Miller KC241704 Owner's manual

Miller
Brand
Miller
Model
KC241704
Category
Welding System
Type
Owner's manual

This manual is also suitable for

May
1992
FORM:
OM-146
741A
Millerfi
Effective
With
Serial
No.
KC241
704
MODEL:
XMTfi
300
CC
E~UU
OWNERS
MANUAL
IMPORTANT:
Read
and
understand
the
entire
contents
of
this
manual,
with
special
emphasis
on
the
safety
material
throughout
the
manual,
before
installing,
operating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
f~fr
MILLER
ELECTRIC
Mfg.
Co.
A
Miller
Group
itt.
Company
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.
P.O.
BOX
1079
Appleton,
WI
54912
USA
Tel.414-734-9821
coven
1192
ST.152
303-A
PRINTED
IN
USA
LIMITED
WARRANTY
EFFECTIVE:
AUGUST
6.
1990
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
Ii
LIMITED
WARRANTY
Sublect
to
the
terms
and
conditions
hereof,
MILLER
Electric
Mfg.
Co.,
Appleton.
Wisconsin
war
rants
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
furnished
by
MILLER
is
free
from
defect
in
workmanship
and
material
as
of
the
time
and
place
of
delivery
by
MILLER.
No
warranty
us
made
by
MILLER
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
trade
accessories
and
other
items
are
sold
subject
tothe
warranties
of
their
respective
manufacturers.
if
any.
All
engines
are
warrantied
by
their
manufacturer
for
two
years
from
date
of
original
purchase,
except
Deutz
engines
which
have
a
one
year,
2000
hour
warranty.
Except
as
specified
below,
MILLERs
warranty
does
not
apply
to
components
having
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
MILLERMATIC
parts
that
come
in
contact
with
the
welding
wire
including
nozzles
and
nozzle
insulators
where
failure
does
not
result
from
defect
in
workmanship
or
material.
MILLER
shall
be
required
to
honor
warranty
claims
on
war
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
within
the
following
periods
from
the
date
of
delivery
of
Equipment
to
the
original
user:
1.
Arc
welders,
power
sources,
robots,
and
1
year
components
2.
Load
banks
1
year
3.
Original
main
power
rectifiers
3
years
(labor
1
year
only)
4.
All
welding
guns,
feeder/guns
and
torches
90
days
5.
All
other
MILLERMATIC
Feeders
1
year
6.
Replacement
or
repair
parts,
exclusive
of
labor
60
days~
7.
Batteries
6
months
provided
that
MILLER
is
notified
in
writing
within
thirty
(30)
days
of
the
date
of
such
failure.
As
a
matter
of
general
policy
only,
MILLER
may
honor
claims
submitted
by
the
original
user
within
the
foregoing
periods.
In
the
case
of
MILLERs
breach
of
warranty
or
any
other
duty
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
therefore
shall
be.
at
MILLERs
option
(1)
repair
or
(2)
replace
ment
or,
where
authorized
in
writing
by
MILLER
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
MILLER
service
station
or
(4)
payment
of
or
credit
for
the
purchase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
Customers
risk
and
expense.
MILLERs
option
of
repair
or
replacement
will
be
FOB..
Factory
at
Appleton.
Wisconsin.
or
FOB.
at
a
MILLER
authorized
service
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
MILLER
shall
instruct
the
claimant
on
the
warranty
claim
procedures
to
be
followed.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRE
SENTATION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH.
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION.
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING.
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHAN
TABILITY
OR
OF
FITNESS
FOR
PARTICULAR
PURPOSE.
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
WRITING.
MILLER
PRODUCTS
ARE
INTENDED
FOR
ULTIMATE
PURCHASE~
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLERS
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO.
ANY
CONSUMER.
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
damage
that
may
have
occurred
during
shipment.
File
any
claims
for
loss
or
damage
with
the
delivering
carrier.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
distributor
and/or
equipment
manufacturers
Transportation
Department.
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
unit.
The
information
is
located
on
the
rating
label
or
nameplate.
Model
__________
Serial
or
Style
No.
Date
of
Purchase
m~iier
8,91
ERRATA
SHEET
April
12,
1993
Form:
OM-146
741A
Use
above
FORM
number
when
ordering
extra
manuals.
RAfter
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
CHANGES
TO
SECTION
4-OPERATION
~T~RN
TO
~
Replace
Figure
4-10.
Power
Switch
And
Pilot
Light
Figure
4-10.
Power
Switch
And
Power
Light
CHANGES
TO
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
Replace
Figure
5-3.
Changing
AmperageNoitage
Meter
Hold
Function
1
Pilot
Light
2
Power
Switch
Use
this
switch
to
turn
unit
and
pilot
light
ON
and
OFF.
There
is
a
5
second
time
delay
be
fore
the
unit
is
ready
to
weld.
Fan
motor
is
thermostatically
con
trolled
and
only
runs
when
cooling
is
needed.
The
AmperageNoltage
meter
is
able
to
hold
the
displayed
weld
Out.
putvalue
for
15
seconds
after
weld.
ing
stops.
This
procedure
allows
the
hold
function
to
be
turned
ON
or
OFF.
If
the
hold
function
is
not
used,
the
displayed
value
leaves
when
weld
ing
stops.
Turn
OFF
welding
power
source,
disconnect
input
power,
and
check
voltage
on
input
capacitors
accord.
ing
to
Section
5.2
before
proceed.
ing.
1
MI
Meter
Board
PC5
2
DIP
Switch
S2
S2
is
accessible
from
the
right
side
of
the
unit.
3
Toggle
1
4
Toggle
2
Set
both
toggles
in
desired
posi
tion.
Reinstall
top
of
case.
Tools
Needed:
Figure
5-3.
Changing
Amperage/Voltage
Meter
Hold
Function
CHANGES
TO
SECTION
6-
ELECTRICAL
DIAGRAMS
Replace
Figure
6-1.
Circuit
Diagram
For
Welding
Power
Source
LVE~1
T
T
03
000
0
L~ATED
~
IP~U1
REd.
~ATSD~(
Figure
6-1.
Circuit
Diagram
For
Welding
Power
Source
Effective
With
Serial
No.
KD352528
OM-146
741A
Page
2
LI
F-
RC2
12
0~
a
O
>
~F
CLP4.
12<<PC3I-l0
C
>
OUT
E
IN
RC3
-II
PC3I-3
RC6-8
PC6-
7
PCI
0-P
PC
10-2
PC
2-3
PC4
FILTER
BOARD
RC30~Pt.G3O
RC3I
/Pt.G~I
PASCL
RCI2-P
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C>>
2<<PC3I-5
147
~
>
C~.ASSIS
G~C
24V
R~~T
PC3I-6
~
>
PC3O-7>)
do
OUT
PtJT/
c~(TACT~
0
PT
A
W
L3
L
-0
LP
-0!
0
PCI
cn~tpa
POAPO
PC2/PL02
0C4/PLCI
PC6/PL0o
PCP/PL0P
PC
I
0/PLO
I
0
PCIO/PLOIO
PCIP/PL0IP
PCOP/PL02P
PCOP-7
POOP-
I
PCOP-9
POOP-S
0
PCI
2-
POlO-
I
0
hi
0
POSITIVE
NEGATIVE
SO158
313
OM-146
741A
Page
3
C
?7B(PLG6~
~
ALA
IL
I
_________
~7A~F2I
5LU~
(L2)
WIlT
PACSI
_____________
VP
BA~IL3)
___________
___________________
WAIT
lOA(SP
I-AC
PLG9
~
IIC(F,
I3A(TP2)
PC7
___
,
1
I
IB(F!)
~I~I
~
__
___
~BLK
30A(TEI-I
I6A)PLG6-8I~
~
-,
~f~~PLG7
~
I
PA
PLGA-
7
I
WAIT/BLK
WAIT
j
Al
A)
TP2
T2
I
I
PD.YEI.
L
(
~C
~t4)F2)
-
__________
(BASE
GIC
0
N
C
~
4
___________________
SPLICE
TWISTED
PAIRS
OLI
0
-
(
22
o
L4
0
L3
ol
T~~
hA
C2
L.A.
SECT
TIB
L.A.
SECT
B
TIC
C2
P.M.
SECT
P.M.
SECT
29*)
C9-POS)
BOTT~4
~5A(SPI
P~)
______________
LI(T~)
29e(P13J
J
Replace
Figure
6-2.
Wiring
Diagram
For
Welding
Power
Source
YELLOW
~PEEN
~GPN
vrM
Ii
flU
TWISTED
PAIRS-A
wifl)P(.G28-9
0
PlO
0 0
P9
-
_______
WIIT(PLG2B-7(
:
~
Ill
fl_LI
PM
~
(TI
24A(SP(
IEG)
(
24C(RI1)
LA
(
(DM2-Cl
(
(PM2-E2)
I
11
ro~
21
I
L.A.
SECT
I
2)
22
3
22
P.M.
SECT
22
A
2
P
4
29C(C9-POS)
C9-AEG)
0
P
3
(CB-A~G)
_________I
1)0
3
C
U
BOTTOM
£
PM
I-C
I)
Figure
6-2.
Wiring
Diagram
For
Welding
Power
Source
Effective
With
Serial
No.
KD352528
OM-146
741A
Page
4
CHANGES
TO
SECTION
8
PARTS
LIST
Change
Parts
List
as
follows:
29-7.
29-26
29-
30-45
30-
30-46
30-
30-
30-
30-
155
520
124
684
010
116
010
116
149
452
146
674
Added
150
233
155
634
149
872
150
234
155
634
149
872
Added
Added
157
011
156313
010116
137768
162096
+158
307
155053
+158668
149209
133290
+158308
149209
133290
152775
155053
158443
158444
154702
~First
digit
represents
page
no
digits
following
dash
represent
item
no.
Part
of
042
805
Meter
Kit
Option.
+All
components
remain
the
same
with
listed
exceptions.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Dia.
--
Mkgs.
Part
No.
Replaced
With
27-6....
PC5
29-2...
.
HD1
29-6
29-6
...TP2...
D13-16
Description
Quantity
30-
D9-12...
SN1
TP3
CIRCUIT
CARD,
meter
(Effw/KC330157)
1
TRANSDUCER,
current
300A
1
GROMMET,
(qtychg)
(Effw/KD403197)
2
GROMMET,
rbr
.750
ID
x
.875mtg
hole
(Eff
w/KD403197)
1
TRAY,
mtg
PC
card
(Eff
w/KD4031
97)
1
IGBT,
RH
(Eff
w/KD352528)
1
THERMOSTAT,
NO
(Eff
w/KD352528)
1
RECTIFIER,
si
diode
RH
(Eff
w/KD352528)
1
KIT,
diode
fast
recovery
(Eff
w/KD352528)
1
HEAT
SINK,
rect
(Eff
w/KD352528)
1
RECTIFIER,
si
diode
LH
(Eff
w/KD352528)
1
KIT,
diode
fast
recovery
(Eff
w/KD352528)
1
HEAT
SINK,
rect
(Eff
w/KD352528)
1
SNUBBER,
poly
met
film
.1
uf
600VDC
(Eff
w/KD352528)
.
1
THERMOSTAT,
NO
(Eff
w/KD352528)
1
INSULATOR,
heat
sink
upper
(Eff
w/KD352528)
1
STRIP,
buss
rectifier
(Eff
w/KD352528)
1
INSULATOR,
fuse
holder
1
30-48
149873
30-50
149871
30-
Added
OM-146
741A
Page
6
ARC
WELDING
SAFETY
PRECAUTIONS
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.
WELDING
can
cause
fire
or
explosion.
Sparks
and
spatter
fly
off
from
the
welding
arc.
The
flying
sparks
and
hot
metal,
weld
spatter,
hot
workpiece.
and
hot
equipment
can
cause
fires
and
burns.
Accidental
contact
of
electrode
or
welding
wire
to
metal
objects
can
cause
sparks,
overheating,
or
fire.
1.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
2.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
3.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
If
this
is
not
possible,
tightly
cover
them
with
approved
covers.
4.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
I
small
cracks
and
openings
to
adjacent
areas
FLYING
SPARKS
AND
HOT
METAL
can
cause
injury.
Chipping
and
grinding
cause
flying
metal.
As
welds
cool,
they
can
throw
off
stag.
5.
Property
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
Turn
off
all
equipment
when
not
in
use.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
Do
not
wrap
cables
around
your
body.
Ground
the
workpiece
to
a
good
electrical
(earth)
ground.
Do
not
touch
electrode
while
in
contact
with
the
work
(ground)
circuit.
11.
Use
only
welt-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
12.
Wear
a
safety
harness
to
prevent
fatting
if
working
above
floor
level.
Watch
for
fire.
and
keep
a
fire
extinguisher
nearby.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead.
or
partition
can
cause
fire
on
the
hidden
side.
7.
Do
not
weld
on
closed
containers
such
as
tanks
or
drums.
8.
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.
Do
not
use
welder
to
thaw
frozen
pipes.
Remove
stick
electrode
from
holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
11.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
1.
Wear
approved
fa~e
shield
or
safety
goggles.
Side
shields
recommended.
2.
Wear
proper
body
protection
to
protect
skin.
Ak
WARNING
ARC
WELDING
can
be
hazardous.
PROTECT
YOURSELF
AND
OTHERS
FROM
POSSIBLE
SERIOUS
INJURY
OR
DEATH.
KEEP
CHILDREN
AWAY.
PACEMAKER
WEARERS
KEEP
AWAY
UNTIL
CONSULTING
YOUR
DOCTOR.
In
welding,
as
in
most
jobs,
exposure
to
certain
hazards
occurs.
Welding
is
safe
when
precautions
are
taken.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
that
will
be
found
in
the
Safety
Standards
listed
on
the
next
page.
Read
and
follow
all
Safety
Standards.
HAVE
ALL
INSTALLATION,
OPERATION,
MAINTENANCE,
AND
REPAIR
WORK
PERFORMED
ONLY
BY
QUALIFIED
PEOPLE.
1.
6.
7.
8.
9.
to.
Do
not
touch
live
electrical
parts.
2.
Wear
dry.
hole.free
insulating
gloves
and
body
protection.
3.
Insulate
yourself
from
work
and
ground
using
dry
insulating
mats
or
Covers.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
13.
Keep
all
panels
and
covers
securely
in
place.
/~,.
~,~P
ARC
RAYS
can
burn
eyes
and
skin;
1.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
(see
NOISE
can
damage
hearing.
ANSI
Z49.
I
listed
in
Safety
Standards)
to
protect
your
face
and
eyes
when
welding
or
watching.
Arc
rays
from
the
welding
process
produce
intense
2.
Wear
approved
safety
glasses.
Side
shields
recommended.
heat
and
strong
ultraviolet
rays
that
can
burn
eyes
3.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
skin.
Noise
from
some
processes
can
damage
and
glare;
warn
others
not
to
watch
the
arc.
earing.
4.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
5.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
~,,,
FUMES
AND
GASES
can
be
hazardous
5.
Work
in
a
confined
space
Only
if
it
is
well
ventilated,
or
while
to
your
health.
wearing
an
air-supplied
respirator.
Shielding
gases
used
for
Weldlngproduces
fumes
and
gases.
Breathing
these
welding
can
displace
air
causing
injury
or
death.
Be
sure
the
fumes
and
gases
can
be
hazardous
to
your
health.
breathing
air
is
safe.
6.
Do
not
weld
in
locations
near
degreasing.
cteaning,
or
spraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
I.
Keep
your
head
out
of
the
fumes.
Do
not
breath
the
fumes.
.
.
form
highly
toxic
and
irritating
gases.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
3.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
4.
Read
the
Material
Safety
Data
Sheets
(MSDSs)
and
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
manufacturers
instruction
for
metals,
consumables,
coatings.
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
and
cleaners,
containing
these
elements
can
give
off
toxic
fumes
if
welded.
5.
6.
9.
10.
sri
9/91
CYLINDERS
can
explode
if
damaged.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of
the
welding
process,
be
sure
to
treat
them
carefully.
1.
Protect
compressed
gas
cylinders
from
excessive
heat.
mechanical
shocks,
and
arcs.
2.
Install
and
secure
cylinders
in
an
upright
position
by
chaining
them
to
a
stationary
support
or
equipment
cylinder
rack
to
prevent
falling
or
tipping.
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
4.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
5.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
6.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
7.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
8.
Read
and
follow
instructions
on
compressed
gas
cylinders.
associated
equipment,
and
CGA
publication
P.1
listed
in
Safety
Standards.
a
WARNING
ENGINES
can
be
hazardous.
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
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
Ameri
can
Welding
Society
Standard
AWS
F4.
1,
from
American
Welding
So
ciety,
550
N.W.
LeJeune
Ad,
Miami,
FL
33126
National
Electncal
Code,
NFPA
Standard
70.
from
National
Fire
Pro
tection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
High
way,
Suite
501,
Arlington,
VA
22202.
Code
for
Safety
in
Welding
and
Cutting,
CSA
Standard
Wi
17.2.
from
Canadian
Standards
Association.
Standards
Sales,
178
Rexdale
Bou
levard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
Protec
tion.
ANSI
Standard
Z87.1.
from
American
National
Standards
Insti
tue.
1430
Broadway.
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
51
B.
from
National
Fire
Protection
Association,
Batterymarch
Park.
Quincy,
MA
02269.
:~
~
ENGINE
EXHAUST
GASES
can
kill.
1.
Use
equipment
outside
in
open,
well-ventilated
areas.
2.
If
used
in
a
closed
area,
vent
engine
exhaust
outside
and
Engines
produce
harmful
exhaust
gases.
away
from
any
building
air
intakes.
ENGINE
FUEL
can
cause
fire
or
1.
Stop
engine
before
checking
or
adding
fuel.
explosion.
2.
Do
not
add
fuel
while
smoking
or
if
unit
is
near
any
sparks
or
open
flames.
3.
Allow
engine
to
cool
before
fueling.
If
possible,
check
and
add
Engine
fuel
is
highly
flammable.
fuel
to
cold
engine
before
beginning
job.
I
4.
Do
not
overfill
tank
allow
room
for
fuel
to
expand.
5.
Do
not
spill
fuel.
If
fuel
is
spiUed,
clean
up
before
starting
engine.
~
MOVING
PARTS
can
cause
injury.
~
Moving
parts,
such
as
fans,
rotors,
and
belts
can
cut
fingers
and
hands
and
catch loose
clothing,
~
1.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
3.
4.
5.
6.
Have
only
qualified
people
remove
guards
or
covers
for
To
prevent
accidental
starting
during
servicing,
disconnect
maintenance
and
troubleshooting
as
necessary.
negative
()
battery
cable
from
battery.
Keep
hands,
hair,
loose
clothing,
and
tools
away
from
moving
parts.
Reinstall
panels
or
guards
and
close
doors
when
servicing
is
2.
Stop
engine
before
installing
or
connecting
unit.
finished
and
before
starting
engine.
SPARKS
can
cause
BATTERY
GASES
TO
EXPLODE;
BATTERY
ACID
can
burn
eyes
and
skin,
Batteries
contain
acid
and
generate
explosive
gases.
1.
2.
3.
4.
5.
Always
wear
a
face
shield
when
working
on
a
battery.
Stop
engine
before
disconnecting
or
connecting
battery
cables.
Do
not
allow
tools
to
cause
sparks
when
working
on
a
battery.
Do
not
use
welder
to
charge
batteries
or
jump
start
vehicles.
Observe
correct
polarity
(+
and
)
on
batteries.
r~
~.
?~.~%WWi~..
~
Y
~
STEAM
AND
PRESSURIZED
HOT
COOLANT
can
burn
face,
eyes,
and
Li
.
The
coolant
in
the
radiator
can
be
very
hot
and
under
pressure.
1.
2.
3.
Do
not
remove
radiater
cap
when
engine
is
hot.
Allow
engine
to
cool.
~
Wear
gloves
and
put
a
rag
over
cap
area
when
removing
cap.
Allow
pressure
to
escape
before
completely
removing
cap.
srI
9/91
TABLE
OF
CONTENTS
SECTION
1
SAFETY
SIGNAL
WORDS
1
SECTION
2
SPECIFICATIONS
2-1.
Volt-Ampere
Curves
2
2-2.
Duty
Cycle
2
SECTION
3
INSTALLATION
3-1.
Selecting
A
Location
And
Moving
Welding
Power
Source
3
3-2.
Selecting
And
Preparing
Weld
Output
Cables
4
3-3.
Connecting
To
Weld
Output
Receptacles
5
3-4.
Remote
14
Receptacle
Information
And
Connections
5
3-5.
Connecting
Input
Power
6
SECTION
4OPERATION
7
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
5-1.
Routine
Maintenance
11
5-2.
Removing
Top
Of
Case
And
Measuring
Input
Capacitor
Voltage
12
5-3.
Overload
Protection
13
5-4.
Changing
AmperageNoltage
Meter
Hold
Function
14
5-5.
Troubleshooting
15
SECTION
6
ELECTRICAL
DIAGRAMS
18
SECTiON
7TUNGSTEN
ELECTRODE
7-1.
Selecting
Tungsten
Electrode
22
7-2.
Preparing
Tungsten
23
SECTION
8
PARTS
LIST
Figure
8-1.
Main
Assembly
24
Figure
8-2.
Panel,
Front
w/Components
26
Figure
8-3.
Chassis,
Mid
28
OM-146
741
5)92
SECTION
1
SAFETY
SIGNAL
WORDS
modl.I
9/91
The
following
safety
alert
symbol
and
signal
words
are
used
throughout
this
manual
to
call
attention
to
and
identify
different
levels
of
hazard
and
special
instructions.
4~
WARNING
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
serious
personal
injury
or
loss
of
life.
a
CAUTION
CAUTION
statements
Identify
procedures
or
practices
which
must
be
followed
to
avoid
minor
personal
injury
or
damage
to
this
equipment.
~
IMPORTANT:
statements
identifi~
special
instructions
necessaiy
for
the
most
efficient
operation
of
this
equipment.
SECTION
2
SPECIFICATIONS
Table
2-1.
Welding
Power
Source
Specification
Description
Type
Of
Output
Rated
Weld
Output
Type
Of
Input
Input
Amperes
At
Rated
Output
I(VA
Used
At
Rated
Output
KW
Used
At
Rated
Output
Amperage Range
Max.
Open-Circuit
Voltage
Welding
Processes
Constant
Current
(CC),
Direct
Current
(DC)
300
Amperes.
32
Volts
DC
At
60%
Duty
Cycle
(See
Section
2-2)
380
Or
415
Volts
AC;
50
Hz;
Three
Phase
25
Amperes
At
380
Volts,
23
Amperes
At
415
Volts
18.4
ICVA
11.3kW
Input
Power
Cord
Overall
Dimensions
Weight
Options
5.375
Amperes
80
Volts
DC
Scratch
Start
Gas
Tungsten
Arc
(GTAW),
Scratch
Start
Gas
Tungsten
Arc
-
Pulsed
(GTAW-P),
Shielded
Metal
Arc
(SMAW)
Welding
13.1
ft.
(4
m)
Length:
21-3/4
in.
(522
mm);
WIdth:
12
in.
(305
mm);
Height:
17-3/8
In.
(441
mm)
Shipping:
82
lbs.
(37
kg);
Net:
77
lbs.
(35
kg)
PC-300,
RFC-14,
Foot
Control,
RHC-14,
RMLS-14,
FTC-14
Hand
Controls,
Extension
Cords,
Econo
my
Cart,
Cylinder
Cart,
Wire
Feeder
Quick
Disconnect,
Digital
LCD
A/V
Meter,
HF-251D-1
High
Fre
quency
Unit,
VHS
Video
OM-146
741
Page
1
2-1.
Volt-Ampere
Curves
Figure
2-1.
Volt-Ampere
Curves
2-2.
Duty
Cycle
a
CAUTION
EX
S
CEEDIN
Do
not
exce
G
DUTY
CYCLE
RATINGS
will
damage
unit.
ed
indicated
duty
cycles.
waml.1
2/92
..
Duty
cycle
s
how
long
the
unit
can
=
::
operate
within
a
ten
minute
period
withoutcausingoverheatingor
~.
::
==
::
damage.
-~
:
:
-
=
:
:
Thisunitisratedat6O%dutycycle
allowlngwelding6minutesoutot
(I)
~
z
=
-
=
:
-
::
=
:
-
::
every
10
minutes
at
rated
load.
If
theweldlngamperesdecrease,the
dutycycleincreases.
<
-
-
---
-
- -
- -
3PHASE
OPERATION
~:
~-
0-


-
-
10
11
202130
40
5010701080100
%
DUTY
CYCLE
.
,
sbl.22l92SB-153970
Figure
2-2.
Duty
Cycle
Chart
The
volt-ampere
curves
show
the
minimum
and
maximum
voltage
100
and
amperage
output
capabilities
of
the
welding
power
source.
90
Curves
of
other
settings
fall
be
~,een
the
curves
shown.
80
70
0)80
50
0
>
I
40
30
20
10
0
0
100
200
300
400
AMPERES
ssbl,1
10191
SB-146679-B
I
GIftW
MIN
MIN
L
ARC
CONTROL
I
~
~0Z~25~
~50Z
I1~~~iOO~
~
OM-146
741
Page
2
SECTION
3INSTALLATION
3-1.
Selecting
A
Location
And
Moving
Welding
Power
Source
__
A~
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Disconnect
input
power
conductors
from
deenergized
supply
line
BEFORE
moving
welding
power
source.
FIRE
OR
EXPLOSiON
can
result
from
placing~-.~
unit-,
on,
over,
or
near
combustible
surfaces.
Do
not
locate
unit
on,
over,
or
near
combustible
surfaces.
Do
not
install
unit
near
flammables.
BLOCKED
AIRFLOW
causes
overheating
and
possible
damage
to
unit.
Do
not
block
or
filter
airflow.
Warranty
is
void
if
any
type
of
filter
is
used.
FUMES
can
be
hazardous;
LACK
OF
~.
4~
FRESH
AIR
AND
PROPER
VENTILATION
can
be
harmful
~
Do
not
breathe
welding
fumes.
Place
unit
only
where
there
is
a
good
fresh
air
supply
and
proper
ventilation.
FALLING
EQUIPMENT
can
cause
serious
personal
injury
and
equipment
damage.
Lift
unit
at
handles.
Have
two
person
of
adequate
physical
strength
lift
unit.
Move
unit
with
hand
cart
or
similar
device
of
adequate
capacity.
If
using
a
fork
lift
vehicle,
secure
unit
on
a
proper
skid
before
transporting.
swamil
~2192
Figure
3-1.
Location
And
Movement
Of
Welding
Power
Source
,1
1
3
in.
(78
mm)
Open
Space
At
Sides.
6
in.
(156
mm)
At
Rear
For
Good
Airflow
2
Uftlng
Handles
Use
handles
to
move
unit.
3
Rating
Label
Locate
unit
near
correct
input
pow.
er
supply.
ST.152
303,A
I
Ref.
S1~15I
556
OM-146
741
Page
3
3-2.
Selecting
And
Preparing
Weld
Output
Cables
Figure
3-2.
SelectIng
And
Preparing
Weld
Output
Cables
Table
3-1.
Weld
Cable
Size*
WeldIng
Amperes
Total
Cable
(Copper)
Length
In
Weld
Circuit
Not
Exceedlng*
100
ft.
(30
m)
Or
Less
150
ft.
200
ft.
I
250
ft.
I
300
ft.
I
350
ft.
400
ft.
(45
m)
(60
m)
(70
m)
(90
m)
J
(105
m)
j
(120
m)
10
To
60%
Duty
Cycle
60
Thru
100%
Duty
Cycle
10
Thru
100%
Duty
Cycle
100
150
200
250
300
350
4
3
3
2
1
1/0
4
3
2
1
1/0
2/0
4
2
1
1/0
2/0
3/0
3
1
1/0
2/0
3/0
4/0
2
1/0
2/0
3/0
4/0
2-2/0
1
2/0
3/0
4/0
-
2-2/0
2-3/0
1/0
3/0
4/0
2-2/0
2-3/0
2-3/0
1/P
3/0
4/0
2-2/0
2-310
2-4/0
SOOO7-A17-9~
*
Weld
cable
size
(AWG)
is
based
on
either
a
4
volts
or
less
drop
or
a
current
density
of
not
more
than
300
circular
mils
per
ampere.
Use
weld
cable
with
insulation
rating
equal
to
or
greater
than
the
open-circuit
voltage
of
the
unit..
OM-146
741
Page
4
For
Example,
Total
Cable
Length
In
Weld
Circuit
=
20
ft.
(6
m)
1
Weld
Output
Cable
Determine
total
cable
length
in
weld
circuit
and
maximum
welding
amperes.
Use
Table
3-1
to
select
proper
cable
size.
Use
shortest
cables
possible.
Do
not
use
damaged
cables.
2
Terminal
Lug
Use
lugs
of
proper
amperage
Ca
pacity
and
hole
size
for
connecting
to
work
clamp,
electrode
holder,
or
wire
feeder.
3
Insulated
Electrode
Holder
Install
according
to
manufacturers
instructions.
4
Work
Clamp
Install
Onto
work
cable.
5
Dinse-Type
Connector
6
Weld
Output
Cable
7
Insulator
Slide
cable
through
insulator
and
remove
I
in.
(25
mm)
insulation
from
end
of
cable.
8
Sleeve
9
Connector
Insert
cable
with
sleeve
into
con~
nector
body
so
cable
is
snug
against
bottom.
10
Setscrew
lighten
setscrew
and
push
insula
tor
fully
over
connector.
If
job
requires
cable
larger
than
3/0
AWG,
use
2
ft.
(610mm)
or
shorter
piece
of
3/0
AWG
cable
for
Dinse
Type
connector
installation.
Con
nect
other
end
of
short
cable
to
the
4/0
or
larger
weld
cable.
Tools
Needed:
sb6.2
12J91
S-o6581s-028e-B
3-3.
Connecting
To
Weld
Output
Receptacles
A~
WARNING
ELECTRIC
SHOCK
can
kill;
ARCING
can
burn
skin
or
damage
electrical
equipment.
Do
not
touch
live
electrical
parts.
Turn
OFF
welding
power
source
before
making
any
weld
output
connections.
Do
not
change
position
of
welding
cable
connectors
while
welding.
Be
sure
connectors
are
secure
in
receptacles
before
welding.
swarril2.2
2/92
3
1
Positive
(+)
Weld
Output
Re
ceptacle
2
Negative
()
Weld
Output
Re
ceptacle
3
Connector
For
Electrode
Positive,
connect
work
cable
connector
to
negative
()
receptacle
and
electrode
holder
cable
connector
to
positive
(+)
re
ceptacle.
For
Electrode
Negative,
reverse
cable
connections.
To
connect
to
receptacle,
align
key.
way,
insert
connector,
and
turn
clockwise
until
tight.
Ret
SD-I
34
162
/
Ref.
ST-I
52223
Figure
3-3.
Connecting
To
Weld
Output
Receptacles
3-4.
Remote
14
Receptacle
Information
And
Connections
I
Remote
14
Receptacle
RC2
2
Keyway
3
Plug
2
4
Threaded
Collar
To
connect
to
this
receptacle,
align
keyway,
insert
plug,
and
tighten
threaded
collar.
Socket
Information:
Remote
Coritactor
A,
B
Contact
closure
completes
the
24
volts
ac
contactor
control
circuit.
Protected
by
fuse
F2.
Remote
AmperageNoltage
Control
C
Command
reference
;+10
volts
dc.
0
Control
circuit
common.
E
Input
command
signal
(potentiometer
wiper
or
0-10
volts
dc
source);
0
to
+10
volts
dc.
K
Chassis
common.
The
remaining
socket~.are
not
used.
sb7.I
1192
Ref.
SD-134
I~2-B
I
Ref.
S-0004-A
/
S-082a
FIgure
3-4.
Remote
14
Connections
OM-146
741
Page
5
3-5.
Connecting
input
Power
__
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
OFF
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.
Have
only
qualified
persons
install
unit.
Installation
must
meet
National_Electrical
Code
and
all
other
codes.
A.
Positioning
Jumper
Links
cwarnil
¶0/gi
Move
links
to
match
input
voltage.
For
example,
use
415
volts
posi
tion
when
415
volts
input
power
is
available.
Input
Voltage
380
415
Circuit
Breaker
Size
In
Amperes
37
th~
~
34
thru
45
Fuse
Size
in
Amperes2
35
Figure
3-6.
Location
And
Input
Power
Connections
380
Volts
Jumper
links
allow
operation
on
dif
ferent
input
voltages
and
are
facto
ry
set
for
380
volts
input
power.
Check
input
voltage
available
at
site.
Remove
top
of
case
according
to
Section
5-2.
I
Input
Voltage
Label
2
Look
at
jumper
links
and
compare
link
position
with
unit
label.
Tools
Needed:
2
Input
Voltage
Jumper
Links
Reinstall
top
of
case.
B.
Connecting
To
Input
Power
FIgure
3-5.
Input
Voltage
Jumper
Links
Location
sgb5.1
2/92ST-152
225/Ret.
S,45
063
1
Circuit
breaker
range
is
150%
to
not
more
than
200%
of
rated
input
amperage
of
the
welding
power
source
(ArtIcle
630-12(a)
of
NEC).
4
2
Standard
fuse
size
is
that
closest
to
150%
of
rated
input
amperage
of
the
welding
power
source
(ArtIcle
630-126
of
NEC).
3
Have
only
qualified
persons
make
this
instal
lation.
I
Line
Disconnect
Switch
Of
Proper
Rating
2
Grounding
Conductor
Green
Or
Green
With
Yellow
Stripe(s)
3
Input
Conductors
Install
input
conductors
and
grounding
con
ductor
from
unit
to
deenergized
line
discon
nect
switch.
Be
sure
grounding
conductor
goes
to
an
earth
ground.
4
Line
Fuses
Selectiuses
or
circuit
breakers
using
Table.
Install
into
deenergized
line
disconnect
switch.
sgb2.3
3/92
Ref.
SC-lU
221
/
ST.152
3~3.A
/
Ref.
S.0092C
OM-146
741
Page
6
SECTION
4
OPERATION
a
WARNING
ELECTRIC
SHOCK
can
kill.
Always
wear
dry
insulating
gloves.
Insulate
yourself
from
work
and
ground.
Do
not
touch
live
electrical
parts.
Keep
all
panels
and
covers
securely
in
place
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Keep
your
head
out
of
the
fumes.
Ventilate
area,
or
use
breathing
device.
Read
Material
Safety
Data
Sheets
(MSDS5)
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
moving
parts.
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
arc
welding,
gouging,
or
spot
welding
opera
tions.
See
Safety
Precautions
at
beginning
of
manual
for
ba
sic
welding
safety
information.
swam6.1
¶0/91
7
6
8
5~
4
I
Power
Switch
2
Pilot
Light
3
Amperage
Control
4
Arc
Force
(Dig)
Control
5
Output
(Contactor)
Switch
6
Amperage
Control
Switch
2
7
Process
Selector
Switch
8
Optional
AmperageNoltage
3
Meter
And
Switch
5T-152
224
Figure
4-1.
Controls
2
3
1
Insulating
Gloves
/
2
Safety
Glasses
With
Side
Shields
3
Welding
Helmet
~
~~f
~
~
Wear
dry
insulating
gloves,
safety
glasses
with
side
shields,
and
a
welding
helmet
with
a
correct
shade
of
filter
(see
ANSI
Z49.
1).
sb3.t
10/91
Figure
4-2.
Safety
Equipment
OM-146
741
Page
7
I
Work
Clamp
1
Use
wire
brush
or
sandpaper
to
clean
metal
at
weld
joint
area.
Connect
work
clamp
to
a
clean,
Tools
Needed:
paint-free
location
on
workpiece,
as
close
to
weld
area
as
possible.
.
5b4
1
10/91
Figure
4-3.
Work
Clamp
1
Process
Selector
Switch
Use
switch
to
select
type
of
weld
output.
Use
SMAW
position
for
Shielded
Metal
Arc
Welding.
Use
GTAW
position
for
Gas
Tungsten
Arc
Welding.
Switch
position
determines
the
op
eration
of
the
ARC
FORCE
(DIG)
control
(see
Figure
4-6).
Ref.
SD-134
162
Figure
4-4.
Process
Selector
Switch
I
1
Amperage
Control
Use
control
to
select
weld
amper
age.
Amperage
may
be
adjusted
while
welding.
Figure
4-5.
Amperage
Control
1
Arc
Force
Control
(Dig)
This
control
is
used
for
SMAW
welding
and
only
works
when
Pro
cess
Selector
switch
(see
Figure
4-4)
is
in
the
SMAW
position.
Use
control
to
help
start
an
arc
or
make
vertical
or
overhead
welds
(control
increases
short-circuit
am
perage).
When
set
at
0,
short-circuit
amper
age
is
the
same
as
normal
welding
amperage.
When
set
at
100,
short-circuit
am
perage
increases
to
help
arc
start
ing.
~.
Select
setting
best
suited
for
appli
cation.
Numbers
around
control
are
for
reference
only.
Set
control
at
0
for
GTAW
welding.
Figure
4-6.
Arc
Control
(Dig)
Control
OM.146
741
Page
8
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Miller KC241704 Owner's manual

Miller
Brand
Miller
Model
KC241704
Category
Welding System
Type
Owner's manual
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