Miller KC199289 Owner's manual

Brand: Miller

Model: KC199289

Category: Welding System

Type: Owner's manual

This manual is also suitable for

cover2 1/92 − ST-151 254 PRINTED IN USA

February 1992 FORM: OM-814

Effective With Serial No. KC199289

MODEL: MMP

IMPORTANT: Read and understand the entire contents of both this manual and

the power source manual used with this unit, with special emphasis on the safety

material throughout the manual, before installing, operating, or maintaining this

equipment. This unit and these instructions are for use only by persons trained

and experienced in the safe operation of welding equipment. Do not allow

untrained persons to install, operate, or maintain this unit. Contact your distributor

if you do not fully understand these instructions.

MILLER ELECTRIC Mfg. Co.

A Miller Group Ltd., Company

P.O. Box 1079

Appleton, WI 54912 USA

Tel. 414-734-9821

OWNER’S MANUAL

OM-814 − 2/92

TABLE OF CONTENTS

SECTION 1 − SAFETY SIGNAL WORDS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INSTALLATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − OPERATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − TROUBLESHOOTING 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − ELECTRICAL DIAGRAMS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − PARTS LIST 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-814 Page 1

SECTION 1 − SAFETY SIGNAL WORDS

mod1.1 9/9

The following safety alert symbol and signal words are used throughout this manual to call attention to and identify

different levels of hazard and special instructions.

WARNING

WARNING statements identify procedures or practices which must be followed to avoid serious personal

injury or loss of life.

CAUTION

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 equipment.

SECTION 2 − SPECIFICATIONS

Table 2-1. Pulse Control

Specification Description

Overall Dimensions Height: 8-1/4 in. (210 mm); Width: 7-3/8 in. (187 mm); Depth: 4-3/4 in. (121 mm)

Weight Ship: 12 lbs. (5.4 kg); Net: 7 lbs. (3.2 kg)

Input Power Cord With Plug 20 ft. (6.1 m)

Additional Required Equipment Welding Power Source And Wire Feeder

Welding Power Source Type Needed Constant Current (CC) DC, With Suitable Remote 17 Receptacle

Wire Feeder Type Needed Constant Speed

Welding Process Gas Metal Arc Welding - Pulsed (GMAW-P)

SECTION 3 − INSTALLATION

ST-152 642

Turn OFF welding power source.

1 Welding Power Source

2 17-Socket Receptacle

3 Plug PLG3 From Pulse

Control

Insert plug into matching 17-socket

receptacle on welding power

source, and tighten threaded collar.

4 Mounting Bracket

Mounting holes are 4 in. (102 mm)

apart.

5 User-Supplied Mounting Hard-

ware

Figure 3-1. Connections To Welding Power Source And Optional Wall-Mounting Procedure

OM-814 Page 2

SECTION 4 − OPERATION

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Always wear dry insulating gloves.

• Insulate yourself from work and ground.

• Keep all panels and covers securely in place.

FUMES AND GASES can be hazardous

to your health.

• Keep your head out of the fumes.

• Ventilate area, or use breathing device.

• Read Material Safety Data Sheets (MSDSs) and

manufacturer’s instructions for material used.

WELDING can cause fire or explosion.

• Do not weld near flammable material.

• Watch for fire; keep extinguisher nearby.

• Do not locate unit over combustible surfaces.

• Do not weld on closed containers.

• Allow work and equipment to cool before handling.

ARC RAYS can burn eyes and skin;

NOISE can damage hearing.

• Wear welding helmet with correct shade of filter.

• Wear correct eye, ear, and body protection.

MOVING PARTS can cause injury.

• Keep away from pinch points such as drive rolls.

• Keep all doors, panels, covers, and guards closed

and securely in place.

MAGNETIC FIELDS FROM HIGH CUR-

RENTS can affect pacemaker operation.

• Pacemaker wearers keep away.

• Wearers should consult their doctor before going

near any welding operations.

See Safety Precautions at beginning of manual for ba-

sic welding safety information.

wfwarn3.1 10/91

1 Peak Current Control

Use control to select peak current

level during pulsed welding. The

peak current level is defined as a

percentage (25 − 100%) of maxi-

mum output current of the welding

power source in CC mode.

2 Pulse Width Control

Use control to select length of peak

current pulse. The scale around the

control is in milliseconds.

3 Pulse Frequency Control

Use control to select number of

peak current output pulses per sec-

ond. The scale around the control is

in pulses per second.

4 Background Current Control

Use control to select background

current level. The background cur-

rent level is defined as a percent-

age (3 − 25%) of maximum output

current of the welding power source

in the CC mode.

Every month check labels, cord,

and plug for damage.

Ref. SC-147 389-A

Figure 4-1. Controls

1 Welding Power Source

Set OUTPUT (CONTACTOR)

switch in REMOTE position.

Set mode switch in GTAW (CC) po-

sition.

Set Amperage/Voltage Control

switch in REMOTE 17 position.

Turn ARC CONTROL/INDUC-

TANCE control to minimum.

Figure 4-2. Welding Power Source

OM-814 Page 3

1 Insulating Gloves

2 Safety Glasses With Side

Shields

3 Welding Helmet

Wear dry insulating gloves, safety

glasses with side shields, and a

welding helmet with a correct shade

of filter (see ANSI Z49.1).

2 3

sb3.1 10/91

Figure 4-3. Safety Equipment

Install &

Connect

Equipment

Put On

Personal Safety

Equipment

Set

All

Controls

Turn On

Equipment & Gas

(If Applicable)

Sample

Weld

Readjust Controls

And Prepare

For Production

Figure 4-4. Sequence Of Pulsed Gas Metal Arc Welding (GMAW-P)

SECTION 5 − TROUBLESHOOTING

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Turn OFF welding power source, and disconnect

pulse control before inspecting, maintaining, or

servicing.

HOT PARTS can cause severe burns.

• Allow cooling period before servicing unit.

Troubleshooting to be performed only by qualified

persons.

Table 5-1. Welding Trouble

Trouble Remedy Section

No weld output. Be sure welding power source POWER switch is ON.

Check welding gun and/or wire feeder according to its manual.

No control of weld output. Check welding power source control settings. Figure 4-2

Be sure plug PLG3 is securely connected to REMOTE 17 re-

ceptacle on welding power source.

Figure 3-1

Check pulse control cord and replace if necessary.

Pulse control does not work. Check pulse control potentiometers.

Have Factory Authorized Service Station check circuit board

PC1.

Erratic weld; incorrect weld char-

acteristics.

Check pulse control settings. Figure 4-1

Check wire feed speed at wire feeder.

OM-814 Page 4

SECTION 6 − ELECTRICAL DIAGRAMS

SA-150 213-A

Figure 6-1. Circuit Diagram

SB-150 218

Figure 6-2. Wiring Diagram

OM-814 Page 5

SECTION 7 − PARTS LIST

Description

Part

No.

Dia.

Mkgs.

Complete Assembly

Quantity

C1 145 697 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PC1 150 419 CIRCUIT CARD, remote pendant 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

097 132 STAND-OFF, No. 6-32 x .375 lg 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG1 115 092 HOUSING PLUG & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113 746 TERMINAL, female 1skt 24-18 wire 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG2 135 558 HOUSING PLUG & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

079 747 TERMINAL, contact hdr 24-18 wire 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R1-4 073 562 POTENTIOMETER, C sltd sft 1/T 2W 10K ohm 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

097 922 KNOB, pointer .875dia x .250 ID 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

123 531 STRAIN RELIEF, cable flexible .231-.394 cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120 104 CABLE, pwr shld 18ga 6/c (order by ft) 20ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

073 296 CLAMP, cable 97-3057-12-6 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

097 866 PLUG, 17 pin MS-3106A-20-29P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150 211 CASE SECTION, front ends 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150 210 PANEL, rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150 208 WRAPPER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NAMEPLATE, (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150 212 GUARD, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150 209 BRACKET, mtg pendant 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

019 663 MOUNT, nprn 15/16 OD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.