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
8
OPEN
123
4
56 7
8
OPEN
123
4
56 7
8
OPEN
123
4
56 7
1
2
3
5
6
8
OPEN
123
4
56 7
4
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.
1
2
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.
1
2
3
8
4
5
6
7
+
−
++
−
+
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.
1
2
3
4
5
6
7
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.
32
1
1
1
23
2
3
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
1
1
23
1
2
3
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
K
G
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
2
equivalent weld cable sizes.
OM-201 344 Page 8
11 Circuit Diagram
201 330
OM-201 344 Page 9
12 Parts List
1
3
2
4
5
6
7
8
9
10
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
/