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TIG-RIG (Basic) Models And Models With

Optional Pulser And Electroslope

Processes

Description

TIG (GTAW) Welding

Enables Welding Power Source to
provide TIG as well as Stick capability

OM-530J

May 1993

Eff. w/Serial Number KC237900

Stick (SMAW) Welding

Shielded Metal Arc
(Stick) Welding

Automatic Welding

Summary of Contents for KC237900

Page 1: ...lser And Electroslope Processes Description TIG GTAW Welding Enables Welding Power Source to provide TIG as well as Stick capability OM 530J May 1993 Eff w Serial Number KC237900 Stick SMAW Welding Sh...

Page 2: ...alue 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 agains...

Page 3: ...Gas Coolant Postflow Control 12 4 5 Remote Hand Controls 13 4 6 High Frequency Switch 13 4 7 High Frequency Control 14 4 8 Meters Optional 14 4 9 Pulser Switch Pulser Models Only 14 4 10 On Time Contr...

Page 4: ...8 5 General Installation Procedures 29 8 6 Guidelines For Installation Of High Frequency Assisted Arc Welding Power Sources 31 8 7 Installation Guidelines Checklist 31 SECTION 9 PARTS LIST Figure 9 1...

Page 5: ...power source Owner s Manual 1 2 SAFETY ALERT SYMBOL AND SIGNAL WORDS The following safety alert symbol and signal words are used throughout this manual to call attention to and identify different lev...

Page 6: ...ges 3 2 TRANSPORTING METHODS This unit is equipped with a lifting eye for moving during installation Weight capacity of the lifting eye only allows for supporting the unit and welding power source WAR...

Page 7: ...n a proper manner The valves are labeled ensure that connections are cor rect see Figure 4 1 and Sections 3 11 and 3 12 7 Install proper welding cables see welding power source s Owner s Manual for co...

Page 8: ...allation is com plete and the TIG Unit is ready to be put in oper ation 9 Open access door on lower front of TIG Unit re move component bag and route short intercon necting cord approximately 4 ft or...

Page 9: ...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...

Page 10: ...n 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 Elect...

Page 11: ...t be employed 3 Route cord through supplied connector on rear of TIG Unit and attach it to terminals labeled 115V on terminal strip TE1 located on center mounting panel toward back of TIG Unit see Fig...

Page 12: ...ng operation 2 Mount Preflow ON OFF switch S200 in the 1 2 in 12 7 mm diameter hole using supplied hardware 3 Mount Preflow Time control with attached printed circuit card assembly TD2 in the 3 8 in 9...

Page 13: ...a proper lead dress inside the unit l Replace left side panel and top cover 9 For Models Prior to Serial No HK261770 a Locate lead 32 between transformer T1 and in tegrated rectifier SR2 Splice lead 3...

Page 14: ...controls 5 Attach supplied knob to Spot Time control shaft B Electrical Installation Figure 3 2 IMPORTANT Before preceeding with this installation familiarize yourself with the circuit diagram provid...

Page 15: ...and recirculating coolant system make connections from the coolant system directly to the torch hoses Do not use water connections on the TIG Unit The COOLANT IN and COOLANT OUT fittings have 5 8 18...

Page 16: ...DJUSTMENT control on the TIG Unit al ways functions as a fine amperage adjustment cali brated in percent of the AMPERAGE ADJUSTMENT control on the welding power source If a remote control is used and...

Page 17: ...r is deenergized the postflow timer begins to time out the selected period of postflow time Once the timer has timed out the gas and coolant valves close and thereby cut off shielding gas and cool ant...

Page 18: ...g as the momentary contact switch is held closed Provided that an arc has been established releasing the momen tary contact switch will deenergize the high frequency If an arc is not established the h...

Page 19: ...is operational only when the PULSES switch is in the ON position Rotating the PULSES SECOND control in a clockwise direction increases the pulse frequency The scale surrounding the PULSES SECOND contr...

Page 20: ...OM 530 Page 16 ST 009 477 D ST 007 648 G...

Page 21: ...nit is in the PANEL position whenever the Electroslope is to be utilized The AMPERAGE ADJUSTMENT control on the TIG Unit has complete control of the amperage at this point 4 15 PERCENTAGE INITIAL AMPE...

Page 22: ...ding the PREFLOW TIME control is calibrated in seconds to aid in the selec tion of a preflow time period suited to the individual weld ing operation As soon as the remote contactor control switch has...

Page 23: ...safety information 5 1 GAS TUNGSTEN ARC WELDING WARNING Read and follow safety informa tion at beginning of entire Section 5 before proceeding 1 Make all necessary connections as instructed in Section...

Page 24: ...Select and obtain proper electrode and insert into electrode holder 7 Depress the POWER switch on the welding power source to the ON position 8 Connect the 115 volts ac plug from the TIG Unit to its p...

Page 25: ...used for ac or dc electrode positive welding before beginning the welding operation Weld amperage causes the tungsten elec trode to form the balled end The diameter of the end should not exceed the d...

Page 26: ...RECOMMENDED The figures listed are intended as a guide and are a composite of recommendations from American Welding Society AWS and electrode manufacturers S 0009 8 88 Green Band Red Band Brown Band 6...

Page 27: ...ncy out put A Fuse F1 Fuse F1 is a 3 ampere glass fuse located on the center mounting panel below terminal strip 1T If this fuse should open there would be no remote control of the contactor B Fuse F2...

Page 28: ...to welding power source output terminals Check connections Be sure that they are correct and secure see Sections 3 3 and 3 4 No output from welding power source See welding power source Owner s Manual...

Page 29: ...OM 530 Page 25 SECTION 7 ELECTRICAL DIAGRAMS Circuit Diagram No SC 121 852 A Diagram 7 1 Circuit Diagram For TIG Unit With Options...

Page 30: ...OM 530 Page 26 Circuit Diagram No SA 045 288 C Diagram 7 2 Circuit Diagram For Postflow Timer Circuit Diagram No SB 088 800 A Diagram 7 3 Circuit Diagram For Pulser Optional...

Page 31: ...OM 530 Page 27 Circuit Diagram No SC 080 063 E Diagram 7 4 Circuit Diagram For Electroslope Optional...

Page 32: ...OM 530 Page 28 Circuit Diagram No SA 096 935 A Diagram 7 5 Circuit Diagram For Preflow Timer Optional Circuit Diagram No SA 049 109 A Diagram 7 6 Circuit Diagram For Spot Timer Optional...

Page 33: ...GTAW process In these cases it will take several thousand volts to cause an electrical spark to jump this gap between the electrode and the work creating an in itial path of ionization that the arc c...

Page 34: ...ungrounded metal objects or unshielded wiring in the immediate vicinity conducted some distance and reradiated This can be a troublesome source of inter ference 8 4 LOCATION Locate the high frequency...

Page 35: ...ogether as by welding each piece of metal to all other adjacent pieces For metal buildings adjacent metal panels should be bolted or welded together at fre quent intervals All windows and doorways sho...

Page 36: ...p setting to the minimum setting given in this manual 8 Secure all service and access doors before operat ing 9 Visualize the welding zone as a sphere with a 50 ft 15 m radius centered on a point betw...

Page 37: ...ower source 1 1 1 1 2 006 017 COVER box used when unit is mounted on power source 1 1 1 1 3 026 627 GASKET lifting eye cover 1 1 1 1 4 008 267 LIFT EYE 1 1 1 1 5 Fig 9 2 PANEL control rear w component...

Page 38: ...tg hole Field installed units only 3 3 3 3 057 359 BLANK snap in nyl 375mtg hole 2 2 2 2 110 089 CABLE interconnecting consisting of 1 1 1 1 141 162 CONNECTOR PINS consisting of 1 1 1 1 134 731 CONNEC...

Page 39: ...r 115 250V 1 1 1 1 6 Shunt 030 081 SHUNT meter 50MV 500A 300A 1 1 1 1 6 Shunt 030 084 SHUNT meter 50MV 600A 400A 1 1 1 1 6 Shunt 079 388 SHUNT meter 50MV 800A 500 600A 1 1 1 1 7 012 571 HOLDER fuse mi...

Page 40: ...ilm 10uf 250VAC 2 8 C3 17 096 761 CAPACITOR mica 002uf 10000VDC 2 9 010 885 STRIP conductor 4 602 042 SCREW 10 32 x 1 00 rndhd slt brs 1 10 111 181 LINK connecting 1 11 020 623 SPARK GAP ASSEMBLY cons...

Page 41: ...3 3 5 019 603 KNOB ball 1 1 1 1 6 129 060 PANEL front 1 1 1 1 7 P1 025 701 FILTER HF dc volts amp meter 2 2 2 2 8 S4 011 611 SWITCH tgl DPDT 15A 125V 1 1 1 1 9 R1 072 462 POTENTIOMETER w shaft lock co...

Page 42: ...1 1 1 21 C1 113 501 CAPACITOR 1 1 1 1 22 RC1 604 176 RECEPTACLE str dx grd 2P3W 15A 125V 1 1 1 1 073 690 PLUG str grd armd 2P3W 15A 125V P S 5266DF 23 039 047 TERMINAL pwr output red consisting of 2 2...

Page 43: ...isting of 1 5 011 645 CONTACT ASSEMBLY movable switch consisting of 2 6 011 075 SPRING pressure contact switch 1 7 011 953 CONTACT switch 2 8 011 074 SPRING pressure contact switch 1 9 010 805 HANDLE...

Page 44: ...NNECTOR rect skt 24 18ga Amp 350980 1 12 5 073 756 STAND OFF 6 32 x 625 lg 5 6 010 116 GROMMET rbr 375 ID x 500mtg hole 1 7 072 307 CIRCUIT CARD filter 1 8 027 144 TUBING nylon 150 ID x 250 OD x 250 2...

Page 45: ...NECTOR SOCKETS consisting of 1 079 747 CONNECTOR rect skt 24 18ga Amp 350980 1 12 079 748 CONNECTOR rect 18skt plug Amp 1 640250 8 1 079 747 CONNECTOR rect skt 24 18ga Amp 350980 1 18 5 073 756 STAND...

Page 46: ...itch plrt 1 8 601 836 NUT brs hex 250 20 jam hvy 4 9 052 413 STUD brs 250 20 x 875 2 10 103 633 BUS BAR shorting switch plrt 4 11 103 634 MOUNTING BOARD cmpnt plrt switch 1 12 024 694 BEARING plrt swi...

Page 47: ...A 1 1 4 SR2 005 882 RECTIFIER integ 6A 600V 1 1 5 052 194 TIMER delay on make 0 60 sec consisting of 1 1 6 039 449 BRACKET mtg circuit card 1 1 7 TD1 045 874 CIRCUIT CARD timer 1 1 8 CR1 070 744 RELAY...

Page 48: ...ect skt 24 18ga Amp 350980 1 7 097 922 KNOB pointer illustrated on Fig 9 4 1 006 301 BRACKET mtg component 1 106 625 SPACER nyl 250 OD x 140 ID x 1 000mtg hole 4 See Fig 9 4 for additional parts 041 4...

Page 49: ...Notes...

Page 50: ...mperage and weld with 1 8 in 3 2 mm Stick electrode without returning to the power source AMPSET can be considered when cable connected box type remote hand controls are impractical when operating a l...

Page 51: ...ting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 Spoolmate 250 Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as...

Page 52: ...complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGEN...

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