Miller Electric KC237900 manual Procedure When Mounting To 600 Ampere Welding Power Sources

placed on front of welding power source. Secure in place with two sheet-metal screws, one on either side of lifting eye near center of cover. Do not install the remaining sheet-metal screws (three on each end) until instructed to do so.

3.Remove blank snap-in from access hole toward rear of cover installed on welding power source. In- stall supplied grommet into access hole.

4.Place TIG-Unit on top of welding power source (controls facing same direction); lifting eye from welding power source fits through bottom of TIG- Unit (into U-shaped section at bottom of TIG-Unit’s lifting eye bracket).

5.Insert supplied 3/4 in. (19 mm) diameter bolt (in component bag under front access door of TIG- Unit) through U-shaped section at bottom of TIG- Unit’s lifting eye bracket and lifting eye of welding power source; before securing bolt, align end holes in bottom of TIG-Unit with end holes in top of weld- ing power source.

6.Install the six sheet-metal screws (three in each end) into end holes to secure TIG-Unit (and cover) to top of welding power source. Secure 3/4 in. (19 mm) diameter bolt.

7.Remove left side panel from welding power source.

8.Locate the two 5 foot (1.5 m) leads (with terminal lugs attached) inside component bag which are to be used for obtaining 230 volts ac from the welding power source.

9.Connect the two leads to the welding power source as follows:

a.For 60 Hertz Welding Power Sources

Locate fan motor leads 9 and 36. Trace these leads to the inside of the primary terminal board. Connect the 230 volts leads to the two terminals on inside (not jumper link side) of pri- mary terminal board where fan motor leads 9 and 36 are connected.

b.For 50 Hertz Welding Power Sources

Locate fan motor leads 9 and 20. Trace lead 9 to the inside of the primary terminal board. Con- nect one of the 230 volts leads to this terminal on inside (not jumper link side) of primary termi- nal board where lead 9 is connected. Trace fan motor lead 20 to splice (covered with sleeving) near main transformer. Slide sleeving back to expose the connection, and splice remaining 230 volts lead to this connection in a proper manner.

10.Maintain a proper lead dress around fan and wind tunnel, and route leads through access hole in cover into TIG-Unit.

11.Connect the two leads to the terminal labeled 230V on rear terminal strip TE1 (on center mounting pan- el; see Figure 3-2).

12.Repeat Steps 9 through 17 from method A.

13.Reinstall cover (set aside in Step 1) onto TIG-Unit and right side panel onto welding power source, and connect the necessary associated equipment (shielding gas, water, etc.).

C. Procedure When Mounting To 600 Ampere Welding Power Sources.

For installation onto 600 ampere welding power sources, the mounting procedure is different since the holes in the bottom of the TIG-Unit do not line up with the top of the welding power source. The rest of the installa- tion is the same. To mount the TIG-Unit to a 600 ampere welding power source, proceed as follows:

1.Remove top cover from TIG-Unit, and lay it aside.

2.Place TIG-Unit on top of welding power source (controls facing same direction); lifting eye from welding power source fits through bottom of TIG- Unit (into U-shaped section at bottom of TIG-Unit’s lifting eye bracket). Insert supplied 3/4 in. (19 mm) diameter bolt (in bag) through U-shaped section at bottom of TIG-Unit’s lifting eye bracket and lifting eye of welding power source; do not secure bolt at this time.

3.Using bottom of TIG-Unit as a template, mark loca- tions for mounting holes and location of lead access hole (if 230 volts ac from the welding power source is to be used for operational power).

4.Remove 3/4 in. (19 mm) bolt, and remove TIG-Unit from top of welding power source.

CAUTION: METAL FILINGS AND/OR TOOL CONTACT WITH INTERNAL COMPONENTS can damage unit.

•Cover internal components.

•Clean unit, and remove internal covering ma- terial before resuming operation.

5.Drill six 5/32 in. (3.9 mm) holes in marked locations for mounting TIG-Unit to welding power source.

6.If desired, drill a 1/2 in. (12.7 mm) lead access hole in marked location.

7.Place TIG-Unit on top of welding power source, in- sert 3/4 in. (19 mm) bolt, and install the six supplied sheet-metal screws. Tighten screws and secure bolt. Install supplied grommet into access opening, if applicable.

8.Proceed to Section 3-4A Step 6, or Section 3-4B Step 7 as selected, and follow the remaining in- structions for the chosen procedure.

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