Miller KC179876 Owner's manual

Miller
Brand
Miller
Model
KC179876
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Millerfi
March
1992
FORM:
OM-146
741
Effective
With
Serial
No.
KC179876
MODEL:
XMTfi
300
CC
OWNERS
MANUAL
IMPORTANT:
Read
and
understand
the
entire
contents
of
this
manual,
with
special
emphasis
on
the
safety
material
throughout
the
manual,
before
installing,
operating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equipment.
Do
not
allow
untrained
persons
to
install,
operate,
ormaintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
MILLER
ELECTRIC
Mfg.
Co.
A
M~1er
Group
Ltd..
Compeny
P~
Box
1079
Appleton,
WI
54912
USA
T~.
414-734-9821
~ver1
1/92
-
ST-152
303-A
PRINTED
IN
USA
I
\~7
~LI
LIMITED
WARRANTY
EFFECTIVE:
AUGUST
6.
1990
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied
LIMITED
WARRANTY
Sublect
to
the
terms
and
conditions
hereof.
MILLER
Electric
Mfg.
Co.,
Appleton.
Wisconsin
war
rants
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
furnished
by
MILLER
is
free
from
defect
in
workmanship
and
material
as
of
the
time
and
place
of
delivery
by
MILLER.
No
warranty
iS
made
by
MILLER
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
trade
accessories
and
other
items
are
sold
sublect
to
the
warranties
of
their
respective
manufacturers.
if
any.
All
engines
are
warrantied
by
their
manufacturer
for
two
years
from
date
of
original
purchase.
except
Deutz
engines
which
have
a
one
year,
2000
hOur
warranty
Except
as
specified
below.
MILLERs
warranty
does
not
apply
to
components
having
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points.
MILLERMATIC
parts
that
come
in
contact
with
the
welding
wire
including
nozzles
and
nozzle
insulators
where
failure
does
not
result
from
defect
in
workmanship
or
material,
MILLER
shall
be
required
to
honor
warranty
claims
on
war
ranted
Equipment
in
the
event
of
failure
resulting
from
a
detect
within
the
following
periods
from
the
date
of
delivery
of
Equipment
to
the
original
user:
1.
Arc
welders,
power
sources,
robots.
and
1
year
components
2.
Load
banks
1
year
3.
Original
main
power
rectifiers
3
years
(labor
1
year
only)
4.
All
welding
guns.
feeder/guns
and
torches
.
.
.
90
days
5.
All
other
MILLERMATIC
Feeders
1
year
6.
Replacement
or
repair
parts,
exclusive
of
labor
.
60
days
7.
Batteries
6
months
provided
that
MILLER
is
notified
in
writing
within
thirty
(30)
days
of
the
date
of
such
failure.
As
a
matter
of
general
policy
only,
MILLER
may
honor
claims
submitted
by
the
original
user
within
the
foregoing
periods.
In
the
case
of
MILLERS
breach
of
warranty
or
any
other
duty
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
therefore
shall
be.
at
MILLERs
option
(1
(repair
or
(2)
replace
ment
or.
where
authorized
in
writing
by
MILLER
in
appropriate
cases.
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
MILLER
service
station
or
(4)
payment
of
or
credit
for
the
purchase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
Customers
risk
and
expense.
MILLERs
option
of
repair
or
replacement
will
be
F
O.B..
Factory
at
Appleton,
Wisconsin,
or
F
0
B
at
a
MILLER
authorized
service
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed
Upon
receipt
of
notice
of
apparent
defect
or
failure,
MILLER
shall
instruct
the
claimant
on
the
warranty
claim
procedures
to
be
followed.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRE
SENTATION
AS
TO
PERFORMANCE.
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION.
MIGHT
ARISE
BY
IMPLICATION.
OPERATION
OF
LAW.
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING.
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCI-IAN
lABILITY
OR
OF
FITNESS
FOR
PARTICULAR
PURPOSE.
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLERS
WARRANTIES
DO NOT
EXTEND
TO.
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO.
ANY
CONSUMER.
I
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
damage
that
may
have
occurred
during
shipment.
File
any
cla~rns
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
m~iiar
8,91
ERRATA
SHEET
June
10,
1992
FORM:
OM-146
741
Use
above
FORM
number
when
ordering
extra
manuals.
147824
042517
153736
.
.138114
149209
138
114
149209
042517
155
520
042
805
+155480
+155
605
031
689
155634
031
689
155634
042
805
I
1
1
4
1
4
1
~First
digit
represents
page
no
digits
following
dash
represent
item
no.
Part
of
042
805
Meter
Kit
Option
+For
correct
part
number
of
circuit
card,
check
part
number
located
on
the
circuit
card
in
unit.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
CHANGES
TO
SECTION
8-
PARTS
LIST
Change
Parts
List
as
follows:
--
Dia.
Part
Mkgs.
No.
Replaced
With
Description
Quantity
25-6...
PC5
25-
27-5...
PCi
27-5...
PCi
28-
..
C44-47
28-
..
013-16
28-
..
C40-43
28-
..
D9-12
28-
CIRCUIT
CARD,
meter
METER
KIT
OPTION,
(see
footnote)
CIRCUIT
CARD,
control
or
CIRCUIT
CARD,
control
CAPACITOR,
rectifier
KIT,
diode
fast
recovery
CAPACITOR,
rectifier
KIT,
diode
fast
recovery
METER
KIT
OPTION,
(see
footnote)
ARC
WELDING
SAFETY
PRECAUTIONS
A
WARNING
ARC
WELDING
can
be
hazardous.
PROTECT
YOURSELF
AND
OTHERS
FROM
POSSIBLE
SERIOUS
INJURY
OR
DEATH.
KEEP
CHILDREN
AWAY.
PACEMAKER
WEARERS
KEEP
AWAY
UNTIL
CONSULTiNG
YOUR
DOCTOR.
In
welding,
as
in
most
jobs,
exposure
to
certain
hazards
occurs.
Welding
is
safe
when
precautions
are
taken.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
that
will
be
found
in
the
Safety
Standards
listed
on
the
next
page.
Read
and
follow
all
Safety
Standards.
HAVE
ALL
INSTALLATION,
OPERATION,
MAINTENANCE,
AND
REPAIR
WORK
PERFORMED
ONLY
BY
QUALIFIED
PEOPLE.
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.
1.
Do
not
touch
live
electrical
parts.
2.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
3.
Insulate
yourself
from
work
and
ground
using
dry
insulating
mats
or
covers.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
FLYING
SPARKS
AND
HOT
METAL
can
cause
injury.
Chipping
and
grinding
cause
flying
metal.
As
welds
cool,
they
can
throw
off
slag.
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
6.
Turn
oft
all
equipment
when
not
in
use.
7.
Do
not
use
worn,
damaged.
undersized,
or
poorly
spliced
cables.
8.
Do
not
wrap
cables
around
your
body.
9.
Ground
the
workpiece
to
a
good
electrical
(earth)
ground.
1
0
Do
not
touch
electrode
while
in
contact
with
the
work
(ground)
circuit.
11
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
12.
Wear
a
safety
harness
to
prevent
falling
if
working
above
floor
level.
13.
Keep
all
panels
and
covers
securely
in
place.
/)
.~.
ARC
RAYS
can
burn
eyes
and
skin;
I.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
(see
NOISE
can
damage
hearing.
ANSI
Z49.1
listed
in
Safety
Standards)
to
protect
your
face
and
eyes
when
welding
or
watching.
Arc
rays
from
the
welding
process
produce
intense
2.
Wear
approved
safety
gfasses.
Side
shields
recommended,
heat
arid
strong
ultraviolet
rays
that
can
burn
eyes
3.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
skin.
Noise
from
some
processes
can
damage
and
glare.
warn
others
not
to
watch
the
arc.
hearing.
4.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
5.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
FUMES
AND
GASES
can
be
hazardous
5.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
to
your
health.
wearing
an
air-supplied
respirator.
Shielding
gases
used
for
~
Welding
producesfumesandgases.
Breathing
these
welding
can
displace
air
causing
injury
or
death.
Be
sure
the
fumes
and
gases
can
be
hazardous
to
your
health.
breathing
air
is
safe.
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
1.
Keep
your
head
out
of
the
fumes.
Do
not
breath
the
fumes.
form
highly
toxic
and
irritating
gases.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
7.
Do
not
weld
on
coated
metals,
Such
as
galvanized,
lead,
or
3.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
4.
Read
the
Material
Safety
Data
Sheets
(MSDSs)
and
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
manufacturers
instruction
for
metals,
consumables,
coatings,
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
and
cleaners,
containing
these
elements
can
give
off
toxic
fumes
if
welded.
WELDING
can
cause
fire
or
explosion.
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
Sparks
and
spatter
fly
off
from
the
welding
arc.
The
flying
sparks
and
hot
metal,
weld
spatter,
hot
6.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
workpiece,
and
hot
equipment
can
cause
fires
and
burns.
Accidental
contact
of
electrode
or
welding
wire
7.
Do
not
weld
on
closed
containers
such
as
tanks
or
drums.
to
metal
objects
can
cause
sparks,
overheating,
or
fire.
8.
Connect
work
cable
to
the
work
as
close
to
the
welding
area
as
practical
to
prevent
welding
current
from
traveling
long,
possibly
1.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
2.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
9.
unknown
paths
and
causing
electric
shock
and
fire
hazards.
Do
not
use
welder
to
thaw
frozen
pipes.
3.
Removeallflammableswithin35ft(10.7m)oftheweldingarc.lf
this
is
not
possible,
tightly
cover
them
with
approved
covers,
10.
Remove
stick
electrode
from
holder
or
cutoff
welding
wire
at
contact
tip
when
not
in
use.
4.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
11.
Wear
oil.free
protective
garments
such
as
leather
gloves.
heavy
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
shirt.
cuffless
trousers,
high
shoes,
and
a
cap.
1.
Wear
approved
face
shield
or
safety
goggles.
Side
shields
recommended.
2.
Wear
proper
body
protection
to
protect
skin.
Sri
9/91
CYLINDERS
can
explode
if
damaged.
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.
1.
Protect
compressed
gas
cytinders
from
excessive
heat,
mechanical
shocks,
and
arcs.
2.
Install
and
secure
cylinders
in
an
upright
position
by
chaining
them
to
a
stationary
support
or
equipment
cylinder
rack
to
prevent
falling
or
tipping.
a
WARNING
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
4.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
5
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
6.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
7.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
8.
Read
and
fotlow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
PRINCIPAL
SAFETY
STANDARDS
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.1,
from
American
Welding
Society,
550
NW.
LeJeune
Pd,
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
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
Ameri
can
Welding
Society
Standard
AWS
F4.1,
from
American
Welding
So
ciety,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Pro
tection
Association,
Batterymarch
Park.
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders.
CGA
Pamphlet
P-I,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
High.
way,
Suite
501,
Arlington,
VA
22202.
Cede
for
Safety
in
Welding
and
Cutting,
CSA
Standard
WI
17.2,
from
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Bou
levard,
Rexdale,
Ontario,
Canada
M9W
I
P3.
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
Protec
tion,
ANSI
Standard
Z87.1,
from
American
National
Standards
lnsti
tue.
1430
Broadway,
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
51
B,
from
National
Fire
Protection
Association,
Batterymarch
Park.
Quincy,
MA
02269.
ENGINES
can
be
hazardous.
.
~
:
ENGINE
EXHAUST
GASES
can
kill.
1.
Use
equipment
outside
in
open,
well-ventilated
areas.
2.
If
used
in
a
closed
area,
vent
engine
exhaust
outside
and
Engines
produce
harmful
exhaust
gases.
away
from
any
building
air
intakes.
ENGINE
FUEL
can
cause
fire
or
1.
Stop
engine
before
checking
or
adding
fuel.
explosion.
2.
Do
not
add
fuel
while
smoking
or
if
unit
is
near
any
sparks
or
open
flames.
.
3.
Allow
engine
to
cool
before
fueling.
If
possible,
check
and
add
Engine
fuel
is
highly
flammable.
fuel
to
cold
engine
before
beginning
job.
4.
Do
not
overfill
tank
allow
room
for
fuel
to
expand.
5.
Do
not
spill
fuel.
If
fuel
is
spilled,
clean
up
before
starting
enQine.
MOVING
PARTS
can
cause
injury.
3.
Have
only
qualified
people
remove
guards
or
covers
for
maintenance
and
troubleshooting
as
necessary.
Moving
parts,
such
as
fans,
rotors,
and
belts
can
4.
To
prevent
accidental
starting
during
servicing,
disconnect
cut
fingers
and
hands
and
catch loose
clothing.
negative
()
battery
cable
from
battery.
5.
Keep
hands,
hair,
loose
clothing,
and
tools
away
from
moving
I.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
parts.
securely
in
place.
6.
Reinstall
panels
or
guards
and
close
doors
when
servicing
is
2.
Stop
engine
before
installing
or
connecting
unit,
finished
and
before
starting
engine.
SPARKS
can
cause
BATTERY
GASES
1.
Always
wear
a
face
shield
when
working
on
a
battery.
TO
EXPLODE;
BATTERY
ACID
can
2.
Stop
engine
before
disconnecting
or
connecting
battery
burn
eyes
and
skin,
cables.
3.
Do
not
allow
tools
to
cause
sparks
when
working
on
a
battery.
4.
Do
not
use
welder
to
charge
batteries
or
jump
start
vehicles.
Batteries
contain
acid
and
generate
explosive
gases.
5.
Observe
correct
polarity
(+
and
)
on
batteries.
.t
~
~_.
-
~
STEAM
AND
COOLANT
can
skIn.
The
coolant
in
the
PRESSURIZED
burn
face,
eyes,
radiator
can
be
very
h
HOT
and
ot
and
I.
2.
Do
not
remove
radiater
cap
when
engine
is
hot.
Allow
engine
to
cool.
Wear
gloves
and
put
a
rag
over
cap
area
when
removing
cap.
under
pressure.
3.
Allow
pressure
to
escape
before
completely
removing
cap.
srI
9/91
TABLE
OF
CONTENTS
SECTION
1
-
SAFETY
SIGNAL
WORDS
1
SECTION
2
SPECIFICATIONS
2-1.
Volt-Ampere
Curves
2
2-2.
Duty
Cycle
2
SECTION
3INSTALLATION
3-1.
Selecting
A
Location
And
Moving
Welding
Power
Source
3
3-2.
Selecting
And
Preparing
Weld
Output
Cables
4
3-3.
Connecting
To
Weld
Output
Receptacles
5
3-4.
Remote
14
Receptacle
Information
And
Connections
5
3-5.
Connecting
Input
Power
6
SECTION
4
OPERATION
7
SECTION
5
MAINTENANCE
&
TROUBLESHOOTING
5-1.
Routine
Maintenance
.
.
.
.
11
5-2.
Removing
Top
Of
Case
And
Measuring
Input
Capacitor
Voltage
12
5-3.
Overload
Protection
13
5-4.
Changing
AmperageNoltage
Meter
Hold
Function
14
5-5.
Troubleshooting
15
SECTION
6
ELECTRICAL
DIAGRAMS
17
SECTION
7TUNGSTEN
ELECTRODE
7-1.
Selecting
Tungsten
Electrode
20
7-2.
Preparing
Tungsten
21
SECTION
8
PARTS
LIST
Figure
8-1.
Main
Assembly
22
Figure
8-2.
Panel,
Front
w/Components
24
Figure
8-3.
Chassis,
Mid
26
OM.146
741
3/92
SECTION
1
SAFETY
SIGNAL
WORDS
mO~I
9,91
The
following
safety
alert
symbol
and
signal
words
are
used
throughout
this
manual
to
call
attention
to
and
identify
different
levels
of
hazard
and
special
instructions.
a
WARNING
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
serious
personal
injury
or
loss
of
life.
a
CAUTION
CAUTION
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
minor
personal
~~jury
or
damage
to
this
equipment.
~
IMPORTANT:
statements
identify
special
instructions
necessary
for
the
most
efficient
operation
of
this
equipment.
SECTION
2
SPECIFICATIONS
Table
2-1.
Welding
Power
Source
Specification
Description
Type
Of
Output
Constant
Current
(CC),
Direct
Current
(DC)
Rated
Weld
Output
300
Amperes,
32
Volts
DC
At
60%
Duty
Cycle
(See
Sectlon
2.2)
Type
01
Input
380
Or
415
Volts
AC;
50
Hz;
Three
Phase
Input
Amperes
At
Rated
Output
25
Amperes
At
380
Volts,
23
Amperes
At
415
Volts
IC/A
Used
At
Rated
Output
16.4
kVA
KW
Used
At
Rated
Output
11.3kW
Amperage
Range
5-375
Amperes
Max.
Open-Circuit
Voltage
80
Volts
DC
Welding
Processes
Scratch
Start
Gas
Tungsten
Arc
(GTAW),
Scratch
Start
Gas
Tungsten
Arc.
Pulsed
(GTAW-P),
Shielded
Metal
Arc
(SMAW)
Welding
Input
Power
Cord
13.1
ft.
(4
m)
Overall
Dimensions
Length:
21-3/4
in.
(522
mm);
WIdth:
12
in.
(305mm);
HeIght:
17.3/8
In.
(441
mm)
Weight
ShIpping:
82
lbs.
(37
kg);
Net:
77
lbs.
(35
kg)
Options
PC-300,
RFC.14,
Foot
Control,
RHC-14,
RMLS-14,
FTC14
Hand
Controls,
Extension
Cords,
Econo
my
Cart,
Cylinder
Cart,
Wire
Feeder
Quick
Disconnect.
Digital
LCD
AN
Meter,
HF-251
D-1
High
Fre
quency
Unit,
VHS
Video
OM-146
741
Page
1
2-1.
Volt-Ampere
Curves
Figure
2-1.
Volt-Ampere
Curves
2-2.
Duty
Cycle
a
CAUTION
Duty
cycle
is
how
long
the
unit
can
:
:
operate
within
a
ten
minute
period
without
causing
overheating
or
~.
=
=:
:
:
=
damage.
Thisunitisratedat6o%dutycycle
~-
=
: :
: :
=
:
:
allowingwelding6minutesoutof
(
~
:
~
-
-
:
-
:::
:::
-
-
=
=
:
:
-
s~::
--~3PHASE
-
-
OPERATION
every
10
minutes
at
rated
load.
If
theweldingamperesdecrease,
the
dutycycleincreases.
900
::
::
w
3
~-
100
-
-
--
::
--
-
-
-.
-.
--
0-
~
-
-

-
10
10
20
a
30
4050
eo~eoso10o
%
DUTY
CYCLE
sbl.2
2/92
SB.153
910
Figure
2-2.
Duty
Cycle
Chart
The
volt-ampere
curves
show
the
minimum
and
maximum
voltage
100
and
amperage
output
capabilities
of
the
welding
power
source.
90
Curves
of
other
settings
fall
be
tween
the
curves
shown.
80
70
>4Ol~TMI~~~
30
v/1~Mh1W
MIN
20
~-.....
~c
cotrrRot.
10
I
~0X
5~
I
~
I
%50X
%75~~ioox
0
I
I
II
Ii
I I
0
100
200
300
400
AMPERES
ssbl.I
10/91
S8.146
879-8
EXCEEDING
DUTY
CYCLE
RATINGS
will
damage
unit.
S
Do
not
exceed
indicated
duty
cycles.
warnl,1
2/92
OM-146
741
Page
2
SECTION
3INSTALLATION
3-1.
Selecting
A
Location
And
Moving
Welding
Power
Source
a
WARNING
ELECTRIC
SHOCK
can
kill.
S
Do
not
touch
live
electrical
parts.
Disconnect
input
power
conductors
from
deenergized
supply
line
BEFORE
moving
welding
power
source.
FIRE
OR
EXPLOSION
can
result
from
placing
unit
on,
over,
or
near
combustible
surfaces.
Do
not
locate
unit
on,
over,
or
near
combustible
surfaces.
Do
not
install
unit
near
flammables.
BLOCKED
AIRFLOW
causes
overheating
and
possible
damage
to
Unit.
FALLING
EQUIPMENT
can
cause
serious
personal
injury
and
equipment
damage.
Lift
unit
at
handles.
Have
two
person
of
adequate
physical
strength
lift
unit.
Move
unit
with
hand
cart
or
similar
device
of
adequate
capacity.
If
using
a
fork
lift
vehicle,
secure
unit
on
a
proper
skid
before
transporting.
FUMES
can
be
hazardous;
LACK
OF
FRESH
AIR
AND
PROPER
VENTILATION
can
be
harmful.
Do
not
breathe
welding
fumes.
Place
unit
only
where
there
is
a
good
fresh
supply
and
proper
ventilation.
air
Do
not
block
or
filter
airflow.
Warranty
is
void
1
any
type
of
fitter
is
used.
Swarnhl
2/92
2
1
3
in.
(78
mm)
Open
Space
At
Sides,
6
in.
(156
mm)
At
Rear
For
Good
Airflow
2
Lifting
Handles
Use
handles
to
move
unit.
3
Rating
Label
Locate
unit
near
correct
input
pow
er
supply.
S7-152303-A/Rf.
ST-t51
558
Figure
3-1.
Location
And
Movement
Of
Welding
Power
Source
OM-146
741
Page
3
3-2.
Selecting
And
Preparing
Weld
Output
Cables
Figure
3-2.
Selecting
And
Preparing
Weld
Output
Cables
Table
3-1.
Weld
Cable
Size*
Welding
Amperes
100
150
200
Total
Cable
(Copper)
Length
In
Weld
Circuit
Not
Exceeding*
100
ft.
(30
m)
Or
Less
150
ft.
I
200
ft.
250
ft.
I
300
ft.
I
350
ft.
1
400
ft.
(45
m)
(60
m)
(70
m)
(90
m)
(105
m)
(120
m)
10
To
60%
Duty
Cycle
4
3
3
60
Thru
100%
Duty
Cycle
4
3
2
10
Thru
100%
Duty
Cycle
4
3
2
1
1/0
1/0
2
1
1/0
210
3/0
3/0
1
1/0
2/0
3/0
4/0
4/0
250
300
350
2
1
1/0
1
1/0
2/0
1/0
2/0
3/0
2/0
3/0
4/0
3/0
4/0
2-2/0
4/0
2-2/0
2-3/0
2.210
2-3/0
2-3/0
2-2/0
2-3/0
2-4/0
S-0001AfT-91
Weld
cable
size
(AWG)
is
based
on
either
a
4
volts
or
less
drop
or
a
current
density
of
not
more
than
300
circular
mils
per
ampere.
Use
weld
cable
with
insulation
rating
equal
to
or
greater
than
the
open-circuit
voltage
of
the
unit.
OM-146
741
Page
4
For
Example,
Total
Cable
Length
In
Weld
Circuit
=
20
ft.
(6
m)
1
Weld
Output
Cable
Determine
total
cable
length
in
weld
Circuit
and
maximum
welding
amperes.
Use
Table
3-1
to
select
proper
cable
size.
Use
shortest
cables
possible.
Do
not
use
damaged
cables.
2
Terminal
Lug
Use
lugs
of
proper
amperage
Ca
pacity
and
hole
size
for
connecting
to
work
clamp,
electrode
holder,
or
wire
feeder.
3
Insulated
Electrode
Holder
Install
according
to
manufacturers
instructions.
4
Work
Clamp
Install
onto
work
cable.
5
Dinse-Type
Connector
6
Weld
Output
Cable
7
Insulator
Slide
cable
through
insulator
and
remove
1
in.
(25
mm)
insulation
from
end
of
cable.
8
Sleeve
9
Connector
Insert
cable
with
sleeve
into
con
nector
body
so
cable
is
snug
against
bottom.
10
Setscrew
Tighten
setscrew
and
push
insula
tor
fully
over
connector.
If
lob
requires
cable
larger
than
3/0
AWG,
use
2
ft.
(610
mm)
or
shorter
piece
of
3/0
AWG
cable
for
Dinse
Type
connector
installation.
Con
nect
other
end
of
short
cable
to
the
4/0
or
larger
weld
cable.
Tools
Needed:
sb6.2
12/91
-
S-0656
/
S-0288-8
3-3.
Connecting
To
Weld
Output
Receptacles
a
WARNING
ELECTRIC
SHOCK
can
kill;
ARCiNG
can
burn
skin
or
damage
electrical
equipment.
Do
not
touch
live
electrical
parts.
Turn
OFF
welding
power
source
before
making
any
weld
output
connections.
Do
not
change
position
of
welding
cable
connectors
while
welding.
e
Be
sure
connectors
are
secure
in
receptacles
before
welding.
swarnl2
2
2/92
2
3
1
Positive
(+)
Weld
Output
Re
ceptacle
2
Negative
()
Weld
Output
Re
ceptacle
3
Connector
For
Electrode
Positive,
connect
work
cable
connector
to
negative
()
receptacle
and
electrode
holder
cable
connector
to
positive
(+)
re
ceptacle.
For
Electrode
Negative,
reverse
cable
connections.
To
connectto
receptacle,
align
key-
way,
insert
connector,
and
turn
clockwise
until
tight.
Ref.
5Q.t34
~62/Ref.
Sr.15222~
Figure
3-3.
Connecting
To
Weld
Output
Receptacles
3-4.
Remote
14
Receptacle
Information
And
Connections
1
Remote
14
Receptacle
RC2
2
Keyway
3
Plug
2
4
Threaded
Collar
To
connect
to
this
receptacle,
align
keyway,
insert
plug,
and
tighten
threaded
collar.
Socket
Information:
Remote
Contactor
A,
B
Contact
closure
completes
the
24
volts
ac
contactor
control
circuit.
Protected
by
fuse
F2.
Remote
Amperage/Voltage
Control
C
Command
reference
;+10
volts
dc.
0
Control
circuit
common.
E
Input
command
signal
(potentiometer
wiper
or
0-10
volts
dc
source);
0
to
#10
volts
dc.
K
Chassis
common.
The
remaining
sockets
are
not
used.
ebl.1
1)52
Rel.
S0.134
162-B
/
Ret.
5-0004-A
/
5-0626
Figure
3-4.
Remote
14
ConnectIons
OM-146
741
Page
5
3-5.
Connecting
tnput
Power
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
OFF
welding
power
source,
and
disconnect
input
power
before
inspecting
or
instafling.
Have
only
qualified
persons
install
unit.
Installation
must
meet
National
Electrical
Code
and
all
other
codes.
swarr3.1
10/91
A.
Positioning
Jumper
Links
Jumper
links
allow
operation
on
dif
ferent
input
voltages
and
are
facto
ry
set
for
380
volts
input
power.
________
_______
Check
input
voltage
available
at
site.
Remove
top
of
case
according
to
Section
5-2.
I
Input
Voltage
Label
Look
at
jumper
links
and
compare
link
position
with
unit
label.
2
Input
Voltage
Jumper
Links
Move
links
to
match
input
voltage.
For
example,
use
415
volts
posi
tion
when
415
volts
input
power
is
available.
Reinstall
top
of
case.
380
Volts
A
415
Volts
A
L
Tools
Needed:
ssb5.12/92ST-152225/R&
S-145063
Figure
B.
Connecting
To
Input
Power
3-5.
Input
Voltage
Jumper
Links
Location
2
Input
Voltage
380
415
Circuit
Breaker
Size
In
Amperes
t4~i
Fuse
Size
in
Amperes2
35
Circuit
breaker
range
is
150%
to
not
more
than
200%
of
rated
input
amperage
of
the
welding
power
source
(Article
630-12(a)
of
NEC).
2
Standard
fuse
size
is
that
closest
to
150%
of
rated
input
amperage
of
the
welding
power
source
(Article
630-126
of
NEC).
Have
only
qualified
persons
make
this
instal-
3
Input
Conductors
4
Line
Fuses
lation.
1
Line
Disconnect
Switch
Of
Proper
Rating
Install
input
conductors
and
groufldifl9
con-
Select
fuses
or
Circuit
breakers
using
Table.
ductor
from
unit
to
deenergized
line
discon-
Install
into
deenargized
line
disconnect
nect
switch.
switch.
2
Grounding
Conductor
Green
Or
Green
With
Yellow
Stripe(s)
Be
sure
grounding
conductor
goes
to
an
earth
ground.
i$b2.3
3~52
-
Rsf.
SC-I
44221
/
ST-I
52
303-A
/
R&.
5-0092C
4
3
FIgure
3-6.
LocatIon
And
Input
Power
Connections
OM-146
741
Page
6
SECTION
4
OPERATION
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.
S
Wear
welding
helmet
with
correct
shade
of
filter.
Wear
correct
eye,
ear,
and
body
protection.
~11
MOVING
PARTS
can
cause
injury.
S
Keep
away
from
moving
parts.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
MAGNETIC
FIELDS
FROM
HIGH
CUR
RENTS
can
aftect
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
manual
for
ba
sic
welding
safety
information.
swarn6
110/91
Figure
4-2.
Safety
Equipment
a
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
manufacturers
instructions
for
material
used.
8
Power
Switch
Pilot
Light
2
3
4
5
6
7
8
2
3
Amperage
Control
Arc
Force
(Dig)
Control
Output
(Contactor)
Switch
Amperage
Control
Switch
Process
Selector
Switch
Optional
AmperageNoltage
Meter
And
Switch
FIgure
4-1.
Controls
ST152
224
2
3
1
Insulating
Gloves
/
2
Safety
Glasses
With
Side
Shields
3
Welding
l4elmet
glasses
with
side
shields,
and
a
_______
Wear
dry
insulating
gloves,
safety
welding
helmet
with
a
correct
shade
of
filter
(see
ANSI
Z49.
1).
sb3.1
10/91
OM-146
741
Page
7
I
~
Tools
Needed:
~
I
Work
Clamp
Use
wire
brush
or
sandpaper
to
clean
metal
at
weld
joint
area.
paint-free
location
on
workpiece,
as
Connect
work
clamp
to
a
clean,
close
to
weld
area
as
possible.
sb4
10/91
Figure
4-3.
Work
Clamp
I
Process
Selector
Switch
Use
switch
to
select
type
of
weld
output.
Use
SMAW
position
for
Shielded
Metal
Arc
Welding.
Use
GTAW
position
for
Gas
Tungsten
Arc
Welding.
Switch
position
determines
the
op.
eration
of
the
ARC
FORCE
(DIG)
1
control
(see
Figure
4-6).
Ref
SO-134
162
Figure
4-5.
Amperage
Control
I
Arc
Force
Control
(Dig)
This
control
is
used
for
SMAW
welding
and
only
works
when
Pro.
cess
Selector
switch
(see
Figure
4.4)
is
in
the
SMAW
position.
I
Use
control
to
help
start
an
arc
or
make
vertical
or
overhead
welds
(control
increases
short-circuit
am
perage).
When
set
at
0,
short-circuit
amper
age
is
the
same
as
normal
welding
amperage.
When
set
at
100,
short-circuit
am
perage
increases
to
help
arc
start
ing.
Select
setting
best
suited
for
appli
cation.
Numbers
around
control
are
for
reference
only.
Set
control
at
0
for
GTAW
welding.
Figure
4.4.
Process
Selector
Switch
I
Amperage
Control
Use
control
to
select
wel
d
amper
age.
Amperage
may
be
adjusted
while
welding.
Figure
4-6.
Arc
Control
(Dig)
Control
OM-146
741
Page
8
I
Amperage
Control
Switch
Use
switch
to
select
way
of
control
ling
amperage.
For
front
panel
control.
place
switch
in
the
PANEL
position.
For
remote
control,
place
switch
in
REMOTE
14
position
(see
Section
3.4).
Remote
control
gives
percent
affront
panel
Amperage
Control
(see
Figure
4.5).
For
example,
if
front
panel
control
is
set
at
200
A,
remote
control
provides
minimum
to
200
A.
Figure
4-7.
Amperage
Control
Switch
WARNING
E
LECTRIC
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.
swam?
m
1
Output
(Contactor)
Switch
Use
Switch
to
select
way
of
control.
ling
output.
r~~~i
For
front
panel
control,
place
switch
fl
ON
position.
OUTPUT
(CONTACTOR)~,)
For
remote
control,
place
switch
in
REMOTE
14
position
(see
Section
3.4).
Weld
output
terminals
are
energized
when
switch
Is
ON
and
POWER
Is
ON.
Figure
4-8.
Output
(Contactor)
Switch
1
AmperageNoltage
Meter
Use
meter
to
read
amperage
and
voltage
output.
The
preset
value
is
displayed
when
not
welding.
The
actual
value
is
displayed
while
welding
and
is
held
for
15
seconds
after
welding
stops
(see
Section
5.4).
I
See
table
for
the
values
displayed
for
AIV
switch
settings.
2
2
Meter
Switch
Use
switch
to
select
amperage
or
voltage
display.
AN
Switch
Positions
Meter
Display
When
Not
When
Welding
Welding
A
Preset
Amps
Actual
Amps
V
Preset
Amps
Actual
Volts
Figure
4-9.
Amperage/Voltage
Meter
And
Switch
(Optional)
OM-146
741
Page
9
Figure
4-11.
Sequence
Of
Gas
Tungsten
Arc
Welding
(GTAW)
Figure
4-12.
Sequence
Of
Gas
Tungsten
Arc
Welding
-
Pulsed
(GTAW-P)
Figure
4-13.
Sequence
Of
Shielded
Metal
Arc
Welding
(SMAW)
Figure
4-10.
Power
Switch
And
Pilot
Light
Install
&
~\
~
Install
&
Connec~\\
Select
Insert
Connect
)
High-Frequency
)
)
Tungsten
Tunasten
Pe
Put
On
)
Equipment~J
Unit
JJ
(See
Section
Into
Thrch
))
Equipment
rsonal
Safety
Turn
On
Turn
On
))
Turn
On~~~)
Begin
Welding~)
)
Shielding
Gas
I
~1igh-Frequency
Welding
Power
_________________
J
Unit
Source
_________________
ssb8
2192
Install
&
Install
&
Connec))
Install
&
Connec\\
Select
Insert
Connect
1
1
Pulser
Control
High
)
Equipment
},J
Unit
-Frequency
j
)
Tungsten
I
Tungsten
________________
________________
Unit
~JJ
(See
Section
7)])
Into
iorch
_____
_____
_____
_____
_____
~~pment
~
Turn
On
Turn
On
))
Turn
Qn
)
Set
Controls
Shielding
Gas
I
}
High-Frequency
Welding
Power
1
1
Begin
WeIdin9~
________________
})
Unit
Source
)
Install
&
Select
Put
On
)
Equipment~}
Equipment
D)
Into
Holder
I
Connect
Electrode
Personal
Safety
Set
Contro
Electrode
_____
_____
_____
_____
_____
~__~e
~
)
Begin
Weldin~
ssb7.1
2/92
OM-146
741
Page
10
SECTION
5
MAINTENANCE
&
TROUBLESHOOTING
a
WARNING
ELECTRIC
SHOCK
can
kill.
SIGNIFICANT
DC
VOLTAGE
exists
after
removal
of
input
power.
Do
not
touch
live
electrical
parts.
Turn
OFF
welding
power
source,
disconnect
input
power,
wait
60
seconds,
measure
voltage
on
input
capacitors
according
to
Section
5-3,
and
wait
for
voltage
to
drop
to
zero
before
touching
any
parts.
,~
Allow
cooling
penod
before
maintaining
or
HOT
PARTS
can
cause
severe
burns.
servicing.

~
MOVING
PARTS
can
cause
iniury.
Keep
away
from
moving
parts.
Maintenance
to
be
performed
persons.
only
by
qualified
swarn8
1
10/91
5-1.
Routine
Maintenance
Table
5-1.
Routine
Maintenance
Time
Maintenance
Every
month
More
than
normal
equipment
use:
Check
all
labels
(see
6
month
entry),
Repair
any
damaged
insulation
or
replace
weld
cables
if
necessary.
Clean
and
tighten
cable
connections.
Clean
internal
parts
(see
6
month
entry).
Every
3
months
Repair
any
damaged
insulation
or
replace
weld
cables
if
necessary.
Clean
and
tighten
cable
connections.
Every
6
months
Replace
any
labels
that
are
unreadable
or
damaged
(see
Section
8
for
part
number).
Remove
unit
outer
enclosure
to
blow
Out
or
vacuum
dust
and
dirt
from
inside
using
a
clean,
dry
airstream
or
vacuum
suction.
OM-146
741
Page
11
5-2.
Removing
Top
Of
Case
And
Measuring
Input
Capacitor
Voltage
LA
WARNING
ELECTRIC
SHOCK,
HOT
PARTS,
AND
MOVING
PARTS
HAZARDS.
Read
safety
infor
mation
at
beginning
of
Section
5
before
proceeding.
a
CAUTION
STATIC
ELECTRICITY
can
damage
parts
on
circuit
boards.
Put
on
grounded
wrist
strap
BEFORE
handling
boards
or
parts.
fwarn5.
I
9/91
Turn
OFF
welding
power
source
and
disconnect
input
power.
I
lop
Of
Case
2
Handles
3
Outside
Handle
Screws
4
Side
Bolts
To
loosen
top,
remove
two
outside
handle
screws
from
both
handles
and
all
side
bolts.
5
Input
Rectifier
SRi
6
Voltmeter
Measure
the
dc
voltage
across
the
positive
(+)
and
negative
()
termi
nals
at
30
second
intervals
until
vottage
drops
to
0
(zero)
volts.
Proceed
with
job
inside
unit.
Rein
stall
top
of
case
when
finished.
3
4
5
Tools
Needed:
5/32
in.
FIgure
5-1.
RemovIng
Top
Of
Case
And
MeasurIng
Input
Capacitor
Voltage
51-153
512/Pet.
51-153
512
OM-146
741
Page
12
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Miller KC179876 Owner's manual

Miller
Brand
Miller
Model
KC179876
Category
Welding System
Type
Owner's manual
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