Miller LB278281 Owner's manual

Brand: Miller

Model: LB278281

Category: Welding System

Type: Owner's manual

This manual is also suitable for

PARALLEL BOX

OWNER’S MANUAL

OM-201 344B

2007−07

For Paralleling Controller

1 Safety Symbol Definitions

DANGER! − Indicates a hazardous situation which, if not

avoided, will result in death or serious injury. The pos-

sible hazards are shown in the adjoining symbols or

explained in the text.

Beware of electric shock from wiring. Disconnect input

power before working inside machine. Reinstall all pan-

els and covers.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible ha-

zards are shown in the adjoining symbols or explained in

the text.

Breathing welding fumes and gases can harm your

health. Welding requires good ventilation. If ventilation is

impossible, such as when welding in a confined space,

use an air-supplied respirator.

NOTICE

Indicates statements not related to personal injury.

Indicates special instructions.

Arc rays can burn eyes and skin − wear a welding hel-

met with correct filter, and cover exposed skin with non-

flammable clothing.

Wear safety glasses with side shields. Have only trained and qualified persons install, operate,

or service this unit. Call your distributor if you do not

understand the directions. For WELDING SAFETY and

EMF information, read owner’s manual(s).

Welding sparks can cause fire or explosion. Move flam-

mables away. Do not weld on closed tanks or barrels −

they can explode. Clean tanks or barrels properly.

Static electricity can damage parts on circuit boards. Put

on grounded wrist strap before touching board.

2 Specifications

Allows Easy Connection Of Multiple Welding Power Sources For Increased Amperage Applications

Welding Power Source Must Have Full Remote 14-Pin Capability

Uses 24 volts AC, Input Power Supplied Through Welding Power Source 14-Pin Receptacle

Remote Control Connections Through 14-Pin Receptacle

802 737

Dimensions: 3 in (76 mm) Deep, 7-1/2 in (191 mm) Wide, 10 in (254 mm) High

Weight: 6.1 lb (2.8 kg)

OM-201 344 Page 2

3 Setting DIP Switch S1

Ref. 802 741 / 805 018-A

! Turn Off welding power sources

and disconect input power.

Remove controller cover.

1 Grayhill Style Switch

Switches 2 and 5 are shown Closed (On),

all other switches are Open (Off).

2 CTS Style Switch

Switches 2 and 5 are shown Closed (On),

all other switches are Open (Off).

. Some controllers use the Grayhill

style switch, and some machines use

the CTS style switch.

. Place switches in positions shown for

the type of welding power source you

are using (Grayhill switch shown).

3 DIP Switch Settings For:

Summit Arc 1000

Summit Arc 1250

Switches 1 and 4 are Closed (On), all other

switches are Open (Off).

4 DIP Switch Settings For:

Dimension 1000

Dimension 1250

Switches 2 and 5 are Closed (On), all other

switches are Open (Off).

5 DIP Switch Settings For:

Dimension 652

Dimension 812

Goldstar 652

Goldstar 852

Switche 6 is Closed (On), all other

switches are Open (Off).

6 DIP Switch Settings For:

Dimension 452

Dimension 562

Goldstar 452

Goldstar 602

Switche 7 is Closed (On), all other

switches are Open (Off).

Install cover or proceed to Section 4

OPEN

123

56 7

OPEN

123

56 7

OPEN

123

56 7

OPEN

123

56 7

OM-201 344 Page 3

4 Mounting Controller On Welding Power Source

802 738

! Turn Off welding power

source.

1 Welding Power Source

2 Paralleling Controller

Controller can be mounted on top

or on right side of welding power

source.

To secure controller, loosen sheet

metal screw at desired location.

Place controller center mounting

hole over screw as shown. Tighten

screw.

5 Welding Power Source Output Connections (For Two Power Sources)

802 740

! Turn Off welding power sources

and disconnect input power.

! Do not use different polarities at

the same time on a common

workpiece when more than one

welding power source is used.

1 Main Welding Power Source

2 Paralleling Controller

3 Second Welding Power Source

4 Negative Weld Output Cables

5 Paralleled Negative Weld Output

Cable

6 Positive Weld Output Cables

7 Paralleled Positive Weld Output

Cable

. Be sure paralleled weld cables are

connected postive-to-positve and

negative-to-negative.

Paralleled weld output cables need to

be sized for the largest amount of weld

output available from the paralleled

welding power sources. See Section 10

8 Remote 14-Pin Receptacle

Connect remote control device to Re-

mote 14-Pin receptacle.

−

OM-201 344 Page 4

6 Connecting Control Cords To Welding Power Sources (For Two Power Sources)

802 739

! Turn Off welding power sources

and disconnect input power.

Make connections as shown.

1 Main Welding Power Source

2 Paralleling Controller

3 Interconnecting Cable And 14-Pin

Plug PLG4

This is the larger diameter of the two inter-

connecting cables.

4 Second Welding Power Source

5 Interconnecting Cable And 14-Pin

Plug PLG5

6 Remote 14-Pin Receptacle

. The main welding power source can

be in the CC or CV mode, depending

on the particular application. The sec-

ond welding power source must be in

the CC mode since it will be duplicat-

ing the current output by the main

power source.

. Second welding power source must

have the Output switch set to Remote,

the Control switch set to Remote and

the A/V adjust knob set to maximum.

. Set DIP switch S1 for second welding

power source (see Section 3).

7 Cord From Remote Control Device

Connect plug from remote control device

to receptacle as follows: align keyway, in-

sert plug, and tighten threaded collar.

See Section 9 for socket information if re-

mote control device plug does not match

receptacle.

OM-201 344 Page 5

7 Connecting Control Cords To Welding Power Sources (For Three Power Sources)

Ref. 803 957-A

! Turn Off welding power

sources and disconnect input

power.

! Do not use different polarities

at the same time on a common

workpiece when more than one

welding power source is used.

. Welding power source #1 can be

in the CC or CV mode, depending

on the particular application. The

other welding power sources

must be in CC mode since they

will be duplicating the current out-

put of welding power source #1.

. Welding power sources #2 and

#3 must have the Output switch

set to Remote, the Control switch

set to Remote, and the A/V Adjust

knob set to maximum.

. Be sure paralleled weld cables

are connected positive-to -posi-

tive and negative-to-negative.

1 Remote 1

Set DIP Switch S1 for power source

#3.

2 Remote 2

Set DIP Switch S1 for power source

#2.

3 Remote 3

No DIP Switch S1 settings required.

OM-201 344 Page 6

8 Connecting Control Cords To Welding Power Sources (For Four Power Sources)

Ref. 803 957-A

! Turn Off welding power

sources.

! Do not use different polarities

at the same time on a common

workpiece when more than one

welding power source is used.

. Welding power source #1 can be

in the CC or CV mode, depending

on the particular application. The

other welding power sources

must be in CC mode since they

will be duplicating the current out-

put of welding power source #1.

. Welding power sources #2, #3

and #4 must have the Output

switch set to Remote, the Control

switch set to Remote, and the A/V

Adjust knob set to maximum.

. Be sure paralleled weld cables

are connected positive-to -posi-

tive and negative-to-negative.

1 Remote 1

Set DIP Switch S1 for power source

#3.

2 Remote 2

Set DIP Switch S1 for power source

#2.

3 Remote 3

Set DIP Switch S1 for power source

#4.

432

OM-201 344 Page 7

9 Remote 14 Receptacle RC3 Information

Socket Information

24 VOLTS AC

A 24 volts ac from welding power source.

24 VOLTS AC

B Contact closure to A completes 24 volts ac contactor control circuit.

C Command reference from welding power source.

REMOTE OUTPUT CONTROL

D Remote control circuit common.

E 0 to +10 volts dc input command signal from remote control.

F Current feedback, 1 volt dc per 100 amperes.

H Voltage feedback; 1 volt dc per 10 arc volts.

115 VOLTS AC

I 115 volts, 60 Hz ac.

115 VOLTS AC

J Contact closure to I completes 115 volts ac contactor control circuit.

GND

Chassis common.

Circuit common for 24 and 115 volts ac circuits.

10 Weld Cable Size*

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

(105 m)

400 ft

(120 m)

Welding

Amperes

10 To 60%

Duty Cycle

60 Thru 100%

Duty Cycle

10 Thru 100% 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

600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0

700 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0 4-4/0

800 4/0 2-2/0 2-3/0 2-4/0 3-4/0 3-4/0 4-4/0 4-4/0

900 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 4-4/0 4-4/0

1000 2-2/0 2-3/0 2-4/0 3-3/0 4-3/0 4-4/0

1250 2-3/0 2-4/0 3-3/0 4-3/0 4-4/0

1500 2-4/0 3-3/0 3-4/0 4-4/0

*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of not more than 300 circular mils per ampere. Contact your

distributor for the mm

equivalent weld cable sizes.

OM-201 344 Page 8

11 Circuit Diagram

201 330

OM-201 344 Page 9

12 Parts List

802 741

Description

Part

No.

Dia.

Mkgs.

Item

No.

Quantity

1 200 874 COVER, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 PLG1 201 331 PLUG ASSY, elect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 PC1 200 433 CIRCUIT CARD ASSY, parallel box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 115 440 STAND-OFF, no 6-32 x .687 lg .250 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 200 873 CASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 RC3 134 735 CONN, circ ms/cpc 14 skt size 20 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 019 663 MOUNT, nprn 15/16 OD x 3/8 rec 3/16 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 010 916 CONN, clamp cable .750 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 PLG5 201 266 CABLE, interconnecting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 PLG4 201 265 CABLE, interconnecting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .