Miller Electric KC237900 manual Field Installation of Pulser, Field Installation of Electroslope

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3-5. FIELD INSTALLATION OF PULSER

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

•Shut down welding power source, and dis- connect input power employing lockout/tagging procedure before beginning this installation.

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.

1.Remove top cover from TIG-Unit, if applicable.

2.Remove right blank panel from front of TIG-Unit. Save screws; discard blank panel.

3.Examine inside of TIG-Unit behind front panel for lo- cation of lead harnesses, etc.

4.Carefully slide Pulser unit into opening on front pan- el of TIG-Unit. Secure Pulser with the four screws removed from blank panel in Step 2.

5.Route leads from Pulser down top of center mount- ing panel and then to right of terminal strip 1T. (The terminal strip is located on top of center mounting panel toward rear of TIG-Unit; the terminals are la- beled directly below the strip; see Figure 3-2.)

6.Remove jumper link 4 (across terminals 84 and 83) on terminal strip 1T. See Circuit Diagram 7-1.

7.Connect Pulser leads to correspondingly numbered terminals (41, 42, 43, 84, 83, 72) on terminal strip 1T. The leads from Pulser are all numbered.

8.Connect grey lead 42 from rear of Pulser case to front center mounting panel where existing grey lead 42 is connected to chassis (not to terminal strip).

9.Secure leads to existing harness with nylon cable ties or tape to maintain a proper lead dress.

10.Reinstall cover onto TIG-Unit, if applicable.

3-6. FIELD INSTALLATION OF ELECTROSLOPE

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

•Shut down welding power source, and dis- connect input power employing lockout/tagging procedure before beginning this installation.

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.

1.Remove top cover from TIG-Unit, if applicable.

2.Remove left blank panel from front of TIG-Unit. Save screws; discard blank panel.

3.Examine inside of TIG-Unit behind front panel for lo- cation of lead harnesses, etc.

4.Carefully slide Electroslope unit into opening on front panel of TIG-Unit. Secure Electroslope with the four screws removed from blank panel in Step 2.

5.Route leads from Electroslope down top of center mounting panel and then to right of terminal strip 1T. (The terminal strip is located on top of center mount- ing panel toward rear of TIG-Unit; the terminals are labeled directly below the strip; see Figure 3-2.)

6.Connect grey lead 42 from rear of Electroslope case to front center mounting panel where existing grey lead 42 is connected to chassis (not to terminal strip).

7.Remove jumper links 1 (across terminals 3 and 2), 2 (across terminals 71 and 70), and 3 (across termi- nals 76 and 78) on terminal strip 1T. See Circuit Dia- gram 7-1.

8.For Models Effective With Serial No. HK261770: Connect Electroslope leads to correspondingly numbered terminals (3, 2, 5, 6, 7, 41, *42, 43, 71, 70, 56, 61, *42, 62, 76, 78, 72, 58, 59) on terminal strip 1T. Connect Electroslope leads 30 and 37 to corresponding terminal on terminal strip 2T. The leads from Electroslope are all numbered. Connect lead 60 from Electroslope to terminal 1 on relay CR2 (see Figure 3-2).

*Connect only one lead 42 to each 42 terminal. The leads are cut to proper length and will only reach the appropriate segment of the terminal strip.

9.For Models Prior To Serial No. HK261770: Connect Electroslope leads to correspondingly numbered terminals (3, 2, 5, 6, 7, 41, *42, 43, 71, 70, 56, 61, *42, 62, 76, 78, 72) on terminal strip 1T. Connect Electroslope lead 60 to terminal 1 on relay CR2.

If The Unit DOES NOT Have Preflow:

c.Replace existing connector on Electroslope lead 59 with a 3/16 in. female friction connector, and connect lead 59 to terminal 4 on relay CR2.

d.Individually tape and tie remaining Electroslope leads 30, 37, and 58 to existing wiring harness.

If The Unit DOES Have Preflow:

a.Replace existing connectors on Electroslope leads 30 and 37 with a 1/4 in. piggyback (dual friction) connector.

b.Disconnect leads 30 and 37 from Preflow switch S200.

c.Reconnect lead 30 (from Step b) to piggyback connector on Electroslope lead 30, and recon- nect lead 37 (from Step b) to piggyback connec- tor on Electroslope lead 37.

d.Install piggyback connector on Electroslope lead 30 onto terminal of Preflow switch from which lead 30 (from Step b) was removed.

e.Install piggyback connector on Electroslope lead 37 onto terminal of Preflow switch from which lead 37 (from Step b) was removed.

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Contents Processes OM-530JDescription From Miller to You Table of Contents List of Charts and Tables Electrical DiagramsParts List Certification for High Frequency ARC Welding EquipmentGeneral Information and Safety Safety Precautions and Signal WordsSpecifications Safety Alert Symbol and Signal WordsSite Selection Installation or RelocationDescription Transporting MethodsComponent Installation Field Installation of TIG-UNITProcedure When Using An External 115 Volts AC Power Supply Procedure When Using 230 Volts AC Internal PowerProcedure When Mounting To 600 Ampere Welding Power Sources Field Installation of Pulser Field Installation of ElectroslopeProcedure for Remote TIG-UNIT IN- Stallation Location Of Relay CR2 And Other ComponentsElectrical Installation Figure Field Installation of Optional PRE- Flow TimerMechanical Installation Figure Electric Shock can killFront Panel Mounting Hole Layout Field Installation of Optional Spot Timer Figure Remote Amperage Output ContactorOn OFF Overload Press to Start GAS GAS OUTCoolant Coolant OUT Coolant Connections Optional FigureWithout Electroslope Amperage Amperage AdjustmentpanelOperator Controls With ElectroslopePostflow GAS/COOLANT on OFFRemote Hand Controls Highon Frequency OFF High FrequencyPULSES/SECOND On TimeBackground ST-009 477-D ST-007 648-G Percentage Initial Amperage ElectroslopePercentage Upslope Rate Percentage Final Amperage Preflow Time Control & Switch Optional FigureSpot Time Control and Switch Optional Figure Preflow TimeHOT METAL, SPATTER, and Slag can cause fire and burns Sequence of OperationFumes and Gases can seriously harm your health GAS Tungsten ARC WeldingShielded Metal ARC Welding with TIG- Unit Maintenance & TroubleshootingShutting Down Weld Cables Maintenance Schedule FrequencyInternal Cleaning Tungsten ElectrodeThorium Alloyed Tungsten Red Band Green BandZirconium Alloyed Tungsten Brown Band Circuit Board Handling Precautions Overload ProtectionTroubleshooting Trouble Probable Cause RemedyElectrical Diagrams OM-530 OM-530 OM-530 General Certification for High Frequency ARC Welding EquipmentDefinitions HIGH-FREQUENCY Radiation General Installation ProceduresLocation Power Service Shielding Of Miscellaneous Wiring In The Weld- ing ZoneMetal Buildings Installation Guidelines Checklist Parts List Main AssemblyQuantity Item Dia Part Model Description Panel, Control Rear w/Components 111 HF Panel -1 ItemPanel, Front w/Components C19 028 CAPACITOR, polye met film 1uf 250VDC Switch, Polarity 300 & 400A Models -4 Item 011041 Pulser Optional -4 ItemElectroslope 9 Optional -4 Item Switch, Polarity 500 & 600A Models -4 Item 048Panel, Control Front w/Components Optional Equipment Page Gold Star SS Accessories TIG-RIG AccessoriesAmpset Cordless Remote Current Control Call Miller for your local Miller distributor Owner’s Record Miller Electric Mfg. Co

KC237900 specifications

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