Miller KE623992 Owner's manual

Brand: Miller

Model: KE623992

Category: Welding System

Type: Owner's manual

This manual is also suitable for

AUTOMATIC 1DA

Automatic 1DA

Processes

Description

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Submerged (SAW) Welding

Automatic Welding

OM-1578 129 511D

March 1998

Visit our website at

www.MillerWelds.com

Miller Electric manufactures a full line

of welders and welding related equipment.

For information on other quality Miller

products, contact your local Miller distributor

to receive the latest full line catalog or

individual catalog sheets. To locate your nearest

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

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

Thank you and congratulations on choosing Miller. Now

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

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

That’s why when Niels Miller first started building arc

welders in 1929, he made sure his products offered

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

customers couldn’t afford anything less. Miller products

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

be the best you could buy.

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

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

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

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

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

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

made installation and operation quick and easy.

With Miller you can count on years of reliable

service with proper maintenance. And if for

some reason the unit needs repair, there’s a

Troubleshooting section that will help you

figure out what the problem is. The parts list

will then help you to decide which exact part

you may need to fix the problem. Warranty and

service information for your particular model

are also provided.

Miller is the first welding

equipment manufacturer in

the U.S.A. to be registered to

the ISO 9001 Quality System

Standard.

Working as hard as you do

– every power source from

Miller is backed by the most

hassle-free warranty in the

business.

From Miller to You

Miller offers a Technical

Manual which provides

more detailed service and

parts information for your

unit. To obtain a Technical

Manual, contact your local

distributor. Your distributor

can also supply you with

Welding Process Manuals

such as SMAW, GTAW,

GMAW, and GMAW-P.

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2-1. Weld Control 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Weld Parameters 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Typical Equipment Location 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Overall Dimensions And Weight 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Mounting Hole Layout 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Connection Diagram 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Weld Control Connections 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8. 14-Pin Receptacle Information 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-9. Shielding Gas Connection To Regulator/Flowmeter 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-10. Shielding Gas Connections To Gas/Current Sensing Control 12. . . . . . . . . . . . . . . . . . . . . . . . .

2-11. Weld Cable Connections 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-12. Terminal Strip Connections 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-13. Relay Connections For Controlling External Devices 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-14. Weld Control Cycle 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-15. Example Of Relay Use 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-16. Matching Digital Voltage Control (DVC) Board To Welding Power Source 17. . . . . . . . . . . . . . .

2-17. DVC Board Modification For Use With Early Deltaweld Model Welding Power Sources 18. . .

2-18. Motor Speed Calibration 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-19. Installing Hub 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-20. Installing Spool-Type Wire And Adjusting Hub Tension 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-21. Installing Optional Reel-Type Wire 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – OPERATION 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Safety Equipment 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Work Clamp 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Upper Front Panel Controls 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Run-In Controls 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Weld Controls 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Crater/Jog Controls 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Digital Voltage And Wire Speed Meters 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Wire Jogging Switches 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Purge Button 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Start And Stop Pushbutton Switches 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11. Power Switch 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-12. Lower Panel Controls 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13. Shielding Gas 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-14. Sequence Of Operation For Gas Metal Arc Welding (GMAW) And

Flux Cored Arc Welding (FCAW) 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-15. Sequence Of Operation For Gas Metal Arc Welding (GMAW) Spot Welding 26. . . . . . . . . . . . .

SECTION 4 – MAINTENANCE & TROUBLESHOOTING 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Routine Maintenance 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Replacing The Hub Assembly 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Overload Protection 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Troubleshooting 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – ELECTRICAL DIAGRAMS 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – PARTS LIST 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

OM-1578D

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OM-1578 Page 1

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

som _nd_5/97

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in

the adjoining symbols.

Y Marks a special safety message.

. Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions

to avoid the hazards.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see

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

avoid the hazard. The safety information given below is only

a summary of the more complete safety information found in

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

Safety Standards.

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

repair this unit.

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

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks

or severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also

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

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

welding wire are electrically live. Incorrectly installed or improperly

grounded equipment is a hazard.

D Do not touch live electrical parts.

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

D Insulate yourself from work and ground using dry insulating mats

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

or ground.

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

there is a danger of falling.

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

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

unit.

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to its

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

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

power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first – double-check connections.

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

replace cord immediately if damaged – bare wiring can kill.

D Turn off all equipment when not in use.

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

D Do not drape cables over your body.

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

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

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

or another electrode from a different machine.

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

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.

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

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

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

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal of

input power on inverters.

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

capacitors according to instructions in Maintenance Section

before touching any parts.

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

FUMES AND GASES can be hazardous.

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

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

welding fumes and gases.

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

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

manufacturer’s instructions for metals, consumables, coatings,

cleaners, and degreasers.

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

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

person nearby. Welding fumes and gases can displace air and

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

ing air is safe.

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

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

highly toxic and irritating gases.

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

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

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

air-supplied respirator. The coatings and any metals containing

these elements can give off toxic fumes if welded.

OM-1578 Page 2

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays

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

weld.

ARC RAYS can burn eyes and skin.

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

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

and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

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

glare; warn others not to watch the arc.

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

rial (leather and wool) and foot protection.

Welding on closed containers, such as tanks,

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

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

workpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can cause

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

safe before doing any welding.

WELDING can cause fire or explosion.

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

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

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

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

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

easily go through small cracks and openings to adjacent areas.

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

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

cause fire on the hidden side.

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

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

Safety Standards).

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

practical to prevent welding current from traveling long, possibly

unknown paths and causing electric shock and fire hazards.

D Do not use welder to thaw frozen pipes.

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

contact tip when not in use.

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

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

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

from your person before doing any welding.

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.

D Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.

D Allow cooling period before working on gun or

torch.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.

D Wearers should consult their doctor before

going near arc welding, gouging, or spot

welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

D Wear approved ear protection if noise level is

high.

Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode. Since

gas cylinders are normally part of the welding

process, be sure to treat them carefully.

CYLINDERS can explode if damaged.

D Protect compressed gas cylinders from excessive heat, mechani-

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

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

support or cylinder rack to prevent falling or tipping.

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

D Never drape a welding torch over a gas cylinder.

D Never allow a welding electrode to touch any cylinder.

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

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

tings designed for the specific application; maintain them and

associated parts in good condition.

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

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

use or connected for use.

D Read and follow instructions on compressed gas cylinders,

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

Standards.

OM-1578 Page 3

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

FIRE OR EXPLOSION hazard.

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

combustible surfaces.

D Do not install unit near flammables.

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

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

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

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

long enough to extend beyond opposite side of

unit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.

D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

D Keep away from moving parts.

D Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do

so.

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

other people, or any metal when threading

welding wire.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guards

closed and securely in place.

H.F. RADIATION can cause interference.

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

navigation, safety services, computers, and

communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

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

ly correct any interference problem resulting from the installa-

tion.

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

equipment at once.

D Have the installation regularly checked and maintained.

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

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

minimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment

such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

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

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

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

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

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

1-4. Principal Safety Standards

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

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

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

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

20402.

Recommended Safe Practices for the Preparation for Welding and Cut-

ting of Containers That Have Held Hazardous Substances, American

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

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

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

tion Association, Batterymarch Park, Quincy, MA 02269.

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

from Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

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

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face

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

Institute, 1430 Broadway, New York, NY 10018.

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

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

OM-1578 Page 4

1-5. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

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

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

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

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

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

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

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

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

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

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

To reduce magnetic fields in the workplace, use the following

procedures:

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

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

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

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

tor as practical.

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

ble.

About Pacemakers:

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

then following the above procedures is recommended.

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OM-1578 Page 8

1-4. Principales normes de sécurité

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

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

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

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

20402.

Recommended Safe Practice for the Preparation for Welding and Cut-

ting of Containers That Have Held Hazardous Substances, norme AWS

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

33126

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

tion Association, Batterymarch Park, Quincy, MA 02269.

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

de la Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

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

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

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

Safe Practices For Occupation And Educational Eye And Face Protec-

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

1430 Broadway, New York, NY 10018.

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

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5. Information sur les champs électromagnétiques

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

des champs magnétiques basse fréquence

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

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

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

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

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

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

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

magnétiques et champs électriques à haute fréquence représente un

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

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

clusions finales de la recherche soient établies, il vous serait

souhaitable de réduire votre exposition aux champs électromagnéti-

ques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques dans l’environnement

de travail, respecter les consignes suivantes :

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif.

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

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

votre corps.

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

vous.

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

soudure.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout

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

alors recommandé de respecter les consignes ci–dessus.

OM-1578 Page 9

SECTION 2 – INSTALLATION

2-1. Weld Control

Specification Description

Input Power 115 Volts AC From Welding Power Source

Wire Feed Motor Type: Constant Wire Feed Speed

Range: 50 To 780 ipm (1.8 To 19.8 mpm) Standard Motor

15 To 200 ipm (0.4 To 5.1 mpm) Low Speed Motor

Wire Size .023 Thru 3/32 in (0.6 Thru 2.4 mm) Standard Motor

5/64 Thru 5/32 in (2.0 Thru 4.0 mm) Low Speed Motor

Welding Power Source CV/DC With Remote Voltage And Contactor Control Capabilities

Weld Voltage And Amperage See Welding Power Source Specifications

Overall Dimensions And Weight See Section 2-4

2-2. Weld Parameters

Controls

Weld Cycle Wire Speed Voltage Time

Preflow X

Run-In X

♦ ♦

Weld X X

Crater (Jog) X X X

Burnback X

Postflow X

X = Standard ♦ = Optional

2-3. Typical Equipment Location

ST-131 138-A

1 Welding Power Source

2 Gas Cylinder

3 Side Beam

4 Gas/Current Sensing Control

5 Weld Control

6 Spool Support

7 Wire Drive Assembly

8 Automatic Welding Gun

OM-1578 Page 10

2-4. Overall Dimensions And Weight

Overall Dimensions Weight

Component Height Width Depth Net Ship

Weld Control 17-1/2 in (445 mm) 14 in (355 mm) 9 in (229 mm) 32-1/2 lb (14.7 kg)

Gas/Current Sensing Control 4-1/2 in (108 mm) 5-1/2 in (140 mm) 10-1/2 in (267 mm) 4-1/2 lb (2.0 kg) Total 50 lb (23 kg)

Spool Support Assembly 13 in (330 mm) 9-1/2 in (241 mm) 8-1/2 in (216 mm) 6 lb (2.7 kg)

2-5. Mounting Hole Layout

ST-070 484-J / ST-092 440-A / ST-080 486-C

Inches Millimeters

A 8 203

B 16-3/4 426

C 2-7/8 73

D 9-7/8 251

E 3-1/2 89

F 2-1/2 64

G 5/16 Dia 7.9 Dia

Weld Control

Gas/Current Sensing Control

Spool Support Assembly

(Shown With Optional Wire Reel)

2-6. Connection Diagram

Ref. S-0261

1 Weld Control Right Side

2 25 ft (8 m) Voltage Sensing

Cord

3 Automatic Flux Valve

(Optional For SAW Welding)

4 5 ft (1.5 m) Motor Control

Cord

5 Wire Drive Assembly

6 Workpiece

7 Gas/Current Sensing Control

8 10 ft (3 m) Control Cord

9 Welding Power Source

10 25 ft (8 m) Interconnecting

Cord

11 Accessory Equipment

Connection (Flux Valve,

Fixture, Remote Switch, Etc.)

12 3

687

910

. Customer must supply wire drive

assembly and drive rolls, gun,

welding wire, and shielding gas or

flux for desired application.

OM-1578 Page 11

2-7. Weld Control Connections

ST-160 551-B / Ref. ST-160 543-A / Ref. S-0004-A / S-0750

1 Weld Control

2 Voltage Sensing Cord

Ring terminal connects to wire drive

assembly. Clamp attaches to workpiece.

See Section 2-11.

3 Motor Control Cord

4 Gas/Current Sensing Control Cord

5 Remote 14 Interconnecting Cord

6 Remote 14 Receptacle RC11 (See

Section 2-8)

7 Keyway

8 Plug

9 Threaded Collar

To make connections, align keyway, insert

plug, and tighten threaded collar.

2-8. 14-Pin Receptacle Information

Pin* Pin Information

I 115 volts ac with respect to socket G. Protected by fuse F1.

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

G Circuit common for 115 volts AC circuit.

C +10 volts dc input to voltage control with respect to socket D.

D Remote control circuit common.

E 0 to +10 volts dc output command signal to welding power source.

K Chassis common.

*The remaining pins are not used.

OM-1578 Page 12

2-9. Shielding Gas Connection To Regulator/Flowmeter

ssb3.1 5/94 – ST-158 697-A

Obtain gas cylinder and chain to running

gear, wall, or other stationary support so

cylinder cannot fall and break off valve.

1 Cap

2 Cylinder Valve

Remove cap, stand to side of valve, and

open valve slightly. Gas flow blows dust

and dirt from valve. Close valve.

3 Cylinder

4 Regulator/Flowmeter

Install so face is vertical.

5 Gas Hose Connection

Fitting has 5/8-18 right-hand threads. Ob-

tain and install gas hose.

6 Flow Adjust

Typical flow rate is 20 cfh (cubic feet per

hour). Check wire manufacturer’s

recommended flow rate.

Make sure flow adjust is closed when

opening cylinder to avoid damage to the

flowmeter.

7CO

Adapter

8 O-Ring

Install adapter with O-ring between

regulator/flowmeter and CO

cylinder.

Obtain gas cylinder and chain to running

gear, wall, or other stationary support so

cylinder cannot fall and break off valve.

Tools Needed:

1-1/8, 5/8 in

Gas

7 8

Argon Gas

2-10. Shielding Gas Connections To Gas/Current Sensing Control

ST-080 485-A

1 Gas/Current Sensing Control

2 Shielding Gas Valve Fitting

Tools Needed:

5/8 in

From Regulator/

Flowmeter

To Gun

OM-1578 Page 13

2-11. Weld Cable Connections

ST-160 543-A

DC Electrode Positive (DCEP) polarity

shown.

1 Welding Power Source

2 Positive Weld Output Cable

3 Gas/Current Sensing Control

Be sure weld cable is routed through

current sensing reed relay. This

provides current feedback to the weld

control.

4 Weld Cable Terminal

5 Weld Cable

6 Voltage Sensing Lead With Ring

Terminal

7 Negative Weld Output Cable

8 Workpiece

9 Voltage Sensing Lead With Clamp

Voltage sensing connections provide

voltage feedback to the weld control.

Tools Needed:

9/16, 3/4 in

OM-1578 Page 14

2-12. Terminal Strip Connections

Ref. ST-112 519-C / ST-161 138

Route leads from external devices through

strain relief on control side panel.

1 Remote Start/Stop Switches

A momentary-contact, normally-open

push button switch is required for start

control. A normally-closed switch is

required for stop control.

2 Remote Start/Stop Relay

Energizing the relay starts the weld while

opening the relay contacts stops the weld.

3 Skip Weld Start/Stop Switch

A double-pole, single-throw, maintained-

contact switch is required.

Closing the switch starts the spot weld

cycle. Preflow and postflow times

determine the skip time. The spot weld

cycle repeats until the switch is opened.

Other Connections

A flux valve can be powered and controlled

by the weld control. Make connections

from flux valve to terminals 1TC and 2TD.

Flux valve energizes when the Start button

is pressed and turns off at the end of post-

flow.

Water flow can be controlled by the gun

trigger. Locate lead 1 from gas/ current

sensing receptacle RC3 at 2TB.

Disconnect lead and reconnect to 1TC.

Make connections as required for the

application. Tighten strain relief, and close

and secure door.

Tools Needed:

OM-1578 Page 15

2-13. Relay Connections For Controlling External Devices

Ref. ST-112 519-C

A set of normally-open and

normally-closed relay contacts are

available to work with the weld

cycle timers. The relay contacts are

rated at 1 A at 120 volts ac.

1 Receptacle RC4

2 Receptacle RC10

Connections can be made to the

3/16 in (4.8 mm) male friction

terminals on RC4 and RC10.

3 Timer Board PC3 With Relays

Remove timer board to ease

installation at RC4 and RC10.

4 Relay CR50

5 Receptacle RC1

6 Relay CR51

7 Relay CR52

8 Relay CR53

9 Receptacle RC2

10 Relay CR54

11 Relay CR55

12 Relay CR56

Tools Needed:

4 5 6 7 8 9 10 11 12

2-14. Weld Control Cycle

S-0779

Timer Board PC3 relays (CR50 thru

CR56) turn on and off during the

weld cycle.

1 Preflow

2 Run-In

3 Arc Initiation

4 Weld

5 Crater

6 Burnback

7 Postflow

8 End Of Cycle – Timers Reset

Tools Needed:

Relay Contacts

Open

Closed

CR56

CR55

CR54

Wire Speed

Start

Time

Stop

CR50

BDE

CR51

FHG

CR52

ML K

CR55

XWV

CR56

CC BB AA

CR54

PQR

RC4 RC10

CR50

CR51

CR52

1234 5 67 8

OM-1578 Page 16

2-15. Example Of Relay Use

Ref. ST-131 138 / Ref. ST-112 519-C

1 Weld Control

2 Side Beam Control

The weld control relays control the

time during the weld cycle that the

side beam carriage moves.

3 Relay CR50 (See Section

2-14)

If the carriage needs to start moving

at run-in and stop at the end of weld,

normally-open contacts of CR50

are used.

4 Receptacle RC4 (See Section

2-14)

Make connections from side beam

to RC4 terminals B and D.

Tools Needed:

Example: Relay Connections For Controlling External Device

OM-1578 Page 17

2-16. Matching Digital Voltage Control (DVC) Board To Welding Power Source

ST-160 541 / SB-152 372 / S-150 864-C

1 DVC Board PC1

2 DIP Switch

Tools Needed:

Non-Conductive

DELTAWELD 300

DELTAWELD 451, 450

DELTAWELD 651, 650

MAXTRON 300, 400

MAXTRON 450

XMT 200/300

ARC PAK 350

SHOPMASTER 300

DIMENSION 400

S2 S1

DVC SWITCH SETTINGS

O – On For Optional Soft Start. Turn Off S1 -3.

∆ – On For Optional Hot Start.

S-150 864-C

PULSTAR 450

1212345

∆∆

OM-1578 Page 18

2-17. DVC Board Modification For Use With Early Deltaweld Model Welding Power Sources

If the weld control is used with a Deltaweld welding power source with a serial

number prior to JJ400026, the DVC board needs modification and interconnecting

cord MILLER Part No. 042 562 is needed to connect the welding power source and

weld control.

NOTE

A. Modifying DVC Board

ST-160 541 / SD-152 373

1 Plug PLG14

2 DVC Board PC1

Disconnect plug PLG14 and leads

at PC1. Remove PC1 from weld

control.

3 Jumper J1

4 Jumper J2

5 Jumper J3

6 Jumper J4

7 Jumper J5

8 Jumper J6

9 Jumper J7

10 Jumper J8

Locate jumpers J1 through J8.

Cut board foil between jumpers J2,

J4, J6, and J8.

Scrape sealant coating from

jumpers J1, J3, J5, and J7. Solder

jumpers together.

Apply a sealant coating over all

jumpers.

Reinstall board into unit. Reconnect

leads. Go to Section 2-17B.

Tools Needed:

OM-1578 Page 19

B. Reconnections At Plug PLG14

Ref. ST-152 372

Disconnect PLG 14 from

receptacle RC1.

Leads 78, 79, and 81 at PLG14

must be removed from PLG14 and

reinserted.

1 Locking Tab

Press tab in and pull lead to remove

socket from PLG14. Bend tab back

out.

2 Receptacle RC1

Lead 78 was connected to PLG14

socket 10. Reconnect lead 78 to

PLG14 socket 9 (see RC1

markings on circuit board).

Lead 79 was connected to PLG14

socket 8. Reconnect to socket 10.

Lead 81 was connected to PLG14

socket 9. Reconnect to socket 8.

Reconnect PLG14 to RC1. Close

and secure door.

Tools Needed:

2-18. Motor Speed Calibration

Ref. ST-112 519-C

The weld control is shipped for use

with a standard speed motor

(16.79:1 gear ratio). DIP switch S50

on low speed calibration board PC8

needs to be changed if a low speed

motor (65.5:1 gear ratio) is used.

1 Low Speed Calibration Board

PC8

2 DIP Switch S50

Place switch in position 1 as shown

for low speed motor.

Close and secure door.

Tools Needed:

Non-Conductive

OM-1578 Page 20

2-19. Installing Hub

ST-126 870-A

Spool support is typically installed

on top of side beam (see Section

2-3).

1 Spool Support

Choose hole in support that allows

wire to enter drive assembly in the

straightest line.

2 Tension Adjustment Nut

3 Fiber Washer

4 Brake Washer

5 Hub Assembly

6 Hub Support Shaft

Remove nut from shaft. Install hub

assembly as shown.

Tools Needed:

9/16 in

2-20. Installing Spool-Type Wire And Adjusting Hub Tension

ST-161 001

1 Retaining Ring

2 Wire Spool

3 Hole In Spool

4 Hub

Remove retaining ring and slide

spool onto hub. Turn spool until hub

pin fits hole in spool. Reinstall re-

taining ring.

5 Tension Adjustment Nut

Grasp spool in one hand and turn

while using a wrench to adjust hex

nut. When a slight force is needed

to turn spool, tension is set.

Tools Needed:

9/16 in

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Miller KE623992 Owner's manual

Brand: Miller

Model: KE623992

Category: Welding System

Type: Owner's manual

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