Miller | LA181070 | Owner Manual | Miller DELTASHIP 502 User manual

Miller DELTASHIP 502 User manual
OM-2227
197 030G
June 2002
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
Deltaship 502
R
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value 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 against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
particular model are also provided.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog orindividual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
TABLE OF CONTENTS
The following terms are
used interchangeably
throughout this manual:
MIG = GMAW
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. General Precautionary Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Input Connection Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Electric Shock And Airflow Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Nameplate Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. 115 VAC Receptacle And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Inductance Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10.Remote 10-Socket Receptacle RC8 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11.Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12.Placing Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-13.Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_4/98
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
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.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Keep your head out of the fumes. Do not breathe the fumes.
D Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first – double-check connections.
D Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-2227 Page 1
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D 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.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-2227 Page 2
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
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.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder – explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring – be sure power supply system is
properly sized, rated, and protected to handle this unit.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
D
OVERUSE can cause OVERHEATING
D
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
D
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. 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 Superintendent 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, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-2227 Page 3
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-2227 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 2 – DEFINITIONS
2-1. General Precautionary Label
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
1.1
1.2
1.3
2
2.1
2.2
2.3
3
3.1
3.2
3.3
4
4.1
5
6
Electric shock from welding
electrode or wiring can kill.
Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
Protect yourself from electric
shock by insulating yourself
from work and ground.
Disconnect input plug or
power before working on
machine.
Breathing welding fumes can
be hazardous to your health.
Keep your head out of the
fumes.
Use forced ventilation or local
exhaust to remove the fumes.
Use ventilating fan to remove
fumes.
Welding sparks can cause
explosion or fire.
Keep flammables away from
welding. Do not weld near
flammables.
Welding sparks can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
Do not weld on drums or any
closed containers.
Arc rays can burn eyes and
injure skin.
Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
Become trained and read the
instructions before working on
the machine or welding.
Do not remove or paint over
(cover) the label.
OM-2227 Page 5
2-2. Input Connection Label
1
1/96
2
3
4
1
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from wiring can
kill.
Disconnect input plug or
power before working on
machine.
Read the Owner’s Manual
before working on this
machine.
Consult rating label for input
power requirements, and
check power available at the
job site – they must match.
Read Owner’s Manual and
inside labels for connection
points and procedures.
Move jumper links as shown
on inside label to match
voltage at job site.
Having a loop of extra length,
connect grounding conductor
first.
Connect line input conductors
as shown on inside label –
double-check all connections,
jumper link positions, and
input voltage before applying
power.
2
3
4
5
1
2
3
?
V
6
?
V
?
A
ÍÍÍÍ
ÍÍÍÍ
ÍÍÍÍ
ÍÍ
ÍÍ
5
7
5
3
8
4
S-179 290
6
7
8
9
9
2-3. Electric Shock And Airflow Label
1
2
1
3
2
3
S-179 563
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from wiring and
exposed weld terminals can
kill.
Close door before turning on
unit.
1/96
2-4. Nameplate Safety Symbols
1
1
1
2
3
4
5
5
2
3
4
6
6
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from welding
electrode or wiring can kill.
Sparks from arcing electrode
can cause explosion or fire –
disconnect cable for process
not in use.
Read Owner’s Manual for
connection procedures.
Electric shock from wiring can
kill.
Disconnect input power
before working on unit or
making terminal strip
connections.
Nameplate D-179 389
OM-2227 Page 6
SECTION 3 – INSTALLATION
3-1. Specifications
Amperes Input at Rated Load Output, 50 Hz,
Three-Phase
Rated Welding
Output
Voltage Range
DC
Max OCV DC
220 V
380 V
400 V
440 V
KVA
KW
350 A @ 38 Volts DC,
100 % Duty Cycle
10 – 45
40
61
2.2*
35
1.2*
34
1.1*
31
1.1*
22.7
0.8*
17.0
0.3*
*While idling
3-2. Duty Cycle And Overheating
WELD AMPERES
1000
900
800
700
600
500
400
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
300
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
200
Y Exceeding duty cycle can
damage unit and void
warranty.
100
10
20
30
40
50 60 70 8090100
% DUTY CYCLE
50% Duty Cycle
5 Minutes Welding
5 Minutes Resting
Overheating
V
0
15
Minutes
OR
Reduce Duty Cycle
duty1 4/95 / 197 033-C
OM-2227 Page 7
3-3. Volt-Ampere Curves
Volt-ampere
curves
show
minimum and maximum voltage
and amperage output capabilities of
unit. Curves of other settings fall
between curves shown.
va_curve1 – 4/95 – 197 034-A
3-4. Selecting A Location
1
2
Lifting Eye
Lifting Forks
Use lifting eye or lifting forks to
move unit.
Movement
If using lifting forks, extend forks
beyond opposite side of unit.
1
3
Rating Label
Use rating label to determine input
power needs. Label located under
front access door.
OR
2
4
Line Disconnect Device
Locate unit near correct input
power supply.
Location And Airflow
Y Special installation may be
required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
Section 20.
4
3
18 in
(460 mm)
18 in
(460 mm)
OM-2227 Page 8
Ref. 800 453-A
3-5. Dimensions And Weights
Dimensions
A
C
B
A
30 in (762 mm) Including lift eye
B
23 in (584 mm)
C
30-1/2 in (775 mm) Including
strain relief
D
27-1/2 in (699 mm)
E
3/4 in (19 mm)
F
21-1/8 in (537 mm)
G
1-1/8 in (29 mm)
H
7/16 in (11 mm) Dia
F
G
H
4 Holes
D
Weight
E
342 lb (155 kg)
Front
800 453-A / 801 530
3-6. Tipping
Y Be careful when placing or
moving unit over uneven
surfaces.
OM-2227 Page 9
3-7. 115 VAC Receptacle And Circuit Breakers
Y Turn Off power before
connecting to receptacle.
1
2
3
3
115 V 15 A AC Receptacle
RC9
Circuit Breaker CB1
Circuit Breaker CB2
CB1 protects 115 volts ac
receptacle RC9 from overload.
2
CB2 protects DS-2 wire drive motor
from overload.
Press button to reset breaker.
1
Ref. 800 452-B
3-8. Weld Output Terminals And Selecting Cable Sizes*
Y ARC WELDING can cause Electromagnetic Interference.
To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed
and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving
the welding machine, using shielded cables, using line filters, or shielding the work area.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Weld Output
Terminals
Y Turn off power before
connecting to weld output terminals.
Welding
Amperes
10 – 60%
Duty
Cycle
60 – 100%
Duty
Cycle
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 3/0
(3x95)
Y Do not use worn, damaged, undersized, or
poorly spliced cables.
+
Positive
–
10 – 100% Duty Cycle
Negative
Ref. 800 452-B
* This
chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
OM-2227 Page 10
S-0007-E–
3-9. Inductance Selection
Y Turn Off power before
changing stabilizer taps.
Remove cover.
1
2
3
4
5
5
1
3
Stabilizer Z
Lead 25
Stabilizer Z Center Tap
Stabilizer Z Ending
Lead 26
Tapped stabilizer Z is factory
connected to the stabilizer center
tap which is recommended for use
with most gas-shielded and selfshielded flux cored wires.
Stabilizer Z controls the inductance
applied to the weld current. To increase inductance, disconnect
lead 26 from stabilizer center tap
and connect to stabilizer ending tap
as shown.
2
Reinstall cover.
4
Tools Needed:
3/8, 7/16 in
3/8 in
802 623
OM-2227 Page 11
3-10. Remote 10-Socket Receptacle RC8 Information
10
Socket
Socket Information
A
24 volts ac output for gas valve control when triggered or when purging
gas.
B
+15 volts dc with gun trigger open, 0 volts dc with gun trigger closed.
C
Circuit common.
D
0 to +10 volts dc input from min to max of Output Command control R1.
E
+10 volts dc output.
F
0 to +10 volts dc input from min to max of Wire Speed control R2.
G
+15 volts dc with Jog switch S3 open, 0 volts dc with switch closed.
H
0 to +24 volts dc output to motor M1 with respect to socket I.
I
Voltage output to wire drive motor M1 with respect to socket H.
J
Not Used
3-11. Electrical Service Guide
Input Voltage
220
380
400
440
Input Amperes At Rated Output
61
35
34
31
Time-Delay 2
70
40
40
35
Normal Operating 3
90
50
50
45
6
8
8
8
151
(46)
294
(90)
326
(99)
395
(120)
8
10
10
10
Max Recommended Standard Fuse Rating In Amperes 1
Min Input Conductor Size In AWG/Kcmil
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil
Reference: 1999 National Electrical Code (NEC)
1 Consult factory for circuit breaker applications.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose – no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
OM-2227 Page 12
3-12. Placing Jumper Links
Y Disconnect and lockout/tagout input power before
installing or moving jumper
links.
Do not overtighten
jumper link nuts.
Check input voltage available at
site.
1
Jumper Link Label
Check label.
2
2
Jumper Link
Move jumper links to match input
voltage, and label on unit.
Close access door, or go on to Section 3-13.
1
3/8, 1/2 in
801 382
OM-2227 Page 13
3-13. Connecting Input Power
= GND/PE Earth Ground
1
9
8
7
3
4
Install conductors into
a deenergized line
disconnect device.
When making connections in
the line disconnect device,
connect the Green Or
Green/Yellow conductor first.
5
6
3
3/8, 1/2 in
801 382
2
Y Disconnect and lockout/tagout input power before connecting input
conductors from unit.
Y Have only qualified persons make
this installation.
See rating label on unit and check input
voltage available at site.
1
2
3
Line Disconnect Device
Input Conductors
Grounding Conductor
Select size and length using Section 3-11.
Conductors must comply with national,
state, and local electrical codes. If applicable, use lugs of proper amperage capacity
and correct hole size.
OM-2227 Page 14
4 Strain Relief
Route conductors through strain relief.
5 Machine Grounding Terminal
6 Machine Line Terminals
Y Make input power connections to
the welding power source before
making connections into a deenergized line disconnect device.
Connect green or green/yellow grounding
conductor to machine grounding terminal
first. Then connect input conductors to line
terminals.
Close access door.
7 Disconnect Device (Supply)
Grounding Terminal
8 Disconnect Device Line Terminals
Y In the deenergized line disconnect
device, connect green or green/yellow grounding conductor to supply
grounding terminal first, never to a
line terminal. Be sure grounding
conductor goes to an earth ground.
Connect input conductors to line terminals.
9
Overcurrent Protection
Select type and size using Section 3-11
(fused disconnect switch shown).
Close door on line disconnect device.
SECTION 4 – OPERATION
4-1. Controls
A. Welding Power Source
1
2
3
4
5
6
196 996-A
1
Analog Meters
to purge gas lines, or to adjust gas regulator.
Voltmeter and ammeter display actual output
voltage and amperage with contactor on.
5
2
At initial gun trigger closure and release, unit
creates and sustains a welding arc using
settings from weld controls on wire feeder
pendant. At second trigger closure, weld
parameters change to settings from crater fill
controls on welding power source. At second
trigger release, welding arc extinguishes.
Crater Fill Wire Speed Control
(Used With Crater Fill Mode Only)
Scale is calibrated in meters per minute.
3
Crater Fill Voltage Adjustment Control
(Used With Crater Fill Mode Only)
Turn control clockwise to increase crater fill
voltage. Control can be adjusted while welding.
4
Purge Switch
Use switch to momentarily energize gas valve
Mode Switch
Crater Fill On
settings from weld controls on wire feeder
pendant. At second trigger closure, welding
arc extinguishes.
Crater Fill/Trigger Hold Off
This setting is normal operation. At gun trigger
closure, unit initiates welding arc using settings
from weld controls on wire feeder pendant. At
trigger release, welding arc extinguishes.
Y Turn Off power before connecting
remote device.
Trigger Hold On
6
At initial gun trigger closure and release, unit
creates and sustains a welding arc using
Light turns on to indicate an overheated
condition that causes output to shutdown.
High Temp Shutdown Light
OM-2227 Page 15
B. Wire Feeder Pendant
Controls are pendant mounted. An
optional remote pendant extension
cord is available.
1
Nameplates
Pendant has three nameplates
stacked one on top of the other. Each
nameplate contains the voltage and
amperage ranges for a different size
flux cored welding wire (for reference only). Unit is shipped with 1.2
mm wire nameplate on top. To
change to 1.4 or 1.6 mm nameplates, see Wire feeder owner’s
manual.
2
Voltage Control
Use control to set welding power
source voltage at the wire feeder.
Numbers are for reference only.
1
3
2
Wire Speed Control
Use control to adjust wire feed speed
from 0 to 20 meters per minute.
. Match colored bands on voltage
and wire speed controls to get
an acceptable welding condition.
4
4
Jog Switch
Use Jog switch to momentarily feed
welding wire at speed set on Wire
Speed control without energizing
welding circuit or shielding gas
valve.
3
Use Nameplates As A Voltage
And Amperage Reference Only.
1
1
Ref. 802 483-A / 196 943 / 199 348 / 199 350
OM-2227 Page 16
SECTION 5 – MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance
Y Disconnect power before maintaining.
3 Months
Clean and
tighten weld
terminals.
Repair or
replace
cracked
weld
cable.
Replace
unreadable
labels.
6 Months
Blow out or vacuum inside.
During heavy service, clean
monthly
Or
5-2. Troubleshooting Table
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position (see Section 3-13).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-13).
Check for proper input power connections (see Section 3-13).
Check for proper jumper link position (see Section 3-12).
No weld output; Power switch pilot light
on.
Check, repair, or replace feeder (see wire feeder Owner’s Manual).
Unit overheated. Allow unit to cool with fan On (see Section 3-2).
Have Factory Authorized Service Agent check control board PC1 and/or motor drive board PC2.
Unit provides only maximum or
minimum weld output.
Have Factory Authorized Service Agent check control board PC1, motor drive board PC2 and Hall
Device HD1.
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 3-8).
Clean and tighten all weld connections.
Check wire feeder installation according to Owner’s Manual.
Use proper tap on stabilizer (see Section 3-9)
Have Factory Authorized Service Agent check control board PC1, motor drive board PC2 and/or SCR
in main rectifier.
No 115 volts ac output at duplex receptacle.
Reset circuit breaker CB1 (see Section 3-7).
Fan not operating. Note: fan runs only
when cooling is necessary.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
OM-2227 Page 17
Trouble
Remedy
Wire does not feed, feeder completely Check 10–pin plug PLG8 connections (see Section 3-10).
inoperative.
Check input power.
Wire does not feed.
Check circuit breaker CB2 on welding power source, and reset if necessary (see Section 3-7).
Check gun trigger connection at wire feeder (see wire feeder owner’s manual). Check gun trigger leads
and trigger switch.
Have Factory Authorized Service Agent check drive motor, control board PC1, and motor board PC2.
Wire feeds erratically.
Readjust hub tension and drive roll pressure (see wire feeder owner’s manual).
Use correct size drive roll (see wire feeder owner’s manual).
Clean or replace dirty or worn drive roll (see wire feeder owner’s manual).
Remove weld spatter around nozzle opening.
Replace contact tip or liner.
Have Factory Authorized Service Agent check drive motor and control board PC1.
Wire feeds when Jog switch is pressed Check gun trigger connection at wire feeder (see wire feeder owner’s manual). Check gun trigger leads
but not when gun trigger is pressed.
and trigger switch.
Wire feeds as soon as power is applied. Check gun trigger.
Wire does not feed until trigger is Check position of Mode switch on welding power source. This is normal operation when switch is in Crater
pressed, but continues to feed after Fill On or Trigger Hold On positions (see Section 4-1).
trigger is released.
Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads.
Gas valve rattles loudly and wire feeds Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads.
slowly or erratically.
Gas does not flow; wire feeds.
OM-2227 Page 18
Check gas valve and flowmeter.
SECTION 6 – ELECTRICAL DIAGRAM
203 351
Figure 6-1. Circuit Diagram
OM-2227 Page 19
SECTION 7 – PARTS LIST
. Hardware is common and
16
2
1
23
24 (Fig 7-4)
22 (Fig 7-3)
3
19
4
20
21
18
6
5
7
25
8
11
9
10
17
15
3
13
14
12 (Fig 7-2)
1
2
not available unless listed.
Figure 7-1. Main Assembly
OM-2227 Page 20
ST-802 606
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . +179 430
. . . 2 . . . . . . . . . . . . . . . 176 254
. . . 3 . . . . . . . . . . . . . . . 197 028
. . . 4 . . . . . . . . . . . . . . . 179 429
. . . 5 . . . . . . . . . . . . . . . 177 279
. . . 6 . . . . . . . . . . . . . . . 162 830
. . . 7 . . . . . . . . . . . . . . . 162 820
. . . 8 . . . . . C16 . . . . . 048 504
. . . 9 . . . . . . . . . . . . . . . 087 111
. . . 10 . . . . . . . . . . . . . . . 173 605
. . . 11 . . . . . HD1 . . . . . 168 829
. . . 12 . . . . . . . . . . . . . Figure 7-2
. . . 13 . . . . . TE1 . . . . . 038 138
. . . . . . . . . . . . . . . . . . . . . 038 618
. . . . . . . . . . . . . . . . . . . . . 175 479
. . . 14 . . . . . . . . . . . . . . . 032 765
. . . 15 . . . C21-23 . . . . 137 771
. . . 16 . . . . . Z1 . . . . . . 196 995
. . . 17 . . . . . . . . . . . . . . . 162 816
. . . 18 . . . . . . . . . . . . . . . 163 533
. . . 19 . . . . . T1 . . . . . . 197 152
. . . 20 . . . . . . . . . . . . . . . 197 303
. . . 21 . . . . . . . . . . . . . . . 197 304
. . . . . . . . . . TP1-2 . . . . 175 405
. . . . . . . . . . TP4-5 . . . . 168 891
. . . . . . . . . PLG13 . . . . 189 873
. . . . . . . . . . PLG6 . . . . 168 847
. . . . . . . . . . . RC6 . . . . . 168 845
. . . 22 . . . . . . . . . . . . . Figure 7-3
. . . 23 . . . . . . . . . . . . . . . 161 294
. . . 24 . . . . . SR1 . . . Figure 7-4
. . . . . . . . . . PLG7 . . . . 152 249
. . . . . . . . . . . RC7 . . . . . 168 846
. . . . . . . . . PLG14 . . . . 115 094
25 . . . . . . . . . . . . . . . . . . 604 536
. . . . Panel, Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Label, General Precautionary Wordless, Intl . . . . . . . . . . . . . . . . . . . . . .
. . . . Baffle, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Gasket, Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Lift Eye, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bar, Mtg Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Capacitor, Elctlt 5000 Uf 50 Vdc Can 1.39 Dia . . . . . . . . . . . . . . . . . . . .
. . . . Clamp, Capacitor 1.375 Dia Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bracket, Mtg Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . .
. . . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Term Assy, Pri 3ph 3v (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . Jumper, Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . Jumper, Link 220V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bracket, Support Leads Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Capacitor, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Stabilizer, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Channel, Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Base, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Xfmr, Power Main 380/400/440 (consisting of) . . . . . . . . . . . . . . . . . . . .
. . . . . Coil, Pri/Sec 380/400/440 Coil #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . Coil, Pri/Sec 380/400/440 Coil #2, #3 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . Thermostat, Nc Open/Close 135C (Included w/T1) . . . . . . . . . . . . . . .
. . . . . Thermostat, Nc Open 80C Close 50C (Included w/T1) . . . . . . . . . . . .
. . . . Connector & Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Connector & Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bracket, Mtg Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Rectifier, Si Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Connector & Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Connector & Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Screw, 312-18 x 1.75 Hex Hd-Pln Gr 5 Pld . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
1
1
1
2
1
1
1
1
1
1
3
6
2
3
1
4
1
1
1
2
2
2
1
1
1
1
2
1
1
1
1 .
2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2227 Page 21
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-2. Panel, Rear w/Components (Figure 7-1 Item 12)
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
. . . . . . . . . . . . . . . 173 283
. . . . . . . . . . . . . . . 180 165
. . . . . . . . . . . . . . . 162 807
. . . . . . . . . . . . . . . 168 343
. . . . . . . . . . . . . . +162 818
. . . . . . . . . . . . . . . 179 290
. . . . . . . . . . . . . . . 010 467
. . . . . . . . . . . . . . . 124 274
. . . . . R3 . . . . . . 114 808
. . . . . FM . . . . . 116 190
. . . . Chamber, Plenum 14 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Blade, Fan 14.000 3wg 28deg .375 Bore Ccw Gal . . . . . . . . . . . . . . . . .
. . . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Hinge, Cont Polyolefin Copolymer 2.000 L W/.125h . . . . . . . . . . . . . . .
. . . . Door, Access Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Label, Warning Electric Shock Input Connection Ce W . . . . . . . . . . . . .
. . . . Conn, Clamp Cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bracket, Mtg Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Resistor, Ww Fxd 375 W 5 Ohm W/Hardwa . . . . . . . . . . . . . . . . . . . . . .
. . . . Motor, 1/12hp 230v 1550 Rpm 50/60hz 1.5a . . . . . . . . . . . . . . . . . . . . .
. Hardware is common and
4
3
not available unless listed.
1
1
1
2
1
1
1
1
1
1
5
6
2
1
7
9
8
ST-802 608
10
Figure 7-2. Panel, Rear w/Components
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2227 Page 22
. Hardware is common and
3
not available unless listed.
2
4
8
7
5
9
6
1
10
18
11
17
12
9
13
27
28
29
30
14
19
26
25
15
16
24
ST-802 607
20
23
22
21
Figure 7-3. Panel, Front w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-3. Panel, Front w/Components (Figure 7-1 Item 22)
. . . 1 . . . . . . . . . . . . . . . 197 733
. . . 2 . . . . . PC1 . . . . . 196 994
. . . . . . . . . . PLG3 . . . . 169 240
. . . . . . . . . . PLG5 . . . . 152 249
. . . 3 . . . . . CB1 . . . . . 093 995
. . . 4 . . . . . CB2 . . . . . 161 078
. . . 5 . . . . . RC9 . . . . . 604 176
. . . 6 . . . . . . . . . . . . . . . 203 355
. . . . . . . . . . . RC8 . . . . . 039 718
. . . . . . . C3, C6, C15 . 180 889
. . . 7 . . . . . . . . . . . . . . . 196 992
. . . 8 . . . . POS . . . . . 181 245
. . . 9 . . . . C4-5 . . . . . 128 750
. . . 10 . . . . . PL1 . . . . . 163 562
. . . 11 . . . . . S1 . . . . . . 128 756
. . . 12 . . . . . . . . . . . . . . . 161 303
. . . 13 . . . . NEG . . . . . 181 246
. . . 14 . . . . . . . . . . . . . . . 172 587
. . . 15 . . . . . . . . . . . . . . +179 563
. . . 16 . . . . . . . . . . . . . . . 160 935
. . . 17 . . . . . SN1 . . . . . 197 868
. . . 18 . . . . . CR3 . . . . . 052 964
. . . 19 . . . . . PC2 . . . . . 201 702
. . . . . . . . . PLG10 . . . . 168 071
. . . . . . . . . . PLG11 . . . . 169 240
. . . 20 . . . . . . . . . . . . . . . 192 174
. . . 21 . . . . . . . . . . . . . . . 196 996
. . . 22 . . . . . PL2 . . . . . 159 522
. . . . Electronics Box, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Circuit Card Assy, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Circuit Breaker, Man Reset 1P 15A 250 Vac . . . . . . . . . . . . . . . . . . . . . .
. . . . Circuit Breaker, Man Reset 1P 7A 250 Vac . . . . . . . . . . . . . . . . . . . . . . .
. . . . Rcpt, Str Dx Grd 2P3W 15A 125V *5-15R . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Receptacle/Capacitor w/Leads (Consisting Of) . . . . . . . . . . . . . . . . . . . .
. . . . . Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Capacitor, Cer Disc .1 Uf 500 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . . .
. . . . Light, Ind Wht Lens 125vac Snap–in Neon Non–relampa . . . . . . . . . . .
. . . . Switch, Tgl 3pst 40a 600vac Scr Term Wide Tgl . . . . . . . . . . . . . . . . . .
. . . . Spring, Cprsn .600 Od X .072 Wire X 1.500 Pld . . . . . . . . . . . . . . . . . . .
. . . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Cover, Output Stud Generic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Label, Electric Shock/Reduce Air Flow (Ce) . . . . . . . . . . . . . . . . . . . . . .
. . . . Clip, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Snubber, Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Relay, Encl 24Vdc Dpdt 10A/120Vac 8Pin Flange Mtg . . . . . . . . . . . . .
. . . . Circuit Card Assy, Motor Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Stand–off, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Nameplate, Miller Deltaship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Led, Yellow 2.1V 20Ma 45.0 Mcd Panel Mtg .250 Hole . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
3
1
1
2
1
1
3
1
1
1
3
1
1
1
1
1
4
1
1
OM-2227 Page 23
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-3. Panel, Front w/Components (Figure 7-1 Item 22) (Continued)
...
...
...
...
...
...
...
...
23
24
25
26
27
28
29
30
...............
...............
...............
...............
. . . . . R5 . . . . . .
. . . . . R4 . . . . . .
. . . . . S2 . . . . . .
. . . . . S4 . . . . . .
159 036
097 922
118 901
118 902
035 897
073 562
011 610
199 691
. . . . Lens, Led Clear Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . .
. . . . Meter, Amp Dc 50mv 0– 500 Scale 2.5 In Black Face . . . . . . . . . . . . .
. . . . Meter, Volt Dc 0– 50 Scale 2.5 In Black Face . . . . . . . . . . . . . . . . . . . . .
. . . . Pot, Cp Std Slot 1T 2. W 1K Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Pot, Cp Std Slot 1T 2. W 10K Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Switch, Tgl Spdt 15A 125Vac On-Off Spd Term Chro . . . . . . . . . . . . . .
. . . . Switch, Tgl Spdt 6A 125Vac On-None-Mc Spd Term . . . . . . . . . . . . . . .
1
2
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
. Hardware is common and
not available unless listed.
4
5
6
1
3
2
7
8
9
ST-800 697-C
Figure 7-4. Rectifier, Si Diode
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-4. Rectifier, Si Diode (Figure 7-1 Item 24)
. . . 1 . . . . . SR1 . . . . .
. . . 2 . . . . C7-12 . . . .
... 3 ...............
... 4 ...............
... 5 ...............
. . . 6 . . . . . TP3 . . . . .
. . . 7 . . . . . TP6 . . . . .
. . . 8 . . . SCR1-6 . . .
. . . . . . . . . . PLG1 . . . .
... 9 ...............
199 468
048 420
177 316
177 317
166 667
185 679
185 680
148 091
158 720
188 692
..
..
..
..
..
..
..
..
..
..
Rectifier, Si Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, cer disc .01uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEAT SINK, rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEAT SINK, rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, thyristor rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THYRISTOR, SCR 865A 300V hockey puck . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, thyristor rectifier 4.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
6
3
2
3
1
1
6
1
3
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2227 Page 24
Effective January 1, 2002
(Equipment with a serial number preface of “LC” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
*
LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure 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.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction Heating Coils and Blankets
*
*
*
*
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
(Exception: brushes, slip rings, and relays are
covered on Bobcat, Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; 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 customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, 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
ARISE
BY
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING 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.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller_warr 6/02
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier for:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
PRINTED IN USA
 2002 Miller Electric Mfg. Co.
5/02
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