Miller LJ000000 Owner's manual

Brand: Miller

Model: LJ000000

Category: Welding System

Type: Owner's manual

This manual is also suitable for

PARALLEL BOX

OWNER’S MANUAL

OM-201 344F

2010−09

For Parallel Control Box

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. Static electricity can damage parts on circuit boards. Put

on grounded wrist strap before touching board.

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.

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 wire feeder and welding power

source manuals.

Proposition 65 Warnings

Welding or cutting equipment 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.)

This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm.

Wash hands after use.

2. Specifications

802 737

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

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 disconnect 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

Sub Arc AC/DC 1000

Sub Arc AC/DC 1250

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

switches are Open (Off).

4 DIP Switch Settings For:

Dimension 1000

Dimension 1250

Sub Arc DC 1000

Sub Arc DC 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

Sub Arc DC 650

Sub Arc DC 800

Switch 6 is Closed (On), all other switches

are Open (Off).

6 DIP Switch Settings For:

Dimension 452

Dimension 562

Goldstar 452

Goldstar 602

Switch 7 is Closed (On), all other switches

are Open (Off).

Install cover or proceed to Section 4

OPEN

56 7

OPEN

56 7

OPEN

56 7

OPEN

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 Parallel Control Box

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 Parallel Control Box

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.

. Place units in CC position when

using Sub Arc AC/DC 1000 or

Sub Arc AC/DC 1250. See Sub Arc

Owners manual for more information.

Make connections as shown.

1 Main Welding Power Source

2 Parallel Control Box

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.

Notes

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

9. Remote 14 Receptacle RC3 Information

Socket Information

24 VOLTS AC

A 24 volts AC from welding power source.

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

REMOTE OUTPUT CONTROL

C Command reference from welding power source.

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.

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

GND

Chassis common.

Circuit common for 24 and 115 volts AC circuits.

OM-201 344 Page 7

10.Weld Cable Size*

NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source

is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine

cable size.

! Turn off power be-

fore connecting to

weld output termi-

nals.

! Do not use worn,

damaged, under-

sized, or poorly

spliced cables.

Weld Output

Terminals

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding***

100 ft (30 m) or Less

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

Welding

Amperes

10 − 60%

Duty

Cycle

AWG (mm

)

60 − 100%

Duty

Cycle

AWG (mm

)

10 − 100% Duty Cycle

AWG (mm

)

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95)

4/0

(120)

4/0

(120)

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95)

4/0

(120)

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95)

4/0

(120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

350 1/0 (60) 2/0 (70) 3/0 (95)

4/0

(120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

400 1/0 (60) 2/0 (70) 3/0 (95)

4/0

(120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 4/0

(2x120)

500 2/0 (70) 3/0 (95) 4/0 (120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

3 ea. 3/0

(3x95)

600 3/0 (95) 4/0 (120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

3 ea. 4/0

(3x120)

3 ea. 4/0

(3x120)

700 4/0 (120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

3 ea. 4/0

(3x120)

3 ea. 4/0

(3x120)

4 ea. 4/0

(4x120)

800 4/0 (120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

3 ea. 4/0

(3x120)

3 ea. 4/0

(3x120)

4 ea. 4/0

(4x120)

4 ea. 4/0

(4x120)

900

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

1000

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

1250

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

4 ea. 3/0

(4x95)

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

( ) = mm

for metric use

***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart)

Ref. S-0007-G 2009−08

OM-201 344 Page 8

11. Circuit Diagram

237 339-A

Slave

Power

Supply

Master

Power

Supply

Remote

Control

Unit

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 237 229 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... .... ... .. ...................................

7 239 388 Bumper, Rbr .875 Od X .188 Id X .39 High Recessed 2... ............. .. ..................

8 010 916 Conn, Clamp Cable .750 2... ............. .. ...........................................

9 PLG5 201 266 Cable, Interconnecting 1... ... ... .. .............................................

10 PLG4 201 265 Cable, Interconnecting 1... ... ... .. .............................................

Miller LJ000000 Owner's manual

Brand: Miller

Model: LJ000000

Category: Welding System

Type: Owner's manual

This manual is also suitable for

PARALLEL BOX

Download PDF

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Miller LJ000000 Owner's manual

This manual is also suitable for

Miller LJ000000 Owner's manual

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