Miller KE607495 Owner's manual

Brand: Miller

Model: KE607495

Category: Welding System

Type: Owner's manual

This manual is also suitable for

INTELLITIG 40

cover 7/93 – SB-129 229-A PRINTED IN USA

 1997 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

OM-894 127 412C

September 1997

Intellitig 40

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.

CERTIFICATE

NAME OF EQUIPMENT: MODEL NO.

SERIAL NO. DATE:

This equipment has been type-tested under standardized field test conditions as recommended

by the Joint Industry Committee on High-Frequency Stabilized Arc Welding Machines found to radiate

less than 10 microvolts per meter at a distance of one mile, the maximum allowable limit established

by the Federal Communications Commission for equipment of this type.

Installations using this equipment on the basis of these tests, may reasonably be expected to

meet the radiation limitations established by the Federal Communications Commission, only when

installed, operated and maintained as specified in the instruction book provided.

USER’S CERTIFICATION

The welding equipment identified above has been installed in accordance with the specific

instructions applicable to this model as outlined in the instruction book furnished. It is being used only

for the purpose for which it was intended and is being maintained and operated in accordance with the

manufacturer’s instructions

Date Installed Signed

OM-894C – 9/97

TABLE OF CONTENTS

Section No. Page No.

SECTION 1 – SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE

1-1. Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. General Precautions 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Arc Welding 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Standards Booklet Index 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – SAFETY PRECAUTIONS AND SIGNAL WORDS

2-1. General Information And Safety 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Safety Alert Symbol And Signal Words 6. . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – SPECIFICATIONS

3-1. Description 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – INSTALLATION OR RELOCATION

4-1. Location 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Setting DIP Switch SW1 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Shielding Gas Connections 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Remote Operator Control Connections 9. . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Welding Power Source Connections 10. . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Weld Input/Output Connections 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Optional Internal Wiring Connections 11. . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – OPERATOR CONTROLS

5-1. Power Switch 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Program/Run/Reset Key Switch 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Mode Selector Switch 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Parameter Select Push Button 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Up Push Button 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Down Push Button 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Purge Push Button 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Gas Control 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Gas Flow Rate Digital Meter 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10. Digital Display 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-11. Weld Amperes Meter 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-12. Remote Operator Control 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – PROGRAMMING

6-1. General 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Displays 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Modes Of Operation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Entering A Program 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Editing A Program 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Dry Run 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7. Stop Watch Feature 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-8. Linking Programs 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-9. Combining Programs 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-10. Running A Program 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – SEQUENCE OF OPERATION

7-1. Gas Tungsten Arc Welding (GTAW) 19. . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Shutting Down 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 – MAINTENANCE & TROUBLESHOOTING

8-1. Routine Maintenance 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Overload Protection 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Tungsten Electrode 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Circuit Board Handling Precautions 22. . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5. Diagnostic Program 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 – ELECTRICAL DIAGRAMS

Diagram 9-1. Circuit Diagram For Control Unit 36. . . . . . . . . . . . . . . . . . . . . . . . .

Diagram 9-2. Circuit Diagram For Remote Operator Control 37. . . . . . . . . . . . . .

Diagram 9-3. Wiring Diagram For Control Unit 38. . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 – CERTIFICATION FOR HIGH FREQUENCY ARC WELDING EQUIPMENT

10-1. General 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2. Definitions 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3. High-Frequency Radiation 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-4. Location 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-5. General Installation Procedures 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-6. Guidelines For Installation Of High-Frequency Assisted Arc Welding

Power Sources 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-7. Installation Guidelines Checklist 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 – PARTS LIST

Figure 11-1. Main Assembly 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 11-2. Pendant 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 11-3. Panel, Rear w/Components 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-894 Page 1

SECTION 1 – SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE

1-1. INTRODUCTION

We learn by experience. Learning safety through per-

sonal experience, like a child touching a hot stove is

harmful, wasteful, and unwise. Let the experience of

others teach you.

Safe practices developed from experience in the use of

welding and cutting are described in this manual. Re-

search, development, and field experience have

evolved reliable equipment and safe installation, opera-

tion, and servicing practices. Accidents occur when

equipment is improperly used or maintained. The rea-

son for the safe practices may not always be given.

Some are based on common sense, others may require

technical volumes to explain. It is wiser to follow the

rules.

Read and understand these safe practices before at-

tempting to install, operate, or service the equipment.

Comply with these procedures as applicable to the par-

ticular equipment used and their instruction manuals,

for personal safety and for the safety of others.

Failure to observe these safe practices may cause seri-

ous injury or death. When safety becomes a habit, the

equipment can be used with confidence.

These safe practices are divided into two Sections:

1-General Precautions, common to arc welding and cut-

ting; and 2-Arc Welding (and Cutting) (only).

Reference standards: Published Standards on safety

are also available for additional and more complete pro-

cedures than those given in this manual. They are listed

in the Standards Index in this manual. ANSI Z49.1 is the

most complete.

The National Electrical Code, Occupational Safety and

Health Administration, local industrial codes, and local

inspection requirements also provide a basis for equip-

ment installation, use, and service.

1-2. GENERAL PRECAUTIONS

Different arc welding processes, electrode alloys,

and fluxes can produce different fumes, gases, and

radiation levels. In addition to the information in

this manual, be sure to consult flux and electrode

manufacturers Material Safety Data Sheets

(MSDSs) for specific technical data and precaution-

ary measures concerning their material.

A. Burn Prevention

Wear protective clothing-gauntlet gloves designed for

use in welding, hat, and high safety-toe shoes. Button

shirt collar and pocket flaps, and wear cuffless trousers

to avoid entry of sparks and slag.

Wear helmet with safety goggles and glasses with side

shields underneath, appropriate filter lenses or plates

(protected by clear cover glass). This is a MUST for

welding or cutting, (and chipping) to protect the eyes

from radiant energy and flying metal. Replace cover

glass when broken, pitted, or spattered. See 1-3A.2.

Avoid oily or greasy clothing. A spark may ignite them.

Hot metal such as electrode stubs and workpieces

should never be handled without gloves.

Medical first aid and eye treatment. First aid facilities

and a qualified first aid person should be available for

each shift unless medical facilities are close by for im-

mediate treatment of flash burns of the eyes and skin

burns.

Ear plugs should be worn when working on overhead or

in a confined space. A hard hat should be worn when

others work overhead.

Flammable hair preparations should not be used by per-

sons intending to weld or cut.

B. Toxic Fume Prevention

Severe discomfort, illness or death can result from

fumes, vapors, heat, or oxygen enrichment or depletion

that welding (or cutting) may produce. Prevent them

with adequate ventilation as described in ANSI Stan-

dard Z49.1 listed in Standards Index. NEVER ventilate

with oxygen.

Lead -, cadmium -, zinc -, mercury -, and beryllium-bear-

ing and similar materials, when welded (or cut) may pro-

duce harmful concentrations of toxic fumes. Adequate

local exhaust ventilation must be used, or each person

in the area as well as the operator must wear an air-sup-

plied respirator. For beryllium, both must be used.

Metals coated with or containing materials that emit

toxic fumes should not be heated unless coating is re-

moved from the work surface, the area is well ventilated

and, if necessary, while wearing an air-supplied respira-

tor.

Work in a confined space only while it is being ventilated

and, if necessary, while wearing an air-supplied respira-

tor.

Gas leaks in a confined space should be avoided.

Leaked gas in large quantities can change oxygen con-

centration dangerously. Do not bring gas cylinders into a

confined space.

Leaving confined space, shut OFF gas supply at source

to prevent possible accumulation of gases in the space if

downstream valves have been accidentally opened or

left open. Check to be sure that the space is safe before

re-entering it.

Vapors from chlorinated solvents can be decomposed

by the heat of the arc (or flame) to form PHOSGENE, a

highly toxic gas, and other lung and eye irritating prod-

ucts. The ultraviolet (radiant) energy of the arc can also

decompose trichloroethylene and perchloroethylene

vapors to form phosgene. DO NOT WELD or cut where

solvent vapors can be drawn into the welding or cutting

OM-894C Page 2

atmosphere or where the radiant energy can penetrate

to atmospheres containing even minute amounts of

trichloroethylene or perchloroethylene.

C. Fire and Explosion Prevention

Causes of fire and explosion are: combustibles reached

by the arc, flame, flying sparks, hot slag or heated mate-

rial; misuse of compressed gases and cylinders; and

short circuits.

BE AWARE THAT flying sparks or falling slag can pass

through cracks, along pipes, through windows or doors,

and through wall or floor openings, out of sight of the

goggled operator. Sparks and slag can fly 35 feet.

To prevent fires and explosion:

Keep equipment clean and operable, free of oil, grease,

and (in electrical parts) of metallic particles that can

cause short circuits.

If combustibles are in area, do NOT weld or cut. Move

the work if practicable, to an area free of combustibles.

Avoid paint spray rooms, dip tanks, storage areas, ven-

tilators. If the work cannot be moved, move comb-

ustibles at least 35 feet away out of reach of sparks and

heat; or protect against ignition with suitable and snug-

fitting, fire-resistant covers or shields.

Walls touching combustibles on opposite sides should

not be welded on (or cut). Walls, ceilings, and floor near

work should be protected by heat-resistant covers or

shields.

Fire watcher must be standing by with suitable fire extin-

guishing equipment during and for some time after weld-

ing or cutting if:

a. appreciable combustibles (including building

construction) are within 35 feet

b. appreciable combustibles are further than 35

feet but can be ignited by sparks

c. openings (concealed or visible) in floors or walls

within 35 feet may expose combustibles to

sparks

d. combustibles adjacent to walls, ceilings, roofs,

or metal partitions can be ignited by radiant or

conducted heat.

Hot work permit should be obtained before operation to

ensure supervisor’s approval that adequate precau-

tions have been taken.

After work is done, check that area is free of sparks,

glowing embers, and flames.

An empty container that held combustibles, or that can

produce flammable or toxic vapors when heated, must

never be welded on or cut, unless container has first

been cleaned as described in AWS Standard A6.0,

listed 7 in Standards Index.

This includes: a thorough steam or caustic cleaning (or

a solvent or water washing, depending on the combusti-

ble’s solubility) followed by purging and inerting with ni-

trogen or carbon dioxide, and using protective equip-

ment as recommended in A6.0. Waterfilling just below

working level may substitute for inerting.

A container with unknown contents should be cleaned

(see preceding paragraph). Do NOT depend on sense

of smell or sight to determine if it is safe to weld or cut.

Hollow castings or containers must be vented before

welding or cutting. They can explode.

Explosive atmospheres. Never weld or cut where the air

may contain flammable dust, gas, or liquid vapors (such

as gasoline).

D. Compressed Gas Equipment

Standard precautions. Comply with precautions in this

manual, and those detailed in CGA Standard P-1, SAFE

HANDLING OF COMPRESSED GASES IN CYLIN-

DERS, listed 11 in Standards Index.

1. Pressure Regulators

Regulator relief valve is designed to protect only the

regulator from overpressure; it is not intended to protect

any downstream equipment. Provide such protection

with one or more relief devices.

Never connect a regulator to a cylinder containing gas

other than that for which the regulator was designed.

Remove faulty regulator from service immediately for

repair (first close cylinder valve). The following symp-

toms indicate a faulty regulator:

Leaks-if gas leaks externally.

Excessive Creep-if delivery pressure continues to rise

with downstream valve closed.

Faulty Gauge-if gauge pointer does not move off stop

pin when pressurized, nor returns to stop pin after pres-

sure release.

Repair. Do NOT attempt to repair. Send faulty regula-

tors for repair to manufacturer’s designated repair cen-

ter, where special techniques and tools are used by

trained personnel.

2. Cylinders

Cylinders must be handled carefully to prevent leaks

and damage to their walls, valves, or safety devices:

Avoid electrical circuit contact with cylinders including

third rails, electrical wires, or welding circuits. They can

produce short circuit arcs that may lead to a serious ac-

cident. (See 1-3C.)

ICC or DOT marking must be on each cylinder. It is an

assurance of safety when the cylinder is properly han-

dled.

Identifying gas content. Use only cylinders with name of

gas marked on them; do not rely on color to identify gas

content. Notify supplier if unmarked. NEVER DEFACE

or alter name, number, or other markings on a cylinder. It

is illegal and hazardous.

Empties: Keep valves closed, replace caps securely;

mark MT; keep them separate from FULLS and return

promptly.

Prohibited use. Never use a cylinder or its contents for

other than its intended use, NEVER as a support or

roller.

OM-894 Page 3

Locate or secure cylinders so they cannot be knocked

over.

Passageways and work areas. Keep cylinders clear of

areas where they may be struck.

Transporting cylinders. With a crane, use a secure sup-

port such as a platform or cradle. Do NOT lift cylinders

off the ground by their valves or caps, or by chains,

slings, or magnets.

Do NOT expose cylinders to excessive heat, sparks,

slag, and flame, etc. that may cause rupture. Do not al-

low contents to exceed 130°F. Cool with water spray

where such exposure exists.

Protect cylinders particularly valves from bumps, falls,

falling objects, and weather. Replace caps securely

when moving cylinders.

Stuck valve. Do NOT use a hammer or wrench to open a

cylinder valve that can not be opened by hand. Notify

your supplier.

Mixing gases. Never try to mix any gases in a cylinder.

Never refill any cylinder.

Cylinder fittings should never be modified or ex-

changed.

3. Hose

Prohibited use. Never use hose other than that de-

signed for the specified gas. A general hose identifica-

tion rule is: red for fuel gas, green for oxygen, and black

for inert gases.

Use ferrules or clamps designed for the hose (not ordi-

nary wire or other substitute) as a binding to connect

hoses to fittings.

No copper tubing splices. Use only standard brass fit-

tings to splice hose.

Avoid long runs to prevent kinks and abuse. Suspend

hose off ground to keep it from being run over, stepped

on, or otherwise damaged.

Coil excess hose to prevent kinks and tangles.

Protect hose from damage by sharp edges, and by

sparks, slag, and open flame.

Examine hose regularly for leaks, wear, and loose con-

nections. Immerse pressured hose in water; bubbles in-

dicate leaks.

Repair leaky or worn hose by cutting area out and splic-

ing (1-2D3). Do NOT tape.

4. Proper Connections

Clean cylinder valve outlet of impurities that may clog

orifices and damage seats before connecting regulator.

Except for hydrogen, crack valve momentarily, pointing

outlet away from people and sources of ignition. Wipe

with a clean lintless cloth.

Match regulator to cylinder. Before connecting, check

that the regulator label and cylinder marking area, and

that the regulator inlet and cylinder outlet match.

NEVER CONNECT a regulator designed for a particular

gas or gases to a cylinder containing any other gas.

Tighten connections. When assembling threaded con-

nections, clean and smooth seats where necessary.

Tighten. If connection leaks, disassemble, clean, and

retighten using properly fitting wrench.

Adapters. Use a CGA adapter (available from your sup-

plier) between cylinder and regulator, if one is required.

use two wrenches to tighten adapter marked RIGHT

and LEFT HAND threads.

Regulator outlet (or hose) connections may be identified

by right hand threads for oxygen and left hand threads

(with grooved hex on nut or shank) for fuel gas.

5. Pressurizing Steps:

Drain regulator of residual gas through suitable vent be-

fore opening cylinder (or manifold valve) by turning ad-

justing screw in (clockwise). Draining prevents exces-

sive compression heat at high pressure seat by allowing

seat to open on pressurization. Leave adjusting screw

engaged slightly on single-stage regulators.

Stand to side of regulator while opening cylinder valve.

Open cylinder valve slowly so that regulator pressure in-

creases slowly. When gauge is pressurized (gauge

reaches regulator maximum) leave cylinder valve in fol-

lowing position: For oxygen, and inert gases, open fully

to seal stem against possible leak. For fuel gas, open to

less than one turn to permit quick emergency shutoff.

Use pressure charts (available from your supplier) for

safe and efficient, recommended pressure settings on

regulators.

Check for leaks on first pressurization and regularly

there-after. Brush with soap solution (capfull of Ivory

Liquid* or equivalent per gallon of water). Bubbles indi-

cate leak. Clean off soapy water after test; dried soap is

combustible.

E. User Responsibilities

Remove leaky or defective equipment from service im-

mediately for repair. See User Responsibility statement

in equipment manual.

F. Leaving Equipment Unattended

Close gas supply at source and drain gas.

G. Rope Staging-Support

Rope staging-support should not be used for welding or

cutting operation; rope may burn.

*Trademark of Proctor & Gamble.

OM-894C Page 4

1-3. ARC WELDING

Comply with precautions in 1-1, 1-2, and this section.

Arc Welding, properly done, is a safe process, but a

careless operator invites trouble. The equipment carries

high currents at significant voltages. The arc is very

bright and hot. Sparks fly, fumes rise, ultraviolet and in-

frared energy radiates, weldments are hot, and com-

pressed gases may be used. The wise operator avoids

unnecessary risks and protects himself and others from

accidents. Precautions are described here and in stan-

dards referenced in index.

A. Burn Protection

Comply with precautions in 1-2.

The welding arc is intense and visibly bright. Its radiation

can damage eyes, penetrate lightweight clothing, reflect

from light-colored surfaces, and burn the skin and eyes.

Skin burns resemble acute sunburn, those from gas-

shielded arcs are more severe and painful. DON’T GET

BURNED; COMPLY WITH PRECAUTIONS.

1. Protective Clothing

Wear long-sleeve clothing (particularly for gas-shielded

arc) in addition to gloves, hat, and shoes (1-2A). As nec-

essary, use additional protective clothing such as

leather jacket or sleeves, flame-proof apron, and fire-re-

sistant leggings. Avoid outer garments of untreated cot-

ton.

Bare skin protection. Wear dark, substantial clothing.

Button collar to protect chest and neck and button pock-

ets to prevent entry of sparks.

2. Eye and Head Protection

Protect eyes from exposure to arc. NEVER look at an

electric arc without protection.

Welding helmet or shield containing a filter plate shade

no. 12 or denser must be used when welding. Place over

face before striking arc.

Protect filter plate with a clear cover plate.

Cracked or broken helmet or shield should NOT be

worn; radiation can pass through to cause burns.

Cracked, broken, or loose filter plates must be replaced

IMMEDIATELY. Replace clear cover plate when broken,

pitted, or spattered.

Flash goggles with side shields MUST be worn under

the helmet to give some protection to the eyes should

the helmet not be lowered over the face before an arc is

struck. Looking at an arc momentarily with unprotected

eyes (particularly a high intensity gas-shielded arc) can

cause a retinal burn that may leave a permanent dark

area in the field of vision.

3. Protection of Nearby Personnel

Enclosed welding area. For production welding, a sepa-

rate room or enclosed bay is best. In open areas, sur-

round the operation with low-reflective, non-combusti-

ble screens or panels. Allow for free air circulation, par-

ticularly at floor level.

Viewing the weld. Provide face shields for all persons

who will be looking directly at the weld.

Others working in area. See that all persons are wearing

flash goggles.

Before starting to weld, make sure that screen flaps or

bay doors are closed.

B. Toxic Fume Prevention

Comply with precautions in 1-2B.

Generator engine exhaust must be vented to the out-

side air. Carbon monoxide can kill.

C. Fire and Explosion Prevention

Comply with precautions in 1-2C.

Equipment’s rated capacity. Do not overload arc weld-

ing equipment. It may overheat cables and cause a fire.

Loose cable connections may overheat or flash and

cause a fire.

Never strike an arc on a cylinder or other pressure ves-

sel. It creates a brittle area that can cause a violent rup-

ture or lead to such a rupture under rough handling.

D. Compressed Gas Equipment

Comply with precautions in 1-2D.

E. Shock Prevention

Exposed hot conductors or other bare metal in the weld-

ing circuit, or in ungrounded, electrically-HOT equip-

ment can fatally shock a person whose body becomes a

conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR

TOUCH a wet surface when welding, without suitable

protection.

To protect against shock:

Wear dry insulating gloves and body protection. Keep

body and clothing dry. Never work in damp area without

adequate insulation against electrical shock. Stay on a

dry duckboard, or rubber mat when dampness or sweat

can not be avoided. Sweat, sea water, or moisture be-

tween body and an electrically HOT part or grounded

metal reduces the electrical resistance, and could en-

able dangerous and possibly lethal currents to flow

through the body.

A voltage will exist between the electrode and any con-

ducting object in the work circuit. Examples of conduct-

ing objects include, but are not limited to, buildings, elec-

trical tools, work benches, welding power source cases,

workpieces, etc. Never touch the electrode and any

metal object unless the welding power source is

off.

1. Grounding the Equipment

Arc welding equipment must be grounded according to

the National Electrical Code, and the work must be

grounded according to ANSI Z49.1 “Safety In Welding

And Cutting.”

When installing, connect the frames of each unit such as

welding power source, control, work table, and water cir-

culator to the building ground. Conductors must be ade-

OM-894 Page 5

quate to carry ground currents safely. Equipment made

electrically HOT by stray current may shock, possibly

fatally. Do NOT GROUND to electrical conduit, or to a

pipe carrying ANY gas or flammable liquid such as oil or

fuel.

Three-phase connection. Check phase requirements of

equipment before installing. If only 3-phase power is

available, connect single-phase equipment to only two

wires of the 3-phase line. Do NOT connect the equip-

ment ground lead to the third (live) wire, or the equip-

ment will become electrically HOT-a dangerous condi-

tion that can shock, possibly fatally.

Before welding, check ground for continuity. Be sure

conductors are touching bare metal of equipment

frames at connections.

If a line cord with a ground lead is provided with the

equipment for connection to a switchbox, connect the

ground lead to the grounded switchbox. If a three-prong

plug is added for connection to a grounded mating re-

ceptacle, the ground lead must be connected to the

ground prong only. If the line cord comes with a three-

prong plug, connect to a grounded mating receptacle.

Never remove the ground prong from a plug, or use a

plug with a broken off ground prong.

2. Electrode Holders

Fully insulated electrode holders should be used. Do

NOT use holders with protruding screws.

3. Connectors

Fully insulated lock-type connectors should be used to

join welding cable lengths.

4. Cables

Frequently inspect cables for wear, cracks and damage.

IMMEDIATELY REPLACE those with excessively worn

or damaged insulation to avoid possibly-lethal shock

from bared cable. Cables with damaged areas may be

taped to give resistance equivalent to original cable.

Keep cable dry, free of oil and grease, and protected

from hot metal and sparks.

5. Terminals And Other Exposed Parts

Terminals and other exposed parts of electrical units

should have insulating covers secured before opera-

tion.

6. Electrode

a. Equipment with output on/off control (contac-

tor)

Welding power sources for use with the gas

metal arc welding (GMAW), gas tungsten arc

welding (GTAW) and similar processes nor-

mally are equipped with devices that permit on-

off control of the welding power output. When

so equipped the electrode wire becomes elec-

trically HOT when the power source switch is

ON and the welding gun switch is closed. Never

touch the electrode wire or any conducting ob-

ject in contact with the electrode circuit unless

the welding power source is off.

b. Equipment without output on/off control (no

contactor)

Welding power sources used with shielded

metal arc welding (SMAW) and similar proc-

esses may not be equipped with welding power

output on-off control devices. With such equip-

ment the electrode is electrically HOT when the

power switch is turned ON. Never touch the

electrode unless the welding power source is

off.

7. Safety Devices

Safety devices such as interlocks and circuit breakers

should not be disconnected or shunted out.

Before installation, inspection, or service, of equipment,

shut OFF all power and remove line fuses (or lock or

red-tag switches) to prevent accidental turning ON of

power. Disconnect all cables from welding power

source, and pull all 115 volts line-cord plugs.

Do not open power circuit or change polarity while weld-

ing. If, in an emergency, it must be disconnected, guard

against shock burns, or flash from switch arcing.

Leaving equipment unattended. Always shut OFF and

disconnect all power to equipment.

Power disconnect switch must be available near the

welding power source.

F. Protection For Wearers of Electronic Life Sup-

port Devices (Pacemakers)

Magnetic fields from high currents can affect pacemak-

er operation. Persons wearing electronic life support

equipment (pacemaker) should consult with their doctor

before going near arc welding, gouging, or spot welding

operations.

1-4. STANDARDS BOOKLET INDEX

For more information, refer to the following standards or

their latest revisions and comply as applicable:

1. ANSI Standard Z49.1, SAFETY IN WELDING

AND CUTTING obtainable from the American

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

FL 33126.

2. NIOSH, SAFETY AND HEALTH IN ARC WELD-

ING AND GAS WELDING AND CUTTING ob-

tainable from the Superintendent of Documents,

U.S. Government Printing Office, Washington,

D.C. 20402.

3. OSHA, SAFETY AND HEALTH STANDARDS,

29CFR 1910, obtainable from the Superinten-

dent of Documents, U.S. Government Printing

Office, Washington, D.C. 20402.

4. ANSI Standard Z87.1, SAFE PRACTICES FOR

OCCUPATION AND EDUCATIONAL EYE AND

FACE PROTECTION obtainable from the Ameri-

can National Standards Institute, 1430 Broad-

way, New York, NY 10018.

OM-894C Page 6

5. ANSI Standard Z41.1, STANDARD FOR MEN’S

SAFETY-TOE FOOTWEAR obtainable from the

American National Standards Institute, 1430

Broadway, New York, NY 10018.

6. ANSI Standard Z49.2, FIRE PREVENTION IN

THE USE OF CUTTING AND WELDING PROC-

ESSES obtainable from the American National

Standards Institute, 1430 Broadway, New York,

NY 10018.

7. AWS Standard A6.0, WELDING AND CUTTING

CONTAINERS WHICH HAVE HELD COMBUS-

TIBLES obtainable from the American Welding

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

8. NFPA Standard 51, OXYGEN-FUEL GAS SYS-

TEMS FOR WELDING, CUTTING, AND ALLIED

PROCESSES obtainable from the National Fire

Protection Association, Batterymarch Park,

Quincy, MA 02269.

9. NFPA Standard 70, NATIONAL ELECTRICAL

CODE obtainable from the National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA

02269.

10. NFPA Standard 51B, CUTTING AND WELDING

PROCESSES obtainable from the National Fire

Protection Association, Batterymarch Park,

Quincy, MA 02269.

11. CGA Pamphlet P-1, SAFE HANDLING OF

COMPRESSED GASES IN CYLINDERS obtain-

able from the Compressed Gas Association,

1235 Jefferson Davis Highway, Suite 501, Ar-

lington, VA 22202.

12. CSA Standard W117.2, CODE FOR SAFETY IN

WELDING AND CUTTING obtainable from the

Canadian Standards Association, Standards

Sales, 178 Rexdale Boulevard, Rexdale, On-

tario, Canada M9W 1R3.

13. NWSA booklet, WELDING SAFETY BIBLIOG-

RAPHY obtainable from the National Welding

Supply Association, 1900 Arch Street, Philadel-

phia, PA 19103.

14. American Welding Society Standard AWSF4.1,

RECOMMENDED SAFE PRACTICES FOR

THE PREPARATION FOR WELDING AND

CUTTING OF CONTAINERS AND PIPING

THAT HAVE HELD HAZARDOUS SUB-

STANCES, obtainable from the American Weld-

ing Society, 550 N.W. LeJeune Rd, Miami, FL

33126.

15. ANSI Standard Z88.2, PRACTICE FOR RESPI-

RATORY PROTECTION, obtainable from the

American National Standards Institute, 1430

Broadway, New York, NY 10018.

SECTION 2 – SAFETY PRECAUTIONS AND SIGNAL WORDS

2-1. GENERAL INFORMATION AND SAFETY

A. General

Information presented in this manual and on various la-

bels, tags, and plates on the unit pertains to equipment

design, installation, operation, maintenance, and

troubleshooting which should be read, understood, and

followed for the safe and effective use of this equipment.

The nameplate of this unit uses international symbols

for labeling the front panel controls. The symbols also

appear at the appropriate section in the text.

B. Safety

The installation, operation, maintenance, and trouble-

shooting of arc welding equipment requires practices

and procedures which ensure personal safety and the

safety of others. Therefore, this equipment is to be in-

stalled, operated, and maintained only by qualified per-

sons in accordance with this manual and all applicable

codes such as, but not limited to, those listed at the end

of Section 1 – Safety Rules For Operation Of Arc Weld-

ing Power Source.

2-2. SAFETY ALERT SYMBOL AND SIGNAL

WORDS

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 instruc-

tions.

This safety alert symbol is used with the signal

words WARNING and CAUTION to call atten-

tion to the safety statements.

WARNING statements identify procedures or

practices which must be followed to avoid seri-

ous personal injury or loss of life.

CAUTION statements identify procedures or

practices which must be followed to avoid minor

personal injury or damage to this equipment.

IMPORTANT statements identify special instructions

necessary for the most efficient operation of this equip-

ment.

OM-894 Page 7

SECTION 3 – SPECIFICATIONS

16 in.

(406 mm)

9-3/4 in.

(248 mm)

13-1/8 in.

(333 mm)

SB-129 229-A

Figure 3-1. Dimensional Drawing

Table 3-1. Specifications

Input Power

Requirements

Weight

Net Ship

115 Volts AC

At 1 Ampere

44 lbs.

(20 kg)

49 lbs.

(22.2 kg)

3-1. DESCRIPTION

This unit is a microprocessor-controlled Gas Tungsten

Arc Welding (GTAW) control unit designed for use with

inverter welding power sources. This unit allows the

user to create programs that control functions of the

weld process. Programs can be run individually or linked

to run in a sequence defined by the user.

When properly connected to the welding power source,

this unit provides high frequency, preflow time, initial

current, initial slope time, final slope time, final current,

postflow time, and amperage selection of weld/peak

current for either a pulsing or nonpulsing weld current.

Pulsing controls include on/off selection, pulse time,

peak current, background current, and pulse frequency.

This unit provides a delay time for wire feed on/off con-

trol and gas flow control.

SECTION 4 – INSTALLATION OR RELOCATION

4-1. LOCATION

IMPORTANT: Read entire Section 10 regarding high-

frequency equipment location and installation require-

ments before installing this equipment.

Locate the control unit close to the work station. This will

allow torch and work weld cables to be kept as short as

possible, thereby minimizing high frequency radiation.

4-2. SETTING DIP SWITCH SW1 (Figures 4-1 And

5-1)

Eight-position DIP switch SW1 allows the operator to

define certain functions of the control unit. To set the po-

sitions of SW1, proceed as follows:

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Shut down control unit and welding power

source, and disconnect input power employ-

ing lockout/tagging procedures before begin-

ning this procedure.

Lockout/tagging procedures consist of pad-

locking line disconnect switch in open position,

removing fuses from fuse box, or shutting off

and red-tagging circuit breaker or other discon-

necting device.

CAUTION: ELECTROSTATIC DISCHARGE

(ESD) can damage circuit boards.

• Put on properly grounded wrist strap BE-

FORE handling circuit boards.

• Perform work only at a static-safe work area.

OM-894 Page 8

16. Loosen the front panel retaining screw (see Fig-

ure 5-1) and swing the hinged front panel down.

17. Locate DIP switch SW1 on vertically mounted

Control Board PC1 (see Figure 4-1).

18. Set the applicable positions of SW1 as desired.

SW1 settings are explained in Subsections A

through D in this section.

19. After setting position(s) of SW1, swing the hinged

front panel up into normal operating position, and

securely tighten the retaining screw.

IMPORTANT: The eight positions on DIP switch SW1

resemble miniature rocker switches. Each position has

two possible states: ON or OFF. To set a position OFF,

fully depress the end of the position nearest the side of

the DIP switch labeled OFF. To set a position ON, fully

depress the end of the position farthest from the side of

the switch labeled OFF.

IMPORTANT: The DIP switch is only read by the control

unit when power is applied after a power down, or when

a RESET is initiated through the PROGRAM/RUN/RE-

SET key switch.

A. Defining Amperage Adjustment Limits

(Positions 1 And 2)

WARNING: Read and follow safety informa-

tion at beginning of Section 4-2 before pro-

ceeding.

While welding is taking place, weld amperage can be

adjusted up or down through the use of the Remote Op-

erator Control. Amperage adjustment limits are defined

by positions 1 and 2 (see Table 4-1).

Table 4-1. Amperage Adjustment Limits Definition

Position Position

Defined Amperage

Adjustment Limit

ON ON 5 Amperes

OFF

10 Amperes

20 Amperes

40 Amperes

B. Defining Pulser Time Values (Position 3)

WARNING: Read and follow safety informa-

tion at beginning of Section 4-2 before pro-

ceeding.

Two methods are provided for defining the amount of

time spent in peak current and the amount of time spent

in background current during pulsing. The first method

allows each value to be defined as a time value, and the

second method allows direct frequency entry with the

time spent in peak current to be defined as a percentage

of the total period. The remainder of the period is then

spent in background current.

To use the first method of defining peak current/back-

ground current time, set position 3 ON. To use the sec-

ond method of defining frequency/peak time percent-

age, set position 3 OFF.

C. Selecting RUN Or Diagnostics (Position 4)

WARNING: Read and follow safety informa-

tion at beginning of Section 4-2 before pro-

ceeding.

When RUN is chosen on the PROGRAM/RUN/RESET

key switch, the control unit will either enter the program

execution mode or carry out a diagnostics routine, de-

pending on position 4. To enter the program execution

mode when RUN is chosen on the key switch, set posi-

tion 4 ON. To carry out the diagnostics routine when

RUN is chosen, set position 4 OFF.

D. Defining The Welding Power Source Used With

The Control Unit (Positions 5 Through 8)

WARNING: Read and follow safety informa-

tion at beginning of Section 4-2 before pro-

ceeding.

Positions 5-8 allow the user to define the welding power

source that is being used with the control unit (see Table

4-2). When a non-Miller welding power source is indi-

cated, a series of displays requests the information re-

quired by the control unit.

Ref. SB-132 634

Center Panel

Power

Distribution

Board PC3

Filter Board PC10

DIP Switch SW1

Control Board PC1

Line Filter FL5

Figure 4-1. Inside Front View

OM-894 Page 9

*Table 4-2. Welding Power Source Definition

Position 5 Position 6 Position 7 Position 8

Defined Welding

Power Source

ON ON ON ON Maxstar 90

ON ON ON OFF Maxstar 150 or 151

ON ON OFF ON XMT 200

ON ON OFF OFF Maxtron 300/XMT 300

ON OFF ON ON Arc Pak 350

OFF OFF OFF OFF

Non-Listed Power

Source**

*Unlisted combinations for DIP switch positions 5-8 are interpreted by the control unit as de-

fining the Maxstar 151.

**A welding power source that is not listed in the table. It must meet the following

requirements to be usable with this control unit:

1. It must be capable of doing Gas Tungsten Arc Welding (GTAW).

2. It must be capable of responding to a 0-10V control signal.

4-3. SHIELDING GAS CONNECTIONS (Figure

4-2)

IMPORTANT: Allowable pressure range for shielding

gas input is 30-50 psi.

The gas fittings on the control unit have 5/8-18 right-

hand threads. Obtain shielding gas hose of proper size,

type and length to connect from shielding gas supply to

control unit. Proceed as follows:

1. Install gas fitting onto one end of shielding gas

hose from shielding gas supply.

2. Connect hose from shielding gas supply to gas IN

fitting on rear of control unit.

3. Connect shielding gas hose from torch to gas

OUT fitting on rear of control unit.

4-4. REMOTE OPERATOR CONTROL CONNEC-

TIONS (Figure 4-2)

TO OPERATOR CONTROL receptacle RC2 is used to

connect the supplied Remote Operator Control to the

control unit.To make connections, align keyway, insert

plug, and rotate threaded collar fully clockwise.

The sockets in TO OPERATOR CONTROL receptacle

RC2 function as follows:

Socket A: Provides normally closed contact with

socket C. Contact is opened when Remote

Operator Control STOP push button is

pressed.

Socket B: Provides normally open contact with socket

C. Contact is closed when Remote Opera-

tor Control DECREASE push button is

pressed.

SB-129 230-A

To Operator

Control Receptacle

Strain Relief Clamp

Gas Out Fitting

Electrode Terminal

Negative Terminal

Positive/Work

Gas In Fitting

To Power Source

Receptacle

Power Switch

Terminal

Figure 4-2. Rear View

OM-894 Page 10

Socket C: Circuit common with respect to control unit

chassis.

Socket D: Provides normally open contact with socket

C. Contact is closed when Remote Opera-

tor Control START/INCREASE push but-

ton is pressed.

Ref. S-0446-A

Figure 4-3. Front View Of TO OPERATOR

CONTROL Receptacle With Socket Locations

4-5. WELDING POWER SOURCE CONNEC-

TIONS (Figures 4-2 And 4-3)

The pins of TO POWER SOURCE receptacle RC1

function as follows:

Pin A: Provides connection to program-controlled

relay contact internal to control unit; contact

makes connection with relay contact connected

to pin B to energize welding power source.

Pin B: Provides connection to program-controlled

relay contact internal to control unit; contact

makes connection with relay contact connected

to pin A to energize welding power source.

Pin D: Control circuit common with respect to pin E.

Pin E: Provides 0-10 volt command signal with re-

spect to pin D.

Pin G: 115 volts ac circuit common; also connected to

welding power source chassis.

Pin I: Up to 1.5 amperes of 115 volts ac, 60 Hz, with

respect to socket G (circuit common).

Pin K: Machine chassis (circuit common).

IMPORTANT: The remaining pins in the receptacle are

not used.

Ref. S-0004-A

Figure 4-4. Front View Of TO POWER SOURCE

Receptacle With Pin Locations

These signals can be obtained by making connections

to a welding power source that provides one of the fol-

lowing combinations:

a. A suitable REMOTE 14 receptacle that pro-

vides all the necessary signals.

b. A suitable REMOTE 14 receptacle that pro-

vides all the necessary signals except the

115VAC across pins I and G (a 115VAC recep-

tacle must be available).

c. A suitable 5-socket Remote Contactor Control

receptacle that provides all the necessary sig-

nals except the 115VAC across pins I and G (a

115VAC receptacle must be available).

Each type of welding power source receptacle combina-

tion requires a different interconnection cord. To make

interconnections, proceed as follows:

1. An interconnection cord is provided that con-

nects to a Remote 14 receptacle that provides all

necessary signals. If the welding power source in

use does not have such a receptacle, obtain cor-

rect interconnecting cord.

2. Connect 14-socket plug on interconnecting cord

to the 14-pin TO POWER SOURCE receptacle

on rear of control unit as follows: align keyway, in-

sert plug, and rotate threaded collar fully clock-

wise.

3. If remaining end of cord has a 14-pin plug, con-

nect plug to the REMOTE 14 receptacle on weld-

ing power source as follows: align keyway, insert

plug, and rotate threaded collar fully clockwise.

4. If remaining end of cord has a 14-pin or 5-pin plug

and a 3-prong plug, insert 3-prong plug into

115VAC receptacle. Connect remaining plug to

applicable receptacle as follows: align keyway,

insert plug, and rotate threaded collar fully clock-

wise.

4-6. WELD INPUT/OUTPUT CONNECTIONS (Fig-

ure 4-2)

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Shut down control unit and welding power

source, and disconnect input power employ-

ing lockout/tagging procedures before in-

specting or installing.

Lockout/tagging procedures consist of pad-

locking line disconnect switch in open position,

removing fuses from fuse box, or shutting off

and red-tagging circuit breaker or other discon-

necting device.

Three terminals are provided on the rear panel of the

control unit for weld input/output connections. Make

connections to the terminals as follows:

1. Connect weld cable from positive (+) terminal on

welding power source to POSITIVE/WORK ter-

minal on control unit.

2. Connect weld cable from negative (-) terminal on

welding power source to NEGATIVE terminal on

control unit.

3. Connect weld cable from POSITIVE/WORK ter-

minal on control unit to work.

4. Connect weld cable from ELECTRODE terminal

on control unit to welding torch.

OM-894 Page 11

4-7. OPTIONAL INTERNAL WIRING CONNEC-

TIONS

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Shut down control unit and welding power

source, and disconnect input power employ-

ing lockout/tagging procedures before begin-

ning this procedure.

Lockout/tagging procedures consist of padlock-

ing line disconnect switch in open position, re-

moving fuses from fuse box, or shutting off and

red-tagging circuit breaker or other disconnect-

ing device.

CAUTION: ELECTROSTATIC DISCHARGE

(ESD) can damage circuit boards.

• Put on properly grounded wrist strap BE-

FORE handling circuit boards.

• Perform work only at a static-safe work area.

EXCESSIVE PRESSURE can break circuit

board and terminal strip.

• Use only minimal pressure and gentle move-

ment when disconnecting or connecting

leads.

A. Wiring Connections To Pressure Terminal Strip

RC7 (Figures 4-2, 4-5, 4-6, And 4-7)

WARNING: Read and follow safety informa-

tion at beginning of Section 4-7 before pro-

ceeding.

The states of various internal relay contacts that close

and open during program execution can be used to con-

trol external devices (fixturing control is a common use).

When wired correctly, the internal relay contacts func-

tion as switches. The relay contacts are accessible

through pressure terminal strip RC7 on Interface Board

PC2 (see Figure 4-5 for typical layout of relay contacts).

The contacts are rated at 3 amperes, 120VAC each. Re-

fer to Table 4-3 for an explanation of the various contact

connections available.

A weld profile diagram is shown in Figure 4-6. Relays

CR1 thru CR6 automatically change state at the transi-

tion time points (T

). Each relay resets at the end of

postflow (T

). However, relay CR7 can be programmed

to change state (from normally-open to normally-closed

or vice-versa) any time from the end of initial current

), up to 25 seconds after the end of T

or at the end of

weld current (T

), whichever comes first. Relay CR7 can

then be programmed to change state again any time

from the end of weld current (T

), up to 25 seconds after

the end of T

or until the end of postflow (T

), whichever

comes first. The operator simply programs the delay

time required before relay CR7 should change state.

Relay CR7 is intended for use with external wire feed-

ers; however, it can be used for other purposes at the

discretion of the operator.

To make wiring connections to RC7, proceed as follows:

1. Strip 1/2 in. (13 mm) insulation from ends of leads

to be connected to terminals on RC7.

2. Loosen strain relief clamp (see Figure 4-2) on

rear panel of control unit sufficiently to allow de-

sired number of leads to be inserted.

3. Remove top cover.

4. Locate pressure terminal strip RC7 on Interface

Board PC2 (see Figure 4-7).

5. Route stripped ends of leads through strain relief

clamp on back of control unit.

6. Press down on slotted end of white tab for desired

connection point (1-24), insert stripped end of

applicable lead, and release white tab.

7. Repeat Step 6 for each desired connection point.

IMPORTANT: If making wiring connections to pressure

terminal strip RC3 (used to signal the end of a weld se-

quence in the SEMI-AUTOMATIC mode), proceed di-

rectly to Section 4-7B. Otherwise, continue with the fol-

lowing steps.

8. Reinstall top cover.

9. To avoid high frequency interference, route leads

away from weld cables.

10. Tighten strain relief clamp.

11. Connect leads to external devices.

*CR

Normally Open Contacts Connection

Normally Closed Contacts Connection

Wiper Connection

*The related control relay energizes when its controlling

event takes place (see Table 4-3). For instance, the Start

Postflow contacts change states when postflow begins.

S-0650

Figure 4-5. Typical Layout For Internal Relays

Connected To Terminal Strip RC7

OM-894 Page 12

S-0844

CR1 Reset

CR2 Reset

CR3 Reset

CR4 Reset

CR5 Reset

CR6 Reset

CR7 Reset

CR1

CR2

CR5

CR6

CR7

CR3

CR4

CR7

Preflow

Initial

Current

Initial

Slope

Weld/Peak

Current

Final

Slope

Final

Current

Postflow

Background

Current (when

pulsing

Relay Contacts

PTD 0 to 25 sec. or end T

(whichever comes first, wire feed delay)

PTD 0 to

25 sec.

or end T

(whichever comes first)

= Time

PTD = Programmed Time Delay

Figure 4-6. Weld Profile Diagram

B. Wiring Connections To Pressure Terminal Strip

RC3 (Figures 4-2 And 4-7)

WARNING: Read and follow safety informa-

tion at beginning of Section 4-7 before pro-

ceeding.

The two terminals in pressure terminal strip RC3 are

used in the SEMI-AUTOMATIC Mode to signal the end

of a weld sequence. This is done by closing contacts

that are wired to pressure terminal strip RC3 on Inter-

face Board PC2. To make the needed wiring connec-

tions, proceed as follows:

1. Strip 1/2 in. (13 mm) insulation from ends of

leads to be connected to terminals on RC3.

2. Loosen strain relief clamp on rear panel of control

unit (see Figure 4-2) sufficiently to allow leads to

be inserted.

3. Remove top cover (if applicable).

4. Locate pressure terminal strip RC3 on Interface

Board PC2 (see Figure 4-7).

5. Route stripped ends of leads through strain relief

clamp on back of control unit.

6. Press down on slotted end of white tab for one of

the two connection points, insert stripped end of

applicable lead, and release white tab.

7. Repeat Step 6 for other connection point.

8. Reinstall top cover.

9. To avoid high frequency interference, route leads

away from weld cables.

10. Tighten strain relief clamp.

11. Connect leads from RC3 to relay. If applicable,

connect leads from RC7 to external devices.

Ref. SB-132 634

Fuse F1 Pressure Terminal

Strip RC3

Relay Mounting

Panel

Pressure Terminal

Strip RC7

Interface

Board PC2

Figure 4-7. Inside Top View

OM-894 Page 13

Table 4-3. Pressure Terminal Strip RC7 Connection Functions

Maximum allowable voltage between collector and common is +40 VDC, 100MA

Pressure

Terminal Strip RC7

Function

Common

Signal Synchronized With

+24VDC

Wire Feed Contact N.O.

Wire Feed Contact Wiper

Wire Feed Contact N.C.

Start Postflow N.O.

Start Postflow Wiper

Start Postflow N.C.

Start Final Amperage N.O.

Start Final Amperage Wiper

Start Final Amperage N.C.

Start Final Slope N.O.

Start Final Slope Wiper

Start Final Slope N.C.

Start Weld Amperage N.O.

Start Weld Ameprage Wiper

Start Weld Amperage N.C.

Start Initial Slope N.O.

Start Initial Slope Wiper

Start Initial Slope N.C.

Start Initial Amperage N.O.

Start Initial Amperage Wiper

Start Initial Amperage N.C.

* Open collector – transistor ON during peak current.

N.O. = normally open

N.C. = normally closed

♦

Pulses*

Connection On

Relay

CR7

CR6

CR5

CR4

CR3

CR2

CR1

SECTION 5 – OPERATOR CONTROLS

5-1. POWER SWITCH (Figure 4-2)

Depressing the ON portion of the POWER switch ener-

gizes the control unit and makes it ready to operate. De-

pressing the OFF portion of the POWER switch shuts

down the unit. When the POWER switch is in the ON po-

sition, a display is seen in the digital display area.

5-2. PROGRAM/RUN/RESET KEY SWITCH (Fig-

ure 5-1)

This key switch places the control unit in one of three

states. Selecting PROGRAM allows the operator to en-

ter or modify a program. Selecting RUN locks out any

program changes. Program execution can be carried

out from PROGRAM or RUN. Selecting RESET and

then returning to RUN or PROGRAM has the same ef-

fect as turning the unit OFF and then ON again.

5-3. MODE SELECTOR SWITCH (Figure 5-1)

This switch selects the mode of operation: AUTOMAT-

IC-1, SEMI-AUTOMATIC, MANUAL, or AUTOMAT-

IC-2, (see Section 6-3). During programming, this

switch allows programs to be entered into each mode.

When the unit is placed in RUN, it will operate in the

mode selected on the mode switch.

5-4. PARAMETER SELECT PUSH BUTTON (Fig-

ure 5-1)

The PARAMETER SELECT push button performs a

number of functions. When a display contains more

than one parameter, pressing the PARAMETER SE-

LECT push button selects each parameter in sequence.

Pressing the push button while the last parameter in a

display is selected will de-select that parameter without

selecting another one.

OM-894 Page 14

SB-129 229-A

ST-149 839

Front Panel

Retaining Screw

Weld Amperage

Display

Gas Flow

Meter

Digital Display

Push Button

Down

Push Button

Purge

Push Button

Parameter Select

Push Button

Mode Selector

Switch

Program/Run/Reset

Key Switch

Remote Operator

Control

Stop

Push Button

Start/Increase

Push Button

Decrease

Push Button

4-Pin Plug

Figure 5-1. Control Unit Front Panel View And Remote Operator Control

Pressing the PARAMETER SELECT push button while

the PULSE ON/OFF display is shown will toggle be-

tween one option and the other.

Pressing the PARAMETER SELECT push button in the

RUN condition (see Section 6-2) will increment the

PROGRAM #. Pressing PARAMETER SELECT re-

peatedly will bring up programs one through ten, after

which the PROGRAM “LINK” MODE display is shown

and then the ”COMBINE” MODE display. Pressing the

PARAMETER SELECT push button again brings up

program one again.

5-5. UP PUSH BUTTON (Figure 5-1)

The UP push button carries out two functions. Pressing

the UP push button while a parameter is selected will in-

crease the parameter value (press and hold the push

button to increase the value rapidly). Pressing the UP

push button without a parameter being selected will

show the previous display in the display sequence.

IMPORTANT: To zero a parameter value, select the pa-

rameter and press the UP and DOWN push buttons at

the same time.

5-6. DOWN PUSH BUTTON (Figure 5-1)

The DOWN push button carries out two functions.

Pressing the DOWN push button while a parameter is

selected will decrease the parameter value (press and

hold the push button to decrease the value rapidly).

Pressing the DOWN push button without a parameter

being selected will show the next display in the display

sequence.

IMPORTANT: To zero a parameter value, select the pa-

rameter and press the UP and DOWN push buttons at

the same time.

5-7. PURGE PUSH BUTTON (Figure 5-1)

PURGE

The PURGE push button is a momentary-contact

switch. Pressing the PURGE push button energizes the

gas solenoid and purges the gas line of the welding

torch. The PURGE push button allows the gas flow to be

adjusted without energizing the weld circuitry. PURGE

is active only in the Run condition (see Section 6-2).

5-8. GAS CONTROL (Figure 5-1)

The gas control adjusts the flow of shielding gas. Turn-

ing the control in a clockwise direction decreases the

flow of shielding gas. Turning the control in a counter-

clockwise direction increases the flow.

5-9. GAS FLOW RATE DIGITAL METER (Figure

5-1)

GAS FLOW RATE

(CFH)

The GAS FLOW RATE digital meter indicates the flow

rate of the shielding gas. The meter is calibrated in cubic

feet per hour and has a range of 0-50 cubic feet per hour

with Argon shielding gas. If gas flow rate exceeds 50 cu-

bic feet per second, the display reads OL.

5-10. DIGITAL DISPLAY (Figure 5-1)

The two line by twenty character digital display allows

the user to enter values and to read values once they are

entered. When a program is performed (either in RUN or

DRY RUN), weld sequence displays are shown as they

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Miller KE607495 Owner's manual

Brand: Miller

Model: KE607495

Category: Welding System

Type: Owner's manual

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