Miller | LA136320 | Owner Manual | Miller DELTASHIP 502 User manual

Miller DELTASHIP 502 User manual
OM-2227
April
Millerfi
197030
2000
Processes
MIG
The Power fBlue.
(GMAW) Welding
Flux Cored
(FCAW) Welding
Description
Arc
Welding
Power Source
Deltashipfi 502
0
~/
OWNERS
IIl~
Visit
www
our
website at
MillerWelds
corn
MANUAL
S
S
SECTION 1
SAFETY PRECAUTIONS
-
READ BEFORE USING
-
som
Symbol UØage
1-1.
Means
4A
A
The
There
possible
are
are
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.
This group
special safety message.
a
Arc
I ~2.
Out!
procedure! The possible hazards
adjoining symbols.
shown in the
Marks
Watch
Warning!
hazards with this
UT Means Note~
A
not
related.
safety
symbols
I
Hazards
Welding
are used throughout this manual
identify possible hazards. When you
If earth
shown below
to call attention to and
with
symbol, watch out, and follow the related instructions
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.
seethe
A
Only qualified persons
repair this unit.
A
During operation, keep everybody, especially children, away.
should
a
grounding
or
another electrode from
safety
Wear
a
Keep
all
and
worktable
as near
Do not touch live electrical
Wear
S
Insulate
hole-free
dry,
there is
a
Use AC
If AC
of
output
and
required,
areas, if movement is
confined,
or
the weld
required
use
for the
remote
welding
more
than
on
output
present
and
ground
this
equipment according
to its
S
If ventilation is poor,
use an
S
Read
Safety
the
Material
manufacturers
be hazardous.
a
When
Do not weld in locations
making input connections,
attach
proper
grounding
double-check connections.
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
-
-
Turn off all
equipment
Do not
worn,
when not in
over
your
body.
poorly spliced
cables.
to
approved air-supplied respirator.
(MSDS5)
Data Sheets
and
the
consumables, coatings,
confined space
near
degreasing, cleaning,
operations. The heat and rays of the arc
form highly toxic and irritating gases.
Do not weld
on
coated
plated steel,
weld area, the
or
arc
only if it is well ventilated, or while
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.
cadmium
use.
damaged, undersized,
exhaust at the
cleaners, and degreasers.
an
cables
can
use
instructions for metals,
wearing
-
drape
work cable to any
or
head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or
remove welding fumes and gases.
on
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.
Do not
electrode
fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
Work in
use
one
inverters.
Manual and national, state, and local codes.
-
workpiece to prevent
to
Welding produces
Keep your
process.
control if
input power or stop engine before installing or
equipment. Lockout/tagout input power according
OSHA 29 CFR 191 0.147 (see Safety Standards).
conductor first
workpiece
practical.
as
FUMES AND GASES
if
this
Properly install
place.
body protection.
Disconnect
Owners
in
inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
unit.
servicing
securely
metal-to-metal contact to
falling.
output ONLY if
is
good
Turn Off
I
output in damp
danger
above floor level.
working
SIGNIFICANT DC VOLTAGE exists after removal of
input power
~
Do not useAC
ground,
output terminal.
weld
ground using dry insulating mats
prevent any physical contact with the
to
are
different machine.
parts.
insulating gloves
big enough
ground.
or
single
yourself from work and
or covers
work
in contact with the work,
required, ground
clamp when not connected
object.
Do not connect
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.
S
directly
is
contact with any metal
live
Touching
a
covers
cable with
Insulate work
kill.
harness if
panels
Clamp work
or
can
it
workpiece
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
install, operate, maintain, and
ELECTRIC SHOCK
of the
separate cable.
Do not touch electrode if you
to avoid the hazard. The
to
_nd_4198
area
metals,
such
unless the
is well
can
as
coating
or
spraying
react with vapors to
galvanized, lead,
or
is removed from the
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
BUILDUP OF GAS
ARC RAYS can bum eyes and skin
Shut off
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.
can
injure or
when not in
shielding gas supply
confined
ventilate
spaces
Always
approved air-supplied respirator.
awelding helmet fitted with a propershade offilterto protect
welding or watching (see ANSI Z49. 1
Z87.1 listed in Safety Standards).
kill
use.
or
use
Wear
your face and eyes when
and
Wear
HOT PARTS
can cause severe
burns
with side shields under your
approved safety glasses
helmet.
Do not touch hot
Use
Allow
protective screens or barriers to protect others from flash and
others not to watch the
glare;
warn
Wear
protective clothing made from durable, flame-resistant
(leather and wool) and foot protection.
parts bare handed.
before
cooling period
working
on
gun
or
torch.
arc.
material
MAGNETIC FIELDS can affect pacemakers.
WELDING
can cause fire or
explosion.
Pacemaker
wearers
keep away.
Wearers should consult their doctor before
closed containers, such as tanks,
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.
Protect
Welding
on
drums,
pipes,
yourself
or
and others from
flying sparks
going near arc welding, gouging,
welding operations.
NOISE
can
flying sparks
can
Remove all flammables within 35 ft
this is not
possible, tightly
cover
strike flammable material.
(10.7 m)
them with
Be aware that
can cause
fire
Do not weld
on
keep
welding
on
a
fire
of the welding arc.
approved covers.
closed containers such
as
Connect work cable to the work
unknown
Do not
prevent welding
paths
and
as
causing
tip
when not in
Wear
approved
CYLINDERS
or
ear
protection if
or
can
explode ifdamaged.
welding area as
traveling long, possibly
cut off
welding
wire at
compressed gas cylinders from excessive heat,
slag, open flames, sparks, and arcs.
Protect
mechanical shocks,
Install
as
a
leather
can
gloves, heavy
cap.
Remove any combustibles, such as a butane
from your person before doing any welding.
FLYING METAL
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.
cylinders in an upright position by securing to a stationary
or cylinder rack to prevent falling or tipping.
support
Keep cylinders away from any welding or other electrical
such
lighter or matches,
Injure eyes.
Never
drape
Never allow
Never weld
a
a
welding
welding
on a
torch
over a
gas
pressurized cylinder
-
circuits.
cylinder.
electrode to touch any
cylinder.
explosion
will result.
Use only correct shielding gas cylinders, regulators, hoses,
fittings designed for the specific application; maintain them
associated parts in good condition.
Turn face away from valve outlet when
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
2
noise level is
Shielding
pipes,
(see
to AWS F4.1
pipes.
protective garments
shirt, cuffless trousers, high shoes, and
Page
can
high.
partition
use.
Wear oil-free
OM-2227
equipment
If
electric shock and fire hazards.
Remove stick electrode from holder
contact
or
close to the
current from
welder to thaw frozen
use
or
tanks, drums,
they are properly prepared according
Safety Standards).
to
processes
the hidden side.
unless
practical
some
extinguisher nearby.
ceiling, floor, bulkhead,
on a
damage hearing.
damage hearing.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and
spot
and hot metal.
Noise from
Do not weld where
or
opening cylinder
and
and
valve.
Keep protective cap in place over valve except when cylinder is
use or
connected for
Read and follow instructions
associated
Standards.
in
use.
equipment,
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
.
1-3
Symbols For Installation, Operation, And Maintenance
Additional
MOVING PARTS
FIRE OR EXPLOSION hazard
Do not install
place
or
unit on, over,
Do not install unit
flammables.
building wiring be sure power supply system
properly sized, rated, and protected to handle this unit.
Do not overload
is
near
injury
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
or near
combustible surfaces.
A
can cause
-
FALUNG UNIT
can cause
injury.
HF. RADIATION
lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacityto lift and
interference.
can cause
Use
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications
support unit.
equipment.
only qualified persons familiar with
electronic equipment perform this installation.
Have
using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
If
The
unit.
is
user
promptly
for
responsible
having
correct any interference
a
qualified
electrician
problem resulting
from the
installation.
OVERUSE
Allow
cooling period;
Reduce current
starting
Do not block
or
STATIC (ESD)
Put
or
on
follow rated
reduce
duty cycle.
duty cycle
grounded
boards
or
by
at once.
FCC about interference, stop
regularly
using
the
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.
filter airflow to unit.
can
the
If notified
equipment
Have the installation
before
again.
to weld
handling
OVERHEATING
can cause
damage PC boards.
wrist
strap
BEFORE
parts.
ARC WELDING
static-proof bags and
store, move, or ship PC boards.
Use proper
can cause
interterence.
boxes to
Electromagnetic energy can interfere with
electronic equipment such
as
computers and computer-driven equipment
sensitive
MOVING PARTS
can cause
such
injury.
Keep away
from
moving parts.
Keep away
from
pinch points
as
robots.
all equipment in the welding
electromagnetically compatible.
Be
such
as
To reduce
drive
possible,
rolls.
sure
WELDING WIRE
can cause
injury.
possible interference, keep weld cables as short as
together, and down low, such as on the floor.
welding operation
equipment.
Be
sure
according
Do not press gun
trigger
until instructed to do
welding
machine
is
and
installed
grounded
to this manual.
such
Do not
point gun toward any part of the body,
people, or any metal when threading
welding
1-4
this
100 meters from any sensitive elec
If interference still occurs, the user must take extra measures
as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
so.
other
is
close
Locate
tronic
area
wire.
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 Superinten
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Safe
Handling
of
Compressed
Gases in
Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association,
Highway, Suite 501, Arlington, VA 22202.
1235 Jefferson
Davis
Safety in Welding and Cutting, CSA Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
Code for
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances,
American Welding Society Standard AWS F4.i, from American
Welding Society, 550 N.W. LeJeune Rd. Miami, FL 33126
Protection, ANSI Standard Z87.i,from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Cutting And Welding Processes, NFPA Standard 51 B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Practices For
Occupation
And Educational
Eye
And Face
OM-2227
Page
3
EMF Information
1-5.
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1.
Keep cables
Welding current, as it flows through welding cables, will cause electro
magnetic 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
2.
Arrange
3.
Do not coil
Research Council concluded that: The body of evidence, in the
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
4.
committees
welding
or
magnetic
procedures:
OM-2227 Page 4
cables to
or
together by twisting
one
drape
or
taping
side and away from the
cables around your
Keep welding power
as practical.
source
Connect work
to
and cables
them.
operator.
body.
as
far away from opera
tor
5.
clamp
workpiece
as
close to the weld
as
possible.
About Pacemakers:
cutting.
To reduce
close
fields in
the
workplace,
use
the
following
Pacemaker
then
wearers
following
consult your doctorfirst. If cleared by your doctor,
procedures is recommended.
the above
SECTION 2
2-1.
1/96
-
DEFINITIONS
General Precautionary Label
Warning! Watch
possible hazards
symbols.
1
Out! There
are
shown
the
as
by
Electric shock from welding
electrode or wiring can kill.
dry insulating gloves.
1.1 Wear
Do not touch electrode with
bare hand. Do not wear wet
or
damaged gloves.
yourself from electric
by insulating yourself
work and ground.
1.2 Protect
shock
from
1.3 Disconnect input plug
power before working
or
on
machine.
2
fumes
Breathing welding
can
be hazardous to your health.
2.1
Keep your head out of the
fumes.
2.2 Use forced ventilation
exhaust to
remove
or
local
the fumes.
2.3 Use ventilating fan to
fumes.
remove
3
Welding sparks can
explosion or fire.
3.1
Keep flammables away from
welding. Do not weld near
cause
flammables.
3.2
Welding sparks
can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
3.3 Do not weld
drums
on
or
any
closed containers.
4
Arc rays can burn eyes and
injure skin.
4.1
Wear hat and
Use
shirt
safety glasses.
protection and button
collar. Use welding
ear
helmet with correct shade of
filter. Wear
complete body
protection.
5
Become trained and read the
instructions before working
on
6
the machine
or
Do not
remove or
(cover)
the label.
welding.
paint
over
OM-2227
Page
5
2-2.
Input Connection Label
Warning Watch Out! There
are possible hazards as
shown by the symbols.
1
Electric shock from
kill.
2
.
wiring
can
Disconnect
3
input plug
working
power before
machine.
4
or
on
Read the Owners
Manual
before
this
working
on
machine.
Consult
5
rating label
for
input
power requirements, and
check power available at the
job site they must match.
-
Read Owners Manual and
inside labels for connection
6
points
Move
7
on
8
and procedures.
jumper links as shown
inside label to match
voltage
at
Having
a
connect
site.
job
loop of extra length,
grounding conductor
first.
Connect line input conductors
as shown on inside label
double-check all connections,
jumper link positions, and
input voltage before applying
9
-
power.
Electric Sh ock And Airflow Label
2-3.
1
2
\
\
1
3
\
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
\
\
\
\
2
-e
I
e
~
I
3
0
Electric shock from
and
exposed
can
kill.
wiring
weld terminals
Close door before
turning
on
unit.
S-179 563
1/96
2-4.
Nameplate Safety Symbols
1
1
1
2
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from
electrode
3
Sparks
or
wiring
welding
can
kill.
from
can cause
arcing electrode
explosion or fire
-
disconnect cable for process
not in use.
4
Read Owners
connection
5
Manual for
procedures.
Electric shock from
kill.
wiring
can
2
3
4
6
Disconnect
input power
working on unit or
making terminal strip
before
connections.
Nameplate
OM-2227
Page
6
D-1 79 389
SECTION 3- INSTALLATION
Amperes Input
at Rated Load
Hz,
50
Output,
Three-Phase
Voltage Range
Welding
Volts
DC,
10
-
220 V
Max OCV DC
DC
40
45
Duty Cycle
35
34
31
23.3
17.6
1.6*
1.5*
1.4*
1.04*
0.37*
Duty Cycle
: :
I:
500
~
load without
If
percentage
unit
can
of 1(
weld at rated
overheating.
overheats, thermostat(s)
opens, output stops, and cooli~
fan runs. Wait fifteen minutes
unit to cool. Reduce amperage
duty cycle before welding.
400
A
o
~
200
100
is
minutes that unit
~
< ~oo
~
KW
61
600
~
KVA
2.8*
900
800
700
LiJ
440 V
400 V
380 V
Exceeding duty cycle
damage unit and
warranty.
can
~
30
20
10
40
50
60
70 8090100
% DUTY CYCLE
60%
Duty Cycle
g~-~g~
6 Minutes
4 Minutes
Welding
Resting
Overheating
V
3-3.
Volt-Ampere Curves
Volt-ampere
and
45
MAX
of unit. Curves of
40
FC W
show
curves
and maximum
voltage
amperage output capabilities
minimum
50
between
curves
othersettingsfall
shown.
35
30
~
-J
~
25
20
15
10
MIN
5
0
0
50
100
150
200 250
DC
300
350 400 450 500
AMPERES
vacurvel
-
4/95
-
197 034-A
OM-2227
Page
7
Seb
3-4.
A Location
1
Lifting Eye
2
Lifting
Forks
Use lifting eye
move
Movement
or
lifting
forks to
unit.
If using lifting forks, extend forks
beyond opposite side of unit.
Rating Label
3
Use
rating label to determine input
power needs. Label located under
front access door.
OR
4
Line Disconnect Device
2
Locate
unit
power
supply.
near
correct
input
A Special installation may be
required where gasoline or
volatile liquids are present
Location And Airflow
-
NEC Article 511
Section 20.
see
or
CEC
18 in
(460 mm)
18 in
(460 mm)
3-5.
Dimensions And
Ref. 800 453-A
Weights
Dimensions
D~h____
Height
27-1/4 in (692 mm)
___
4 Holes
I
Width
22-1/4 in (565 mm)
Depth
28-1/4 in (718 mm)
A
27-1/2 in (699 mm)
B
3/4in(lgmm)
C
21 in
(533 mm)
D
1-3/16 in (30 mm)
E
7/16 in (11 mm) Dia
Weight
0
_____
-
1~~
Ref. 153 556-A
OM-2227
Page
8
337 lb
(153 kg)
.
3-7.
115 VAC
Receptacle And Circuit Breakers
A
Turn
Off
connecting
power
to
before
receptacle.
1
ll5Vl5AACReceptacle
2
Circuit Breaker CB1
3
Circuit Breaker CB2
RC9
CB1
115
volts
protects
receptacle RC9
from overload.
CB2
DS-2
protects
wire
ac
drive
motor from overload.
Press button to reset breaker.
Ref. 800 452-B
OM-2227
Page
9
Total Cable
100 ft
Turn Off power before
to weld output
connecting
terminals.
=
-ii
jL
+
Positive
Negative
Ref. 800 452-B
I
200ft
250ft
(60 m)
(70 m)
I
Exceeding
I
300ft
I
350ft
(90 m)
400ft
(105 m)
(120 m)
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
300
1
1/0
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
4/0
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
(AWG) is based on either a 4
mm2 equivalent weld cable sizes.
3-9.
150 ft
(45 m)
In Weld Circuit Not
Welding
Amperes
*WeId cable size
for the
(30 m) Or Less
(Copper) Length
10
60%
-
volts
or
less
60
drop
100%
-
or a
current
10
100%
-
Duty Cycle
density of at least 300 circular mils per ampere. Contact your distributor
S-0007-E
Inductance Selection
A
Turn
Off
changing
Remove
power
stabilizer
before
taps.
cover.
1
Stabilizer Z
2
Lead 25
3
Stabilizer Z Center
4
Stabilizer Z
5
Lead 26
Tap
Ending
stabilizer Z is factory
connected to the stabilizer end tap
Tapped
which is recommended for
most
gas-shielded
flux
use
with
cored
wires.
Stabilizer Z controls the induc
applied to the weld current.
To decrease inductance for recom
mended
with most selfuse
tance
shielded flux cored wires, discon
nect lead 26 from stabilizer end tap
and connect to stabilizer
tap
as
center
shown.
Reinstall
cover.
Tools Needed:
~ 3/8,7/l6in
~Zl~1J
3/8 in
802 623
OM-2227
Page
10
.
3-10. Remote 9 pin
Receptacle RC8
Information
Socket Information
Socket
REMOTE 9
24 volts
ac
output
for gas valve control when
triggered
or
purging
when
gas.
010
trigger open,
2
+15 volts dc with gun
3
Circuit
4
0 to +10 volts dc
5
+10 volts dc
6
0 to +10 volts dc
input
7
+15 volts dc with
Jog
8
0 to +24 volts dc
output
9
Voltage output
0 volts dc with gun
trigger
closed.
common.
input
Output Command
from mm
to max of
from mm
to max of Wire
control Ri.
FEEDER
output.
Speed
control R2.
switch S3 open, 0 volts dc with switch closed.
to motor Mi with
respect
to wire drive motor Mi with
to socket 9.
respect
to socket 8.
3-11. Electrical Service Guide
220
380
400
440
61
35
34
31
2
70
40
40
35
3
90
50
50
45
6
8
8
8
(99)
(120)
10
10
Input Voltage
Input Amperes
At Rated
Output
Max Recommended Standard Fuse
Rating
In
Amperes
Time-Delay
Normal
Mm
Input Conductor
Max Recommended
Mm
Size In AWG/KcmiI
Input Conductor Length
Grounding Conductor Size
2
factory for
circuit breaker
?~1)
(Meters)
10
8
(NEC)
applications.
Time-Delay fuses are UL class RK5.
Operating (general purpose
3 Normal
In Feet
In AWG/Kcmil
Reference: 1999 National Electrical Code
1 Consult
Operating
1
-
no
intentional
delay)
fuses
are
(JL class K5
(up
to and
including
60
amp),
and UL class H
(65
amp and
above).
OM-2227
Page
11
3-12.
Placing Jumper
Links And
Connecting Input
Power
Check
input voltage
available at
site.
2
1
Jumper
Link Label
Check label.
220V
C
L~L2
LTS
~
380 VOLTS
ofit~o
oflflo
~
-
0
~L3
~J,J
.
~L3
foo
oo
400
OLTS
c~, Co ~ a
~
jL~
2
IIcLYQI..TS
~
a
L3
C
L..~j
0O~0
~i
a,>
aft~a
~
Link
jumper links to match input
voltage, and label on unit.
3
L
Jumper
Move
Input
And
Grounding
Conductors
See Section 3-11.
1
4
Line Disconnect Device
See Section 3-11.
Close
access
door.
Li
L2
L3
A Always connect
grounding conductor
=
first.
3
GND/PE
EI~1~~j~u
3/8, 1/2 in
801 382
OM-2227
Page
12
SECTION 4- OPERATION
4-1.
Welding
Power Source Controls
196 996-A
1
Analog
Meters
Voltmeter and ammeter
voltage
2
to purge gas
display
actual
and amperage with contactor
adjust gas regulator.
pendant. At second trigger closure, welding
arc extinguishes.
Crater Fill On
Crater
At initial gun trigger closure and release, unit
creates and sustains a welding arc using
This
Crater Fill Wire Speed Control
(Used With Crater Fill Mode Only)
Crater Fill Voltage Adjustment Control
(Used With Crater Fill Mode Only)
welding.
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.
momentarily energize gas valve
Fill/Trigger
Hold Off
setting is normal operation. At gun trigger
unit initiates welding arc using
settings from weld controls on wire feeder
pendant. At trigger release, welding arc
extinguishes.
closure,
A
Turn
Off
power
before
connecting
remote device.
Trigger
Hold On
6
Purge Switch
Use switch to
to
output
Turn control clockwise to increase crater fill
voltage. Control can be adjusted while
4
or
on.
Scale is calibrated in meters per minute.
3
lines,
Mode Switch
5
At initial gun trigger closure and release, unit
creates and sustains a welding arc using
settings
from weld controls
on
wire feeder
High Temp Shutdown Light
Light
turns
on
condition that
to
indicate
causes
output
an
overheated
to shutdown.
OM-2227
Page
13
4-2.
Pendant Controls
Controls
pendant mounted. An
pendant extension
are
remote
optional
cord is available.
1
.
Nameplates
has
Pendant
nameplates
on
top of the other.
nameplate
contains the vol
stacked
Each
three
one
tage and amperage ranges for
a dif
ferent size flux cored welding wire
(for reference only). Unit is shipped
mm wire nameplate on top.
change to 1.4 or 1.6 mm name
plates, see Wire feeder owners
with 1.2
To
manual.
2
Voltage
Control
Use control to set
source
voltage
Numbers
3
Wire
Use
for reference
are
power
only.
Speed Control
control
speed
welding
at the wire feeder.
to
from
adjust
0 to 20
wire
meters
feed
per
minute.
111)
l~ Match
colored
bands
on
voltage and wire speed cont rols
to get an acceptable welding
4
condition.
4
Jog
Switch
Jog switch to momentarily feed
welding wire at speed set on Wire
Speed control without energizing
welding circuit or shielding gas
Use
valve.
Use
And
Nameplates As A Voltage
Amperage Reference Only.
Ret. 802 483-A / 199 3431199 348 /199 350
OM-2227
Page
14
SECTION 5- MAINTENANCE & TROUBLESHOOTING
5-1.
Routine Maintenance
A
Disconnect power before
maintaining.
__
3 Months
Replace
unreadable
labels.
6 Months
Blow out
or vacuum
-~
inside.
During heavy service,
monthly
clean
Or
Trouble
No weld
output;
inoperative.
unit
Remedy
Place line disconnect switch in On
completely
Check and
replace
Check for proper
line
fuse(s),
No weld
light
output; Power
switch
pilot
Check, repair,
or
replace
if necessary,
connections
input power
Check for proper jumper link
position (see Section 3-12).
or
(see
Section
(see Section 3-12).
3-12).
position (see Section 3-12).
feeder
(see wire
feeder Owners
Manual).
on.
Unit overheated. Allow unit to cool with fan On
Unit
reset circuit breaker
provides only maximum
output.
or
minimum weld
Erratic
or
improper
weld
Authorized Service
Agent
check control board PCi and/or motor drive board PC2.
Have
Factory
Authorized Service
Agent
check control board PCi, motor drive board PC2 and Hall
Device HD1.
Use proper size and
output.
tighten
Use proper
type of
weld cable
tap
on
stabilizer
according
duplex
re-
Reset circuit breaker CB1
to Owners
Manual.
(see Section 3-9)
Factory Authorized Service
SCR in main rectifier.
at
(see Section 3-8).
all weld connections.
Have
output
3-2).
Factory
Check wire feeder installation
ac
Section
Have
Clean and
No 115 volts
(see
Agent
check control board
PCi, motor drive board PC2 and/or
(see Section 3-7).
ceptacle.
Fan not
when
operating. Note: fan
cooling is necessary.
runs
only
Check for and
Have
Factory
remove
anything blocking
Authorized Service
Agent
fan movement.
check fan motor.
OM-2227
Page
15
Remedy
Trouble
Wire does not
feed, feeder completely
Check
9-pin plug PLG8
Check
input
connections
(see Section 3-10).
inoperative.
.
power.
Check circuit breaker CB2
Wire does not feed.
on
Check gun trigger connection at wire feeder
and trigger switch.
Have
Wire feeds
erratically.
Service
Factory Authorized
Readjust
or
replace dirty
Remove weld
Replace
Have
Wire feeds when
but not when gun
Wire feeds
Wire
does
pressed,
trigger is
as soon as
not
or
power is
feed
until
trigger
is
check drive motor, control board
or worn
wire feeder owners
drive roll
(see
tip
or
Check
PCi, and
trigger leads
motor board PC2.
manual).
manual).
wire feeder owners
manual).
liner.
Authorized Service
Agent
check drive motor and control board PCi.
Check gun trigger connection at wire feeder
and trigger switch.
Check gun
wire feeder owners
Check gun
spatter around nozzle opening.
contact
Factory
(see
(see
(see Section 3-7).
(see wire feeder owners manual). Check gun trigger leads
trigger.
position
Crater Fill On
of Mode switch
or
Trigger
welding power source. This
positions (see Section 4-1).
is normal
on
Hold On
operation
when switch is in
released.
loudly
erratically.
and wire feeds
Gas does not flow; wire feeds.
OM-2227
applied.
but continues to feed after
Gas valve rattles
slowly
Jog switch is pressed
trigger is pressed.
Agent
(see wire feeder owners manual).
hub tension and drive roll pressure
Use correct size drive roll
Clean
source, and reset if necessary
welding power
Page
16
Check for short between gun
trigger
leads and weld cable.
Repair
or
replace gun trigger
leads.
Check for short between gun
trigger
leads and weld cable.
Repair
or
replace gun trigger
leads.
Check gas valve and flowmeter.
SECTION 6- ELECTRICAL DIAGRAM
I
I?
I
~Jo
~
~3-)F~3-)
~-)4
~>--(~
;--~~~--
j~t;
~
m
000000
:fl~:f!:~f~
r~i
~
11
~AAA
RCI-8>>
~(RC36
I
I
~
-~
I
RC1-5>>
<RC35
I,
~(Rcs13
-
~1
~
__________________________________
-
_______
Sc,
RCl-4>>
I
RC1 -3>>
~
RCI 2
______I
~Fc, ~
~:J
-
UT~
~
~
Rd-I
RC3-12
RCI-7)>
RC1-8>>
<<RC3-l1
-~-1
1-~~
~
i~\1
RC1-R>>
RCI-1O>>-
24 VAC GAS VALVE
>
~NTAC1OR
~.9
RC31O>>~RdS8>>~-
aPOJIr ~MMON
~<RC3-7
~
RC3-2>>-
OUTPUT COMMRNO
>~+1O
VOC
REFU~1~E
~_)C~~
~j~<4-~
(cOMMAND
&
RC3-18>>~
~)
~
~x,._____!~ki
~)>~J ~.T~<
~
~
WFS)
~
~
r
V
______
________
i~
AAAA
-~r7
A
~
~
~
9<RCII12
$<RCII-IO
A
RCI 1-16
<RCII-9
RCII-4>
~
L
~ RC1O-3>~
JOG
<601-13
~<RCIO-6
~~~~_uOTOR
POWER
Rd1UW9
<RdlO6
~rr?I~
-o
0
(I,
-,
P1
197 032-C
Figure
6-1. Circuit
Diagram
OM-223
Page
17
SECTION 7- PARTS LIST
Hardware is common and
not available unless listed.
Figure
OM-2227
Page
18
7-1. Main
Assembly
ST-802 606
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
7-1. Main
Quantity
Assembly
2
4
197028
179429
Panel, Side
Label, General Precautionary Wordless, Intl
Baffle, Air
Cover, Top
5
177279
Gasket, Lift Eye
1
6
162830
7
162820
1
+179430
2
176254
3
8
C16
048504
9
087111
10
173605
11
HD1
168829
Figure
12
TEl
7-2
038138
038 618
175 479
.14
15...
032 765
C21-23.... 137 771
Zi
196 995
162 816
163 533
2
1
1
2
1
1.39 Dia
1
1
Transducer, Current 1 000a Module Max Open Loop
1
Panel, Rear
Term Assy, Pri
1
3ph
3v
1
(Consisting Of)
Jumper, Link
Jumper, Link 220V
Bracket, Support Leads
Capacitor
3
6
2
Diode
3
Stabilizer
1
Channel, Upright
4
1
....Base
1
TP1-2
175 405
TP4-5
168 891
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 SOC (Included w/T1)
PLG13.
PLG6
189 873
Connector & Pins
1
168 847
Connector & Sockets
Connector & Pins
Panel, Front
1
Bracket, Mtg Rectifier
Rectifier, Si Diode
2
152249
Connector & Pins
1
168846
Connector & Sockets
Connector & Pins
1
Ti
197 152
.20...
197 303
.21...
197 304
RC6
168845
Figure
7-3
161 294
.23...
...24...
....LiftEye
Bar, Mtg Lift Eye
Capacitor, Elctlt 5000 Ut 50 Vdc Can
Clamp, Capacitor 1.375 Dia Clip
Bracket, Mtg Lem
2
SRi
...
PLG7
Figure
....
RC7
.PLG14....
+When ordering
*Recommended
a
7-4
115094
component originally displaying
Spare
a
1
2
2
2
1
1
1
1
precautionary label, the label should also be ordered.
Parts.
To maintain the factory original performance of your equipment, use only Manufacturers
Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2227
Page
19
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
173 283
180 165
162 807
168 343
..
..
.
8
..
.
9
..
.10
+162 818
..
179290
..
010467
124274
Hardware is
R5
114808
FM
116190
common
7-2.
Quantity
Panel, Rear w/Components (Figure
7-1 Item
12)
Chamber, Plenum 14 In
Blade, Fan 14.000 3wg 28deg .375 Bore Ccw Gal
Panel, Rear
1
Hinge, Cont Polyolefin Copolymer 2.000 L W/.125h
Door, Access Primary
Label, Warning Electric Shock Input Connection Ce
Conn, Clamp Cable 1.250
Bracket, Mtg Fan Motor
2
1
1
1
W
1
1
1
Resistor, Ww Fxd 375 W 5 Ohm W/Hardwa
Motor, 1/l2hp 230v 1550 Rpm 50/60hz 1 .5a
and
3
1
1
4
not available unless listed.
6
8
ST-802 608
Figure
+When
ordering
a
To maintain the
Replacement
OM-2227
Page
20
7-2.
Panel, Rear wlComponents
component originally displaying
a
precautionary label,
the label should also be ordered.
factory original performance of your equipment, use only Manufacturers Suggested
Parts. Model and serial number required when ordering parts from your local distributor.
l~ Hardware is
common
and
3
not available unless listed.
4
8
7
9
I0
.11
2
9
5
26
16
ST-802 607
Figure
Item
No.
Dia.
7-3.
Part
No.
Mkgs.
Description
Figure
197 733
PCi
196 994
PLG3.... 169 240
PLG5.... 152 249
CB1
093 995
Receptacle/Capacitor w/Leads (Consisting Of)
Connector & Sockets
1
Connector, Circ Skt Push-In 14-18 Ga
7
Assy, Elect
Assy, Elect
Assy, Elect
1
Panel, Front
Terminal, Pwr Output Red
1
Capacitor, Cer Disc .1 Ut 500 Vdc W~Terms
Light, md Wht Lens i25vac Snap-in Neon Non-relampa
Switch, Tgl 3pst 40a 600vac Scr Term Wide Tgl
Spring, Cprsn .600 Od X .072 Wire X 1.500 PId
Terminal, Pwr Output Black
2
C3
197 751
Lead
197 753
C15
197 755
Lead
Lead
181 245
128 750
PL1
163 562
Si
128 756
161 303
181 246
14
172587
15
+179 563
16
160935
SN1
CR1
197868
052964
PC2
196998
....PLG1O.... 168071
PLG11
169240
PL2
1
1
1
1
3
1
Cover, Output Stud Generic
Label, Electric Shock/Reduce Air Flow (Ce)
1
Clip, Spring
Snubber, Assy
Relay, End 24Vdc Dpdt 1OA/l2OVac
Circuit Card Assy, Motor Drive
3
1
1
8Pm
1
Flange Mtg
1
1
Stand-off
4
196996
Nameplate, Miller Deltaship
1
159522
Led, Yellow 2.1V 2OMa 45.0 Mcd Panel Mtg .250 Hole
1
192174
21
1
Connector & Sockets
Connector & Sockets
....
20
1
079 534
C6
NEG
1
199 894
11
22
1
197 748
10
19
1
1
1
604 176
12
22)
1
RC9
..PoS
C4-5
7-1 Item
Electronics Box
Circuit Card Assy, Control
Connector & Sockets
161 078
196 992
18
Panel, Front w/Components (Figure
CB2
RC8
17
7-3.
Quantity
Connector & Sockets
Circuit Breaker, Man Reset 1 P 1 5A 250 Vac
Circuit Breaker, Man Reset 1 P 7A 250 Vac
Rcpt, Str Dx Grd 2P3W iSA 125V *515R
...6
13
Panel, Front w/Components
1
OM-2227
Page
21
Owners
Please
complete
Record
and retain with your
Number
Serial/Style
Model Name
Purchase Date
(Date
which
equipment
was
personal records.
delivered to
original customer.)
Distributor
Address
City
Zip
State
Resources Available
Always provide
Model Name and
Contact your Distributor for:
a distributor or service agency
you, call 1-800-4-A-Miller or visit our
website at www.MillerWelds.com
To locate
Serial/Style
Welding Supplies
Options
Number.
and Consumables
and Accessories
near
Personal
Safety Equipment
Service and
Repair
Replacement
Mitler Etectiic
company
~635 West Spencer Street:
App~toa,WI54914USA
Training (Schools, Videos, Books)
International
Technical Manuals
and Parts)
Mfg CO~
An illinois Tool ~rks
Parts
(Servicing
Information
Headquarters-liSA
USA Ptione~ 920-735-4505 Auto-Attended
USA & Canada.FAX 920-7354134
.:
tmationai FAX 920-735-4125
Circuit
Diagrams
Welding
~uropeanHeadquarteis
:Unftad
Process Handbooks
www
Delivering Carrier for:
File
a
claim for loss
or
MdlerWekls
corn
.~
damage during
shipment.
For assistance in
filing
or
settling claims,
equipment
Department.
contact your distributor and/or
manufacturer s Transportation
_
~I/i Miller
W
PRINTED IN USA
'
2000 Miller Electric
.
..
44(0)1204-593493
44 (0)1204598066
Phone:
FAX
Contact the
-
Kingdom
Mtg. Co.
1/00
Th~erifBhte.
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