Miller KK001686 Owner's manual

Category
Welding System
Type
Owner's manual

This manual is also suitable for

Visit our website at
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CP/CC-1500P
Processes
Description
Air Carbon Arc (CAC-A)
Cutting and Gouging
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Arc Welding Power Source
OMĆ271 049 517G
April 1999
Submerged (SAW) Welding
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 or
individual 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.
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 Owners 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 parts list
will then help you to decide which exact part
you may need to fix the problem. Warranty and
service information for your particular model
are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You
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.
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols for Installation, Operation, and Maintenance 3. . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage à larc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers supplémentaires en relation avec linstallation, le fonctionnement
et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Information sur les champs électromagnétiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – INSTALLATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Duty Cycle 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Volt-Ampere Curves 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Selecting A Location And Moving The Welding Power Source 10. . . . . . . . . . . . . . . . . . . . . . . .
2-5. Overall Dimensions And Base Mounting Hole Layout 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Selecting And Preparing Weld Output Cables 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Weld Cable Size 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Connecting To Weld Output Terminals 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9. Remote Contactor Control Connections, 115 Volts AC Twistlock Receptacle, And
115 Volts AC Duplex Receptacle 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10. Remote Amperage/Voltage Control Information And Connections 13. . . . . . . . . . . . . . . . . . . . .
2-11. Adapter Cord Installation 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-12. Start Control Selection And Low Input Voltage Adjustment 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
2-13. Contactor Interlock Connections 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-14. Positioning Jumper Links 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-15. Connecting Input Power 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-16. Electrical Service Guide 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – OPERATION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Controls 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Work Clamp 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Ammeter And Voltmeter (Optional) 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Start Amperage Control 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. CV/CC Switch 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Weld Amperage/Voltage Control 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Output (Contactor) Control Switch 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Remote Amperage/Voltage Switch 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Power Switch And Pilot Light 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. Sequence Of Flux Cored Arc Welding (FCAW) 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11. Sequence Of Submerged Arc Welding (SAW) 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12. Sequence Of Air Carbon Arc Cutting And Gouging (CAC-A) 21. . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – MAINTENANCE & TROUBLESHOOTING 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Routine Maintenance 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Output Overload Circuit Breaker CB1 And Control Overload Circuit Breaker CB2 22. . . . . . . .
4-3. Fuses F1, F2, F3, F4, And F5 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Troubleshooting 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – ELECTRICAL DIAGRAMS 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – PARTS LIST 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
OM-271 Page 1
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_5/97
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.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
Y During operation, keep everybody, especially children, away.
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 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
Owners Manual and national, state, and local codes.
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 conduc-
tor 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 drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable do not use work clamp or work cable.
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 Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
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.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
FUMES AND GASES can be hazardous.
D Keep your head out of the fumes. Do not breathe the fumes.
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
manufacturers 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 watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
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-271 Page 2
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.
ARC RAYS can burn eyes and skin.
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 mate-
rial (leather and wool) and foot protection.
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.
WELDING can cause fire or explosion.
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.
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.
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.
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.
CYLINDERS can explode if damaged.
D Protect compressed gas cylinders from excessive heat, mechani-
cal 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 fit-
tings 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.
OM-271 Page 3
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
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.
FALLING UNIT can cause injury.
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.
OVERUSE can cause OVERHEATING
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.
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.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
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.
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
H.F. RADIATION can cause interference.
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.
D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D 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.
ARC WELDING can cause interference.
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.
D To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
D Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
D Be sure this welding machine is installed and grounded
according to this manual.
D 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 Superinten-
dent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cut-
ting 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 Protec-
tion 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-271 Page 4
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 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
Research Council concluded that: The body of evidence, in the
committees judgment, has not demonstrated that exposure to power-
frequency 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:
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 opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
OM-271 Page 8
1-4. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de lAmerican Wel-
ding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cut-
ting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de lAmerican Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126
National Electrical Code, NFPA Standard 70, de la National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de lAssociation canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protec-
tion, norme ANSI Z87.1, de lAmerican National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour lorganisme,
des champs magnétiques basse fréquence
Le courant de soudage, pendant son passage dans les câbles de sou-
dage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir ex-
aminé plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National Re-
search Council a conclu: Laccumulation de preuves, suivant le
jugement du comité, na pas démontré que lexposition aux champs
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine. Toutefois, des études sont toujours en cours
et les preuves continuent à être examinées. En attendant que les con-
clusions finales de la recherche soient établies, il vous serait
souhaitable de réduire votre exposition aux champs électromagnéti-
ques pendant le soudage ou le coupage.
Afin de réduire les champs électromagnétiques dans lenvironnement
de travail, respecter les consignes suivantes :
1 Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
2 Mettre tous les câbles du côté opposé de lopérateur.
3 Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
4 Garder le poste de soudage et les câbles le plus loin possible de
vous.
5 Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est
alors recommandé de respecter les consignes cidessus.
OM-271 Page 9
SECTION 2 INSTALLATION
2-1. Specifications
Amperage Voltage Maximum
Amperes Input at Rated Load
Output, Three-Phase
Rated Welding
Output
Range In CC
Mode
Range In
CV Mode
Open-Circuit
Voltage DC
230 V
60 HZ
380 V
50 HZ
460 V
60 HZ
575 V
60 HZ
KVA KW
1500 A @ 44 Volts
DC, 100% Duty
Cycle
1151820 A
2560 Volts
DC
80 274 A 166 A 137 A 110 A 109 80
Continuous Welding
2-2. Duty Cycle
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
voltage, or duty cycle before
welding.
Y Exceeding duty cycle can
damage unit and void war-
ranty.
sduty1 5/95 / ST-007 972-B
100% Duty Cycle
ssb1.1 10/91 ST-049 581-B
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding power source. Curves
of other settings fall between the
curves shown.
2-3. Volt-Ampere Curves
OM-271 Page 10
Ref. ST-159 482-C
1 18 in (460 mm) Open Space
On Front And Rear For Good
Airflow
2 Lifting Eye
Use lifting eye to move unit.
3 Lifting Forks
If using lifting forks, extend forks out
opposite side of unit.
4 Rating Label
Locate unit near correct input pow-
er supply.
1
Front
Rear
2
4
3
2-4. Selecting A Location And Moving The Welding Power Source
OM-271 Page 11
ST-159 484
2-5. Overall Dimensions And Base Mounting Hole Layout
B
A
C
Weight: 1870 lb (848 kg)
Inches Millimeters
A 59-3/4 1518
B 27-1/4 696
C 46 1168
D 1-5/8 41
E 42-3/4 1086
F 15/16 24
G 25-3/8 644
H 21/32 17
H
DE
F
G
Ref. S-0752
2-6. Selecting And Preparing Weld Output Cables
1 Weld Output Cable
Determine total cable length in weld
circuit and maximum welding am-
peres. Use Section 2-7 to select
proper cable size.
Use shortest cables possible.
Do not use damaged cables.
2 Terminal Lug
Use lugs of proper amperage
capacity and hole size for connect-
ing to weld output terminals.
3 Weld Cable Ends
Install connectors onto cable ends
necessary to connect cables to
welding system equipment.
10 ft (3 m)
1
Total Cable
Length In Weld
Circuit = 20 ft (6 m)
10 ft (3 m)
For Example,
2
3
Tools Needed:
S-0008-B
OM-271 Page 12
2-7. Weld Cable Size
Total Cable (Copper) Length In Weld Circuit Not Exceeding*
50 ft Or Less
(15m)
100 ft
(30m)
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 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 2 2 1 1/0 2/0 3/0 4/0 4/0
250 1 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1/0 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
350 2/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0
400 2/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0
500 4/0 4/0 4/0 2-2/0 2-3/0 2-4/0 1000 1000
600 4/0 4/0 2-2/0 2-3/0 2-4/0 1000 1000 2-750
700 4/0 2-2/0 2-3/0 2-4/0 1000 1000 2-750 2-750
800 2-2/0 2-2/0 2-3/0 2-4/0 1000 2-750 2-750 2-1000
900 2-3/0 2-3/0 2-4/0 1000 1000 2-750 2-1000 2-1000
1000 2-3/0 2-3/0 2-4/0 1000 2-7500 2-750 2-1000 2-1000
1250 2-4/0 2-4/0 750 2-750 2-750 2-1000 2-1000
1500 500 750 1000 2-750 2-1000 2-1000
1750 750 1000 2-750 2-1000 2-1000
2000 750 1000 2-750 2-1000
*Weld cable size (AWG and MCM) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
Ref. ST-048 680-C
2-8. Connecting To Weld Output Terminals
1 Door
Open door.
2 Positive (+) Weld Output
Terminal
3 Negative () Weld Output Ter-
minal
For Electrode Positive (DCEP),
connect work cable to negative ()
terminal and welding system equip-
ment cable to positive (+) terminal.
For Electrode Negative (DCEN),
reverse cable connections.
Close door.
2
Tools Needed:
7/8 in
3
1
OM-271 Page 13
Ref. ST-048 680-C
2-9. 115 Volts AC Duplex Receptacle
1 115 Volts AC Duplex
Receptacle
A total of 15 amperes of 115 volts ac
power is shared between the du-
plex receptacle and Remote 14 re-
ceptacle pin I (see Section 2-11).
Circuit breaker CB3 (see Section
4-2) protects the duplex receptacle
and the 115 volts portion of the Re-
mote 14 receptacle from overload.
1
2-10. Connecting Remote Control
Ref. ST-193 901 / Ref. S-0005-A / S-0750
1 Remote Amperage/Voltage
Control Receptacle
2 Keyway
3 Plug
4 Threaded Collar
To connect to this receptacle, align
keyway, insert plug, and tighten
threaded collar.
5 Remote Amperage/Voltage
Switch (See Section 3-8)
For Socket information, see Sec-
tion 2-11.
1
34
5
AJ
B
K
I
C
L
NH
D
M
G
E
F
2
OM-271 Page 14
2-11. Remote 14 Receptacle RC4 Information
Socket
on RC4
Information
A 24 volts, 15 amperes, 60 Hz ac. Protected by circuit breaker CB4.
24 VOLTS AC
B Contact closure to A completes 24 volts ac contactor control circuit.
C Command reference; +10 volts dc.
REMOTE OUTPUT CONTROL
D Remote control circuit common.
E 0 to +10 volts dc input command signal from remote control.
I 115 volts, 15 amperes, 60 Hz ac. Protected by circuit breaker CB3.
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.
A/V AMPERAGE
F Current feedback; +1 volt dc per 200 amperes (or, +1 volt dc per 100
amperes, see Section 2-12).
VOLTAGE
H Voltage feedback; +1 volt dc per 10 output terminal volts.
2-12. Start Control Selection, Low Input Voltage Adjustment, And Current Feedback
Scaling
Ref. ST-159 572-A / Ref. SB-193 713
1 Front Panel Circuit Board Ac-
cess Door
2 Circuit Board PC1
3 DIP Switch S1
S1 switch functions:
1 Low primary On (Down) for
low primary compensation
2 Not Used
3 Current Signal Scaling On
(Down) for 1 volt dc/100 amps
4 Not Used
5 Start control disable On
(Down) to disable start control
This unit is shipped so that start
control works in the CC mode. To
turn Off start control in the CC
mode, place switch S1-5 in the On
(Down) position. NOTE: Start con-
trol is automatically disabled in the
CV mode.
If input voltage is usually low, place
S1-1 in the On (Down) position.
NOTE: Low primary voltage com-
pensation only works in the CV
mode. While in the CC mode, the
position of S1-1 has no affect on
output.
This unit is shipped so that current
feedback scaling from pin F of the
Remote 14 receptacle is 1 volt dc
per 200 amperes. To change scal-
ing to 1 volt dc per 100 amperes,
place S1-3 in On (Down) position.
Close and secure access door.
Do not operate unit in the low input voltage position
if input voltage is normal, otherwise output control
becomes more sensitive and difficult to adjust.
Tools Needed:
2
1
3
OM-271 Page 15
2-13. Contactor Interlock Connections
Ref. ST-159 483
A set of normally-open contacts is
provided on the contactor interlock
for connecting equipment that re-
quires a contact closure for opera-
tion. To make connections, proceed
as follows:
Remove top and right side panel.
1 Strain Relief Connector
2 Equipment Cord
Insert cord from equipment through
strain relief.
3 Contactor Terminal NO
4 Contactor Terminal C
Connect equipment cord to termi-
nals NO and C. Use lugs of proper
amperage capacity and correct
hole size.
Tighten strain relief.
Reinstall top and side panel, or go
to Section 2-14 or 2-15 as
applicable.
1
Tools Needed:
3/8 in
2
3
4
Right Side
OM-271 Page 16
2-14. Positioning Jumper Links
Single voltage 50 Hz models do not have an input terminal board and jumper links.
Check the unit data label for input voltage requirements.
NOTE
Ref. ST-159 481-B
Jumper links allow operation on dif-
ferent input voltages and are facto-
ry set for the highest input voltage.
Check input voltage available at
site.
Remove right side panel to check
jumper links.
1 Input Voltage Label Only
One Is On Unit
Look at jumper links and compare
link position with unit label.
2 Input Voltage Jumper Links
3 Bus Bars
Move bars and links to match input
voltage. For example, use 230 volts
position when 230 volts input power
is available.
Reinstall side panel or go on to Sec-
tion 2-15.
Tools Needed:
11/16 in
3/8 in
3
1
2
1
460 VOLTS 575 VOLTS
S-158 866
230 VOLTS 460 VOLTS
S-158 867
OM-271 Page 17
2-15. Connecting Input Power
Have only qualified persons make
this installation.
Remove right side panel.
1 Line Disconnect Device Of
Proper Rating
2 Strain Relief Connector
3 Input Conductors
4 Grounding Conductor
Select size and length using Sec-
tion 2-16. Conductor insulation
must comply with national, state,
and local electrical codes. Use lug
with correct hole size for grounding
conductor.
5 Contactor
6 Line Terminals
7 Ground Terminal
Insert conductors through strain
relief.
Connect input conductors into line
terminals on contactor as shown,
and connect grounding conductor
to ground terminal.
Install and connect input conduc-
tors and grounding conductor in
conduit or equivalent to deener-
gized line disconnect switch.
Be sure grounding conductor goes
to an earth ground.
Reinstall side panel.
8 Overcurrent Protection
Select type and size using Section
2-16. Install into deenergized line
disconnect device (fused discon-
nect switch shown).
ssb2.4* 8/92 ST-159 816
1
Tools Needed:
7/16 in
3/8 in
1/4 in
2
3
4
6
7
3
3/4 in (19 mm)
Strip Insulation
Tighten And
Secure
84
5
6
2-16. Electrical Service Guide
Input Voltage
230 380 460 575
Input Amperes At Rated Output
274 166 137 110
Max Recommended Standard Fuse Or Circuit Breaker Rating In
Amperes
400 250 200 175
Min Input Conductor Size In AWG/Kcmil
3/0 2/0 1/0 2
Max Recommended Input Conductor Length In Feet (Meters)
186 (57) 450 (137) 402 (123) 425 (129)
Min Grounding Conductor Size In AWG/Kcmil
3 4 6 6
Reference: 1996 National Electrical Code (NEC). S-0092J
OM-271 Page 18
SECTION 3 OPERATION
3-1. Controls
Ref. ST-048 680-C
1 Voltmeter
2 Ammeter
3 Pilot Light
4 Power Switch
5 Start Amperage Control
6 Weld Amperage/Voltage
Control
7 Remote Amperage/Voltage
Switch
8 Constant Voltage (CV)/Con-
stant Current (CC) Switch
9 Output (Contactor) Switch
10 24 VAC Overload Circuit
Breaker (See Section 4-2)
11 Control Overload Circuit
Breaker (See Section 4-2)
12 115 VAC Overload Circuit
Breaker (See Section 4-2)
13 Output Overload Circuit
Breaker (See Section 4-2)
11
1
7
10
9
23 4 56
8
12
13
3-2. Work Clamp
1 Work Clamp
Use wire brush or sandpaper to
clean metal at weld joint area. Use
chipping hammer to remove slag
after welding.
Connect work clamp to a clean,
paint-free location on workpiece, as
close to weld area as possible.
sb4.1 5/92
Tools Needed:
1
OM-271 Page 19
3-3. Ammeter And Voltmeter (Optional)
Ref. ST-049 187-E
1 Voltmeter
Voltmeter displays voltage at the
weld output terminals, but not nec-
essarily the welding arc due to
cable resistance, poor connec-
tions, etc.
2 Ammeter
Ammeter displays weld amperage
output of unit.
1
2
3-4. Start Amperage Control
1 Start Amperage Control
Use control to help start an arc in
the CC mode.
Set Start Amperage control higher
than Weld Amperage control to as-
sist arc starting in CC mode.
Select setting best suited for appli-
cation. Numbers around control are
for reference only.
This control has no affect in CV
mode.
This control can be adjusted while
welding.
1
Ref. ST-193 901
3-5. CV/CC Switch
1 CV/CC Switch
In the CV position, the unit provides
weld output characteristics specifi-
cally designed for wire feeding
applications.
In the CC position, the unit provides
output for welding applications re-
quiring constant current weld out-
put characteristics.
1
OM-271 Page 20
3-6. Weld Amperage/Voltage Control
1 Weld Amperage/Voltage
Control
Use control as a means of selecting
weld output (weld amperage for CC
mode, weld voltage for CV mode).
This control can be adjusted while
welding.
Numbers around control are for ref-
erence only.
1
3-7. Output (Contactor) Control Switch
WARNING
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Do not touch weld output terminals when contactor is energized.
Do not touch electrode and work clamp at the same time.
swarn7.1 10/91
1 Output (Contactor) Switch
Use switch to select way of control-
ling unit output.
For front panel control, place switch
in On position.
For remote control, place switch in
Remote position.
Weld output terminals are
energized when switch is
On and Power is On.
Ref. ST-193 899
1
3-8. Remote Amperage/Voltage Switch
1 Remote Amperage/Voltage
Switch
For remote control of output, place
switch in Remote position.
For front panel control of output,
place switch in Panel position.
2 Remote 14 Receptacle (see
Sections 2-10 and 2-11)
Ref. ST-193 901
1
2
AJ
B
K
I
C
L
NH
D
M
G
E
F
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Miller KK001686 Owner's manual

Category
Welding System
Type
Owner's manual
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