Miller BALANCING/PARALLELING CONTROL User manual

Miller BALANCING/PARALLELING CONTROL User manual
Millerfi
February
Form:
1995
OM-158 601
Effective With Serial No. KD480481
OWNERS
MANUAL
~GL~
_~c~r'
Balancing/Paralleling
Balances
Varies
Output Of Two Paralleled CV Welding
Welding
Power Source
Uses 115 Volts AC, 60Hz
j~
Control
Power Sources
Output By –10%
Input Power
Welding Power Source Must Have Full Remote
Remote Control Connections
14
Capability
Through Receptacle Or Terminal Strip
Give this manual to the operator.
Read and follow these instructions and all
blocks carefully.
safety
Have
only
and qualified persons
service this unit.
trained
install, operate,
or
For
Call your distributor if you do not understand
the directions.
cover
5/94
-
ST-SOD 055
'
1995 MILLER Electric
or:
help,
call your distributor
MILLER Electric Mfg. Co., P.O. Box 1079,
WI 54912
414-734-9821
Appleton,
Mfg. Co.
PRINTED IN USA
tax
MILLERS
TRUE BLUETM LIMITED WARRANTY
(Equipment
This limited wsrranty
supersedes
I
with
Effective January 1, 1995
serial number preface of KD
a
previous MILLER
all
warranties and is exclusive with
LIMITED WARRANTY
Subject to the terms end conditions below, MILLER Electric
MIg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new
MILLER equipment sold after the effective date ot this limited warranty is tree ot de
tects in material and workmanship at the time it is shipped by MILLER. THIS WAR
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
no
newer)
or
other guarantees
or
warranties expressed
or
Implied.
Remote Controls
Accessory
Kits
Replacement
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT
MILLERS
BlueTM
True
Parts
Limited
Warranty shall
not
apply
to:
NESS.
Items turnished by MILLER, but manutactured by others, such as engines or
trade accessories. These items are covered by the msnutacturers warranty, it
1,
Within the warranty
periods listed below, MILLER will repair or replace any war
parts or components that tail due to such detects in material or workmanship.
be
notitied
in writing within thirty (30) days ot such detect or tailure, at
MILLER must
which time MILLER will provide instructions on the warranty claim procedures to be
ranted
any.
tollowed.
Consumsble components: such
2.
and
MILLER shall honor warranty claims on warranted equipment listed below in the
event ot such a tailure within the warranty time periods. All warranty time periods
start on the date that the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American distributor or eighteen
months after the equipment is sent to an International distributor.
5 Yesrs Parts 3
Original
3.
Equipment
or
as contact
psrts that tail due to normal
tips, cutting nozzles,
contactors
wear.
that has been moditied
ment that has been
by any psrty other than MILLER,
improperly installed, improperly operated or
or
equip
misused
based upon industry standards, or equipment which has not had reasonable
end necessary maintenance, or equipment which has been used tor operation
outside ot the speciticstions tor the equipment.
Years Labor
main power rectitiere
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER
CIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
3YesmPartssndLabor
2.
relays
Transtormer/Rectitier Power Sources
Plasma Arc
Cutting
Power Sources
In the event ot
warranty claim covered by this warranty, the exclusive remedies
option: (1) repair: or (2) replacement: or, where authorized in
in appropriste cases, (3) the ressonsbte cost ot repair or replacemental an authorized MILLER service station: or (4) psymentot orcredittor the pur
chase price (less reasonable depreciation based upon actual use) upon retum otthe
goods at customers risk end expense. MILLERS option ot repair or reptscement
will be FOE., Factory at Appleton, Wisconsin, or FOB. ate MILLER authorized ser
vice tecility as determined by MILLER. Theretore no compensation or reimburse
ment tor transportation costs ot any kind will be allowed.
Semi-Automatic and Automatic Wire Feeders
2 Years
3.
writing by MILLER
Paris and Labor
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the engine manutacturer.)
Air Compressors
1 Year
4.
Parts and Labor
TO THE EXTENT PERMITrED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE THE SDLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE
LtABLE FOR DIRECT, INDIRECT, SPECIAL, tNCIDENTAL OR CONSEQUENTIAL
DAMAGES (INCLUDING LOSS OF PROFtT), WHETHER BASED ON CON
TRACt TORT OR ANY OTHER LEGAL THEORY.
Motor Driven Guns
Process Controllers
Water Coolant
*
a
shsll be, et MILLERS
Robots
Systems
HF Units
Grids
*
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR
RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL
THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARtSE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALtNG, IN
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
Spot Welders
Load Banks
SDX Transtormers
Running Gear/Trailers
Cutting Torches (except APT, ZIPCUT
Tecumseh Engines
Deutz Engines (outside North America)
Field Options
Plasma
*
& PLAZCUT
Models)
Some states in the U.S.A. do not allow limitations ot how long en implied warranty
lssts, or the exctusion ot incidental, indirect, specist or consequential dsmsges, so
the above limitation or exclusion may not apply to you. This warranty provides spa
citic legal rights, end other rights mey be available, but may very trom stste to state.
options are covered under True BlueTM tor the remaining
warranty period ot the product they are installed in, or tor a minimurs ot
whichever is greater.)
one year
(NOTE:
5.
6 Months
6.
91)
Field
Batteries
In
Days
some
provinces provides tor
certain edditionel warranties
remedies other then as stated herein, end to the extent that they mey not be
waived, the limitations end exclusions set out above may not apply. This Limited
Werranty provides specitic legsl rights, end other rights may be available, but may
vary trom province to province.
MIG Guns/TIG Torches
*
Canada, legislation in
or
Parts and Labor
APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches
RECEIVING-HANDLING
unpacking eqUipment, check carton for any damage that may have occurred during shipment. File any claims for loss or damage
delivering carrier. Assistance for filing or settling Claims may be obtained from distributor and/or equipment manufacturers
Transportation Department.
Before
with the
When
requesting information
following
nameplate.
Use the
or
equipment, always provide Model Designation
about this
spaces to record Model
Designation
and Serial
or
Style
and Serial
or
Style
Number.
Number of your unit. The information is located
on
the
rating label
Model
_________
Serial
or
Style
No.
Date of Purchase
miller 1195
SECTION 1
SAFETY IN FORMATION
modl.1 2/93
Read all
safety
U
Obey
safety messages
U
Learn the
all
messages
meaning
throughout
to avoid
this manual.
injury.
of WARNING and CAUTION.
I
Safety
Alert
2
Signal
Word
2
\
Symbol
WARNING means possible death
serious injury can happen.
or
CAUTION
~
CAUTION
MOVING PARTS
can
means possible minor
injury or equipment damage can
happen.
injure.
Keep away from moving parts.
S
Keep all panels and
operating.
covers
closed
when
I
3
I
Statement Of Hazard And
Result
4
Safety
Instructions To Avoid
Hazard
a
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
WARNING
6
5
Hazard
6
Safety Banner
NOTE
~
using high frequency.
NOTE
Special
ation
Figure
1-1.
Safety
Symbol (If Available)
Read safety blocks for each sym
bol shown.
7
Turn Off switch when
-
instructions for best oper
not related to
safety.
Information
SECTION 2INSTALLATION
N OTE
2-1.
Control
can
sit
on
flat surface close to
welding
power
sources.
Installing Control On Welding Power Source
1
Welding
Remove
2
Power Source
screws as
Mounting
Secure to
shown.
Bracket
welding
power
source
with hooks up.
3
Control
Align
slots in bottom of control with
hooks
on
mounting bracket. Slide
control onto bracket and let control
rest on hooks.
Control can be mounted on other
side of welding power source.
Balancing
ward for
control should face for.
ease
of
adjustment.
ST-800 054
Figure
2.1.
Installing Control
OM-158601
Page
1
2-2.
Connecting
Control To
Welding
Power Source
6
I
Plug PLG2
I
14-Pin
2
Master Welding Power
Source
3
Control
4
14-Pin
5
Slave
6
115 Volts AC
Plug PLG3
Power Source
Welding
Plug
Make connections
as
shown.
Remote 14 Receptacle
7
A remote control device must be
used to control the welding power
sources
contactor and
output.
Connect plug from remote control
device to receptacle as follows:
align keyway, insert plug, and tight
en threaded collar.
See Figure 2-3 for socket informa
tion if remote control device plug
does not match receptacle.
ST-eGO 057
Figure
2-2. Cord Connections
2
_______/
_______________________________
________________
m
mm
m
mm
m
~
a~
3
Remote 14 Receptacle
Route leads or cord from remote
control device through strain relief
to 1TB terminals. Make connec
I
li-mm
Strain Relief
Terminal Strip IT
When using iT, remove leads at
1TB that come from Remote 14
receptacle. Receptacle is disabled.
/
/
~
1
2
tions according to the
formation:
following
in
_______________________________
Socket/Terminal Information:
-4<4<44<44
Remote Contactor
A/1T5B
24voltsac.
B / 1T4B
Contact closure to pin A completes
ac contactor control circuit.
24 volts
_____________________
~
I/ 117B
115 volts ac.
J / 1T6B
Contact closure to pin I completes
115 volts ac contactor control circuit.
G / 1T2B
Circuit common for 24 and 115 volts
ac circuits.
________________
____________________________________
L
Remote
Cl 1T3B
D / 1T2B
Amperage/Voltage Control
Command reference; +10 volts dc.
Control circuit
command
3
on
common
master
for 10 volts dc
welding power
source.
E/ 1T1B
Input command signal
(potentiometer wiper or 0 to
K / 1 T2B
Chassis
The
remaining sockets/terminals
are
OM-158 601 Page 2
2-3. Connections To Terminal
Strip
1TB
(Disables
dc).
not used.
sb7.1
Figure
+10 volts
common.
Remote 14
Receptacle)
3/93
ST-800 058
2-3.
Welding
N OTE
Power Source Connections
~
Welding power source input power
together to a proper ground.
grounding
conductors must be tied
WARNING
a
ELECTRIC SHOCK
can
Do not touch live electrical
Turn Off
Have
circuit
welding
kill.
parts.
power source, and disconnect
only qualified
input
power before
inspecting
or
installing.
persons install unit.
Installation must meet National Electrical Code and all other codes.
Do not
use
different
polarities
at the same time on a common
workpiece
See ANSI Z49.1 and OSHA TITLE 29, CHAPTER XVII, PART 1910,
when
more
than
one
welding
power source is used.
Subpart 0.
swam3.1
2
3
1
Master Welding Power
Source
2
Control
3
Slave
4
Negative
5
Paralleled Negative
Output Cable
6
Positive Weld
7
Paralleled Positive Weld
Output Cable
Welding Power
Weld
2/93
Source
Output Cables
Weld
Output
Cables
Paralleled weld output cables need
to be sized for the
largest
amount
of weld output available from the
paralleled welding power
sources.
See Table 2-1.
Be
sure
paralleled
weld cables
connected
postive-to-positve
and negative-to-negative.
are
ST-800 053
Figure
2-4.
Paralleling Welding
Power Sources
OM-158 601 Page 3
Table 2-1. Weld Cable Size*
Total Cable
(30 m) Or Less
100 ft
(Copper) Length
In Weld Circuit Not
200 ft
(45 m)
(60 m)
I
150ft
I
250 ft
(70 m)
Exceeding
I
300ft
I
350ft
(90 m)
400 ft
(105 m)
(120 m)
10 To 60%
60 Thru 100%
Duty Cycle
Duty Cycle
100
4
4
4
3
2
1
1/0
1/0
150
3
3
2
1
1/0
2/0
3/0
3/0
200
3
2
1
1/0
2/0
3/0
4/0
4/0
250
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
Welding
Amperes
10 Thru 100%
Duty Cycle
300
1
110
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
350
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
400
1/0
2/0
3(0
410
2-2/0
2-3/0
2-4/0
2-4/0
500
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-3/0
600
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
700
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
4-4/0
800
4/0
2-2/0
2-3/0
2-4/0
3-4/0
3-4/0
4-4/0
4-4/0
900
2-210
2-3/0
2-4/0
3-3/0
3-4/0
4-4/0
4-4/0
1000
2-2/0
2-3/0
2-4/0
3-3/0
4-3/0
4-4/0
1250
2-3/0
2-4/0
3-3/0
4-3/0
4-4/0
1500
2-4/0
MNeld cable size
(AWG)
3-3/0
is based
on
either
a 4
3-4/0
volts
SECTION 3
or
less
drop
4-4/0
or a
density
current
of not
more
than 300 circular mils per ampere.
S-0007-C
OPERATION & MAINTENANCE
WARNING
a
____
ELECTRIC SHOCK
Always
wear
Insulate
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
kill.
can
dry insulating gloves.
yourself
from work and
Wear
ground.
Do not touch live electrical parts.
Keep all panels and
covers
FUMES AND GASES
to your health.
Keep your
securely
in
MOVING PARTS
Keep
away from
body protection.
can cause
injury.
moving parts.
Keep all doors, panels,
securely in place.
head out of the fumes.
covers, and
guards closed
and
Ventilate area,
or use
breathing
device.
Read Material Safety Data Sheets (MSDSs) and
manufacturers instructions for material used.
WELDING
with correct shade of filter.
place
be hazardous
can
welding helmet
Wear correct eye, ear, and
can cause
Do not weld
near
fire
or
I
explosion.
Pacemaker
keep extinguisher nearby.
~.
Do not locate unit over combustible surfaces.
Do not weld
on
Allow work and
wearers
keep away.
flammable material.
-
Watch for fire;
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
closed containers.
equipment to
cool before
Wearers should consult their doctor before
near arc
or
going
spot welding opera
tions.
See
handling.
welding, gouging,
Safety Precautions at beginning of welding power
manual for basic welding safety information.
source
Swarn6.1* 10/91
OM-158 601 Page 4
1
Balancing
Control
The scale around the control is for
reference only. The control is ac
______________________________________________________________________________________
BA~NCECO~ROL
MASTeR
INCREASE
1~\\l~VI/,1
REMOTE 14
Eo:oo
SL~!
0
0
010
0
tually varying the command signal
welding power source.
The slave output is varied to keep
total output of the two welding pow
to the slave
er sources
balanced.
FEEDER
V
~T~E
~
BALANCING!
PARA~ELING
o~rrptjT
(CONTACTORI
\
5T-158 158/ Ref. S0004-A
Figure
-~
3-1. Front View Of Control
-~
3 Months
3 Months
-~
6 Months
:~:
Ujadable
Clean And
Weld
Connections
Tighten
2-3
Figure
3-2. Maintenance Schedule
OM-158 601
Page
5
SECTION 4
ELECTRICAL DIAGRAMS
PC I
H5
VAC
PC5/PLG5
I5VAC
CONT ACTOR
CONTROL I 15V
C ON T ACT OR
CONTROL I 15V
24VAC
REMOTE
CONTROL
UNIT
CONTACTOR
CONTROL 24V
B
O-IOVDC
COMMAND
E
COMMON
G
CHASSIS
GND
K
PLG2
O-IOVDC
COMMAND
E
GND
0
+IOVDC
C
E
(O-IOVDC
COMMAND)
D
(GND)
3
d
5
6
7
8
9
/0
0
0
0
0
0
0
0
0
3A 4A 5A BA 7A BA 9A IOA
38 4B 58 68 78 88 98 I 08
MASTER
POWER
SUPPLY
SLAVE
POWER
CONTACTOR
CONTROL 24V SUPPLY
B
A
J
SA-158 083
I
Figure
OM-158 601
Page
6
4-1. Circuit
Diagram
For Control
PLG2
PLGI
PLG3
PC I
SC-156 130
Figure
4-2.
Wiring Diagram For
Control
OM-158 601 Page 7
SECTION 5- PARTS LIST
Dia.
Mkgs.
PCi
PC2
PLG1
Part
No.
135400
158099
PLG2,3
023618
141 162
PLG4
134731
079 739
600 797
600342
135558
079747
PLG5
135559
079 747
Al
RC1
Ti
iT
009156
143976
079 534
035759
098828
164263
127363
158098
158097
159 083
010 610
097 922
019 663
073 756
OM-158 601 Page 8
Description
CIRCUIT CARD, power supply
CIRCUIT CARD, interface isolation
CORD SET, 125V 5-15P l6ga 3/c lOft
CONNECTOR & PINS, (consisting of)
CONNECTOR, circ pin push-in 14-l8ga Amp 213603-1
CONNECTOR, circ clamp str nt sz 17-20 Amp 206322-2
CABLE, port No. 16 8/c (order by ft)
CABLE, port No. 16 4/c (order by ft)
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Amp 350980-1
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-lBga Amp 350980-1
POTENTIOMETER, C std slot l/T 2W 2.5K ohm
CONNECTOR w/SOCKETS, (consisting of)
CONNECTOR, circ skt push-in 14-l8ga Amp 66358-6
TRANSFORMER, control mintr 115/36VCT
BLOCK, term bA lOP
BRACKET SUPPORT, terminal strip
LABEL, warning electric shock can kill
CASE SECTION, back/sides/end
COVER, top
NAMEPLATE, (order by model and serial number)
PANEL, mtg control
CONNECTOR, clamp cable .500
KNOB, pointer
MOUNT, nprn 15/16 OD x 3/8rec
STAND-OFF, 6-32 x .625 Ig
Quantity
1
1
1
I
14
1
6ft
6ft
1
7
1
12
1
1
14
1
1
1
1
1
1
1
1
4
1
4
7
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