control
From Min To
Max
Figure 5-1. Maintenance Schedule
5-2. Troubleshooting
Table 5-1. Welding Trouble
Trouble Remedy Section
No amperage or voltage control. Set switches and controls on welding power source or generator. 4-1, 4-2, *
Be sure welding power source Power switch is On. − −
Secure cord connections or replace cords, if necessary. Figure 3-2
No output (contactor) control. Set switch on welding power source or generator. 4-2, *
Be sure welding power source Power switch is On. − −
Secure cord connections or replace cords, if necessary. Figure 3-2
*See welding power source or generator Owner’s Manual.
OM-826 Page 7
SECTION 6 − ELECTRICAL DIAGRAMS
SA-130 542 / SA-130 512
Figure 6-1. Circuit And Wiring Diagram For RFC-14
SA-162 462
Figure 6-2. Circuit Diagram For RFC-23A
OM-826 Page 8
SA-162 463
Figure 6-3. Circuit Diagram For RFC-23AG
SA-162 464
Figure 6-4. Circuit Diagram For RFCS-23
OM-826 Page 9
SA-162 465
Figure 6-5. Circuit Diagram For RFC-23GD25A
OM-826 Page 10
SECTION 7 − PARTS LIST
12
345
6
7
8
9
10
11
12
14
15
31
ST-145 917-B
13
16
17
18
19
20
21
22
23
24
25
30
29
28
17
27
26
Figure 7-1. Complete Assembly
OM-826 Page 11
ModelDescription
Part
No.
Dia.
Mkgs.
Item
No.
RFC-23GD25A RFCS-23Figure 7-1. Complete Assembly RFC-14RFC-23AGRFC-23A
Quantity
1 601 970 SCREW, cap stl hex hd .375-24 x 4.500 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 019 662 PEDAL, foot 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 009 490 PEDAL, foot 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 010 789 SPRING, torsion 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 +159 894 CASE SECTION, cover/end 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
085 220 LABEL, caution electric circuit etc 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 115 104 CONNECTOR, clp - cable .500 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
000 527 BLANK, snap-in nyl .875mtg hole 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 053 786 CORD SET, pwr 115V 16ga 2/c 20ft 1. . . . . . . . . . . . . . . . . . . . .
6 600 733 CORD SET, pwr 115V 16ga 3/c 20ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 136 823 CORD SET, pwr 115V 16ga 2/c 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 039 618 PLUG, twlk 2P 2W 20A 250V 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 035 494 PLUG, twlk grd 2P 3W 15A 250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 600 343 CABLE, port No 16 5/c (order by ft) 20ft 21ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 039 273 PLUG, 5 pin MS3106A-16S-8P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 141 162 HOUSING PLUG & PINS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
134 731 TERMINAL, male 1 pin 18-14 wire 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 079 739 CLAMP, cable strain relief 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 039 685 CLAMP, cable AN-3057-8 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 605 797 PLUG, twlk 3P 3W 20A 125V 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 039 621 PLUG, twlk 4P 4W 20A 250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 600 733 CORD SET, pwr 115V 16ga 3/c 20ft 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . .
12 604 834 CORD, port No 14 4/c (order by ft) 26ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 139 041 BUSHING, strian relief .455/.629 ID 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 014 920 CASE SECTION, base/side 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 019 663 MOUNT, nprn 4 4 4 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 011 628 SWITCH, limit 15A 125V 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 603 947 SWITCH, limit 10A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 159 897 SCREW, shld stl sch .250-20 x .437 1 1 1 2 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 159 895 BAR,pedal - control foot 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 010 795 ACTUATOR, switch - limit 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 159 892 BRACKET, support - arm 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 159 893 ARM, brush holder 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 604 432 SCREW, cap stl sch 8-32 x 1.000 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 018 639 HOLDER, brush 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 *018 640 BRUSH, contact 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 161 306 CAP, brush holder 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 079 625 WASHER, spring stl .500 shakeproof 2 2 2 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 159 896 SCREW, shld stl sch .312-18 x .375 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 601 795 BOLT, mach stl hexhd .250-20 x 4.500 1 1 1 2 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 030 631 RESISTOR, WW adj 130W 15 ohm 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . .
29 030 051 RESISTOR, WW adj 130W 1000 ohm 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 004 652 RESISTOR, WW adj 300W 25 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 601 855 NUT, weld .250-20 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 601 850 NUT, weld stl slflkg hex .375-24 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NAMEPLATE (order by model number) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
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3
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4
-
5
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6
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7
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Miller KD27 Owner's manual
- Category
- Welding System
- Type
- Owner's manual
- This manual is also suitable for
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