Description
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IIl~
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MillerWelds
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Arc
Welding
Power
Source
Deltashipfi
502
OWNERS
MANUAL
OM-2227
197030
Millerfi
The
Power
fBlue.
April
2000
Processes
MIG
(GMAW)
Welding
Flux
Cored
(FCAW)
Welding
S
S
SECTION
1
-
SAFETY
PRECAUTIONS
-
READ
BEFORE
USING
som
_nd_4198
1-1.
Symbol
UØage
4A
Means
Warning!
Watch
Out!
There
are
possible
hazards
with
this
procedure!
The
possible
hazards
are
shown
in
the
adjoining
symbols.
A
Marks
a
special
safety
message.
UT
Means
Note~
not
safety
related.
I
~2.
Arc
Welding
Hazards
I
A
The
symbols
shown
below
are
used
throughout
this
manual
to
call
attention
to
and
identify
possible
hazards.
When
you
seethe
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.
A
Only
qualified
persons
should
install,
operate,
maintain,
and
repair
this
unit.
A
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.
Do
not
touch
live
electrical
parts.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
Insulate
yourself
from
work and
ground
using
dry
insulating
mats
or
covers
big
enough
to
prevent
any
physical
contact
with
the
work
or
ground.
Do
not
useAC
output
in
damp
areas,
if
movement
is
confined,
or
if
there
is
a
danger
of
falling.
Use
AC
output
ONLY
if
required
for
the
welding
process.
If
AC
output
is
required,
use
remote
output
control
if
present
on
unit.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockout/tagout
input
power
according
to
OSHA
29
CFR
191
0.147
(see
Safety
Standards).
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
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.
When
making
input
connections,
attach
proper
grounding
conductor
first
-
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
when
not
in
use.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
Do
not
drape
cables
over
your
body.
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.
If
earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable.
Do
not
touch
electrode
if
you
are
in
contact
with
the
work,
ground,
or
another
electrode
from
a
different
machine.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
Maintain
unit
according
to
manual.
Wear
a
safety
harness
if
working
above
floor
level.
Keep
all
panels
and
covers
securely
in
place.
Clamp
work
cable
with
good
metal-to-metal
contact
to
workpiece
or
worktable
as
near
the
weld
as
practical.
Insulate
work
clamp
when
not
connected
to
workpiece
to
prevent
contact
with
any
metal
object.
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.
Turn
Off
inverter,
disconnect
input
power,
and
discharge
input
capacitors
according
to
instructions
in
Maintenance
Section
before
touching
any
parts.
FUMES
AND
GASES
can
be
hazardous.
I
Welding
produces
fumes
and
gases.
Breathing
~
these
fumes
and
gases
can
be
hazardous
to
your
health.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
Read
the
Material
Safety
Data
Sheets
(MSDS5)
and
the
manufacturers
instructions
for
metals,
consumables,
coatings,
cleaners,
and
degreasers.
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
breathing
air
is
safe.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
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.
S
S
S
S
OM-2227
Page
1
ARC
RAYS
can
bum
eyes
and
skin
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.
Wear
awelding
helmet
fitted
with
a
propershade
offilterto
protect
your
face
and
eyes
when
welding
or
watching
(see
ANSI
Z49.
1
and
Z87.1
listed
in
Safety
Standards).
Wear
approved
safety
glasses
with
side
shields
under
your
helmet.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
glare;
warn
others
not
to
watch
the
arc.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(leather
and
wool)
and
foot
protection.
WELDING
can
cause
fire
or
explosion.
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.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
If
this
is
not
possible,
tightly
cover
them
with
approved
covers.
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
keep
a
fire
extinguisher
nearby.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
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).
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.
Do
not
use
welder
to
thaw
frozen
pipes.
Remove
stick
electrode
from
holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
Remove
any
combustibles,
such
as
a
butane
lighter
or
matches,
from
your
person
before
doing
any
welding.
FLYING
METAL
can
Injure
eyes.
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.
BUILDUP
OF
GAS
can
injure
or
kill
Shut
off
shielding
gas
supply
when
not
in
use.
Always
ventilate
confined
spaces
or
use
approved
air-supplied
respirator.
HOT
PARTS
can
cause
severe
burns
Do
not
touch
hot
parts
bare
handed.
Allow
cooling
period
before
working
on
gun
or
torch.
MAGNETIC
FIELDS
can
affect
pacemakers.
Pacemaker
wearers
keep
away.
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.
Wear
approved
ear
protection
if
noise
level
is
high.
CYLINDERS
can
explode
ifdamaged.
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.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
slag,
open
flames,
sparks,
and
arcs.
Install
cylinders
in
an
upright
position
by
securing
to
a
stationary
support
or
cylinder
rack
to
prevent
falling
or
tipping.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
Never
drape
a
welding
torch
over
a
gas
cylinder.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
Never
weld
on
a
pressurized
cylinder
-
explosion
will
result.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
Read
and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
.
OM-2227
Page
2
FIRE
OR
EXPLOSION
hazard
Do
not
install
or
place
unit
on,
over,
or
near
A
combustible
surfaces.
Do
not
install
unit
near
flammables.
Do
not
overload
building
wiring
-
be
sure
power
supply
system
is
properly
sized,
rated,
and
protected
to
handle
this
unit.
FALUNG
UNIT
can
cause
injury.
Use
lifting
eye
to
lift
unit
only,
NOT
running
gear,
gas
cylinders,
or
any
other
accessories.
Use
equipment
of
adequate
capacityto
lift
and
support
unit.
If
using
lift
forks
to
move
unit,
be
sure
forks
are
long
enough
to
extend
beyond
opposite
side
of
unit.
OVERUSE
can
cause
OVERHEATING
Allow
cooling
period;
follow
rated
duty
cycle.
Reduce
current
or
reduce
duty
cycle
before
starting
to
weld
again.
Do
not
block
or
filter
airflow
to
unit.
STATIC
(ESD)
can
damage
PC
boards.
Put
on
grounded
wrist
strap
BEFORE
handling
boards
or
parts.
Use
proper
static-proof
bags
and
boxes
to
store,
move,
or
ship
PC
boards.
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive
rolls.
WELDING
WIRE
can
cause
injury.
Do
not
press
gun
trigger
until
instructed
to
do
so.
Do
not
point
gun
toward
any
part
of
the
body,
other
people,
or
any
metal
when
threading
welding
wire.
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
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
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
HF.
RADIATION
can
cause
interference.
High-frequency
(H.F.)
can
interfere
with
radio
navigation,
safety
services,
computers,
and
communications
equipment.
Have
only
qualified
persons
familiar
with
electronic
equipment
perform
this
installation.
The
user
is
responsible
for
having
a
qualified
electrician
promptly
correct
any
interference
problem
resulting
from
the
installation.
If
notified
by
the
FCC
about
interference,
stop
using
the
equipment
at
once.
Have
the
installation
regularly
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.
ARC
WELDING
can
cause
interterence.
Electromagnetic
energy
can
interfere
with
sensitive
electronic
equipment
such
as
computers
and
computer-driven
equipment
such
as
robots.
Be
sure
all
equipment
in
the
welding
area
is
electromagnetically
compatible.
To
reduce
possible
interference,
keep
weld
cables
as
short
as
possible,
close
together,
and
down
low,
such
as
on
the
floor.
Locate
welding
operation
100
meters
from
any
sensitive
elec
tronic
equipment.
Be
sure
this
welding
machine
is
installed
and
grounded
according
to
this
manual.
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.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Highway,
Suite
501,
Arlington,
VA
22202.
Code
for
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.
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
Protection,
ANSI
Standard
Z87.i,from
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
51
B,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
1-3
Additional
Symbols
For
Installation,
Operation,
And
Maintenance
MOVING
PARTS
can
cause
injury
Keep
away
from
moving
parts
such
as
fans.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
1-4
Principal
Safety
Standards
OM-2227
Page
3
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
possible.
About
Pacemakers:
Pacemaker
wearers
consult
your
doctorfirst.
If
cleared
by
your
doctor,
then
following
the
above
procedures
is
recommended.
OM-2227
Page
4
SECTION
2
-
DEFINITIONS
2-1.
General
Precautionary
Label
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
1
Electric
shock
from
welding
electrode
or
wiring
can
kill.
1.1
Wear
dry
insulating
gloves.
Do
not
touch
electrode
with
bare
hand.
Do
not
wear
wet
or
damaged
gloves.
1.2
Protect
yourself
from
electric
shock
by
insulating
yourself
from
work
and
ground.
1.3
Disconnect
input
plug
or
power
before
working
on
machine.
2
Breathing
welding
fumes
can
be
hazardous
to
your
health.
2.1
Keep
your
head
out
of
the
fumes.
2.2
Use
forced
ventilation
or
local
exhaust
to
remove
the
fumes.
2.3
Use
ventilating
fan
to
remove
fumes.
3
Welding
sparks
can
cause
explosion
or
fire.
3.1
Keep
flammables
away
from
welding.
Do
not
weld
near
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
on
drums
or
any
closed
containers.
4
Arc
rays
can
burn
eyes
and
injure
skin.
4.1
Wear
hat
and
safety
glasses.
Use
ear
protection
and
button
shirt
collar.
Use
welding
helmet
with
correct
shade
of
filter.
Wear
complete
body
protection.
5
Become
trained
and
read
the
instructions
before
working
on
the
machine
or
welding.
6
Do
not
remove
or
paint
over
(cover)
the
label.
1/96
OM-2227
Page
5
2-2.
Input
Connection
Label
1
Warning
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
2
Electric
shock
from
wiring
can
kill.
3
Disconnect
input
plug
or
power
before
working
on
machine.
4
Read
the
Owners
Manual
before
working
on
this
machine.
5
Consult
rating
label
for
input
power
requirements,
and
check
power
available
at
the
job
site
-
they
must
match.
6
Read
Owners
Manual
and
inside
labels
for
connection
points
and
procedures.
7
Move
jumper
links
as
shown
on
inside
label
to
match
voltage
at
job
site.
8
Having
a
loop
of
extra
length,
connect
grounding
conductor
first.
9
Connect
line
input
conductors
as
shown
on
inside
label
-
double-check
all
connections,
jumper
link
positions,
and
input
voltage
before
applying
power.
.
2-3.
Electric
Sh
ock
And
Airflow
Label
1
\
\
\
2
\
\
3
\
\
1
2
3
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
Electric
shock
from
wiring
and
exposed
weld
terminals
can
kill.
Close
door
before
turning
on
unit.
1/96
I
e
~
I
0
-e
S-179
563
2-4.
Nameplate
Safety
Symbols
1
Warning!
Watch
Out!
There
1
1
2
3
4
5
are
possible
hazards
as
shown
by
the
symbols.
Electric
shock
from
welding
electrode
or
wiring
can
kill.
Sparks
from
arcing
electrode
can
cause
explosion
or
fire
-
disconnect
cable
for
process
not
in
use.
Read
Owners
Manual
for
connection
procedures.
Electric
shock
from
wiring
can
kill.
3
4
6
Disconnect
input
power
before
working
on
unit
or
making
terminal
strip
connections.
Nameplate
D-1
79
389
2
OM-2227
Page
6
SECTION
3-
INSTALLATION
Welding
Voltage
Range
DC
Max
OCV
DC
Amperes
Input
at
Rated
Load
Output,
50
Hz,
Three-Phase
220
V
380
V
400
V
440
V
KVA
KW
Volts
DC,
10
-
45
Duty
Cycle
40
61
35
34
31
2.8*
1.6*
1.5*
1.4*
23.3
17.6
1.04*
0.37*
LiJ
~
~
~
<
800
700
900
600
500
400
~oo
:
:
minutes
that
unit
can
weld
at
rated
load
without
overheating.
Duty
Cycle
is
percentage
of
1(
If
unit
overheats,
thermostat(s)
opens,
output
stops,
and
cooli~
fan
runs.
Wait
fifteen
minutes
unit
to
cool.
Reduce
amperage
duty
cycle
before
welding.
I
:
o
A
Exceeding
duty
cycle
~
~
damage
unit
and
200
warranty.
100
~
10
20
30 40
50
60
70
8090100
%
DUTY
CYCLE
60%
Duty
Cycle
g~-~g~
6
Minutes
Welding
4
Minutes
Resting
Overheating
V
can
3-3.
Volt-Ampere
Curves
-J
~
Volt-ampere
curves
show
minimum
and
maximum
voltage
50
and
amperage
output
capabilities
45
between
curves
shown.
40
FC
W
30
MAX
of
unit.
Curves
of
othersettingsfall
35
~
25
20
15
10
MIN
5
0
0
50
100
150
200
250
300
350
400
450
500
DC
AMPERES
vacurvel
-
4/95
-
197
034-A
OM-2227
Page
7
3-5.
Dimensions
And
Weights
1
Lifting
Eye
2
Lifting
Forks
Use
lifting
eye
or
lifting
forks
to
move
unit.
If
using
lifting
forks,
extend
forks
beyond
opposite
side
of
unit.
3
Rating
Label
Use
rating
label
to
determine
input
power
needs.
Label
located
under
front
access
door.
4
Line
Disconnect
Device
Locate
unit
near
correct
input
power
supply.
A
Special
installation
may
be
required
where
gasoline
or
volatile
liquids
are
present
-
see
NEC
Article
511
or
CEC
Section
20.
.
Height
27-1/4
in
(692
mm)
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
3-4.
Seb
A
Location
Movement
OR
Location
And
Airflow
2
18
in
(460
mm)
18
in
(460
mm)
Ref.
800
453-A
Dimensions
D~h____
___
I
4
Holes
_____
0
1~~
-
Ref.
153
556-A
337
lb
(153
kg)
OM-2227
Page
8
3-7.
115
VAC
Receptacle
And
Circuit
Breakers
A
Turn
Off
power
before
connecting
to
receptacle.
1
ll5Vl5AACReceptacle
RC9
2
Circuit
Breaker
CB1
3
Circuit
Breaker
CB2
CB1
protects
115
volts
ac
receptacle
RC9
from
overload.
CB2
protects
DS-2
wire
drive
motor
from
overload.
Press
button
to
reset
breaker.
Ref.
800
452-B
OM-2227
Page
9
Total
Cable
(Copper)
Length
In
Weld
Circuit
Not
Exceeding
100
ft
(30
m)
Or
Less
150
ft
I
200ft
250ft
I
300ft
I
350ft
I
400ft
(45
m)
(60
m)
(70
m)
(90
m)
(105
m)
(120
m)
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
A
Turn
Off
power
before
changing
stabilizer
taps.
Remove
cover.
1
Stabilizer
Z
2
Lead
25
3
Stabilizer
Z
Center
Tap
4
Stabilizer
Z
Ending
5
Lead
26
Tapped
stabilizer
Z
is
factory
connected
to
the
stabilizer
end
tap
which
is
recommended
for
use
with
most
gas-shielded
flux
cored
wires.
Stabilizer
Z
controls
the
induc
tance
applied
to
the
weld
current.
To
decrease
inductance
for
recom
mended
use
with
most
self-
shielded
flux
cored
wires,
discon
nect
lead
26
from
stabilizer
end
tap
and
connect
to
stabilizer
center
tap
as
shown.
Reinstall
cover.
Welding
Amperes
10
-
60%
Duty
Cycle
60
-
100%
Duty
Cycle
Turn
Off
power
before
connecting
to
weld
output
terminals.
=
10
-
100%
Duty
Cycle
-ii
+
Positive
jL
Negative
Ref.
800
452-B
3-9.
Inductance
Selection
500
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-3/0
*WeId
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.
Contact
your
distributor
for
the
mm2
equivalent
weld
cable
sizes.
S-0007-E
.
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
2
+15
volts
dc
with
gun
trigger
open,
0
volts
dc
with
gun
trigger
closed.
3
Circuit
common.
4
0
to
+10
volts
dc
input
from
mm
to
max
of
Output
Command
control
Ri.
5
+10
volts
dc
output.
6
0
to
+10
volts
dc
input
from mm
to
max
of
Wire
Speed
control
R2.
7
+15
volts
dc
with
Jog
switch
S3
open,
0
volts
dc
with
switch
closed.
8
0
to
+24
volts
dc
output
to
motor
Mi
with
respect
to
socket
9.
Input
Voltage
220
380
400
440
Input
Amperes
At
Rated
Output
61
35
34
31
Max
Recommended
Standard
Fuse
Rating
In
Amperes
1
Time-Delay
2
Normal
Operating
3
70
90
40
50
40
50
35
45
Mm
Input
Conductor
Size
In
AWG/KcmiI
6
8
8
8
Max
Recommended
Input
Conductor
Length
In
Feet
(Meters)
?~1)
(99)
(120)
Mm
Grounding
Conductor
Size
In
AWG/Kcmil
8
10
10
10
Reference:
1999
National
Electrical
Code
(NEC)
1
Consult
factory
for
circuit
breaker
applications.
2
Time-Delay
fuses
are
UL
class
RK5.
3
Normal
Operating
(general
purpose
-
no
intentional
delay)
fuses
are
(JL
class
K5
(up
to
and
including
60
amp),
and
UL
class
H
(65
amp
and
above).
REMOTE
9
Socket
Socket
Information
24
volts
ac
output
for
gas
valve
control
when
triggered
or
when
purging
gas.
010
FEEDER
9
3-11.
Electrical
Service
Guide
Voltage
output
to
wire
drive
motor
Mi
with
respect
to
socket
8.
OM-2227
Page
11
3-12.
Placing
Jumper
Links
And
Connecting
Input
Power
2
220V
LTS
380
VOLTS
-
400
OLTS
IIcLYQI..TS
C
~
ofit~o
0
oflflo
~
oo
foo
c~,
Co
~
a
a
~
C
0O~0
a,>
aft~a
L~L2
~L3
~J,J
.
~L3
~
jL~
L3
L..~j
~i
~
1
Close
access
door.
L
A
Always
connect
grounding
conductor
first.
=
GND/PE
EI~1~~j~u
3/8,
1/2
in
Check
input
voltage
available
at
site.
1
Jumper
Link
Label
Check
label.
2
Jumper
Link
Move
jumper
links
to
match
input
voltage,
and
label
on
unit.
3
Input
And
Grounding
Conductors
See
Section
3-11.
4
Line
Disconnect
Device
See
Section
3-11.
801
382
Li
L2
L3
3
OM-2227
Page
12
1
Analog
Meters
Voltmeter
and
ammeter
display
actual
output
voltage
and
amperage
with
contactor
on.
2
Crater
Fill
Wire
Speed
Control
(Used
With
Crater
Fill
Mode
Only)
Scale
is
calibrated
in
meters
per
minute.
3
Crater
Fill
Voltage
Adjustment
Control
(Used
With
Crater
Fill
Mode
Only)
Turn
control
clockwise
to
increase
crater
fill
voltage.
Control
can
be
adjusted
while
welding.
4
Purge
Switch
Use
switch
to
momentarily
energize
gas
valve
SECTION
4-
OPERATION
4-1.
Welding
Power
Source
Controls
196
996-A
pendant.
At
second
trigger
closure,
welding
arc
extinguishes.
Crater
Fill/Trigger
Hold
Off
This
setting
is
normal
operation.
At
gun
trigger
closure,
unit
initiates
welding
arc
using
settings
from
weld
controls
on
wire
feeder
pendant.
At
trigger
release,
welding
arc
extinguishes.
A
Turn
Off
power
before
connecting
remote
device.
6
High
Temp
Shutdown
Light
Light
turns
on
to
indicate
an
overheated
condition
that
causes
output
to
shutdown.
to
purge
gas
lines,
or
to
adjust
gas
regulator.
5
Mode
Switch
Crater
Fill
On
At
initial
gun
trigger
closure
and
release,
unit
creates
and
sustains
a
welding
arc
using
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.
Trigger
Hold
On
At
initial
gun
trigger
closure
and
release,
unit
creates
and
sustains
a
welding
arc
using
settings
from
weld
controls
on
wire
feeder
OM-2227
Page
13
4-2.
Pendant
Controls
Controls
are
pendant
mounted.
An
optional
remote
pendant
extension
cord
is
available.
1
Nameplates
Pendant
has
three
nameplates
stacked
one
on
top
of
the
other.
Each
nameplate
contains
the
vol
tage
and
amperage
ranges
for
a
dif
ferent
size
flux
cored
welding
wire
(for
reference
only).
Unit
is
shipped
with
1.2
mm
wire
nameplate
on
top.
To
change
to
1.4
or
1.6
mm
name
plates,
see
Wire
feeder
owners
manual.
2
Voltage
Control
Use
control
to
set
welding
power
source
voltage
at
the
wire
feeder.
Numbers
are
for
reference
only.
3
Wire
Speed
Control
Use
control
to
adjust
wire
feed
speed
from
0
to
20
meters
per
minute.
l~
Match
colored
bands
on
voltage
and
wire
speed
cont
rols
to
get
an
acceptable
welding
condition.
4
Jog
Switch
Use
Jog
switch
to
momentarily
feed
welding
wire
at
speed
set
on
Wire
Speed
control
without
energizing
welding
circuit
or
shielding
gas
valve.
.
111)
4
Use
Nameplates
As
A
Voltage
And
Amperage
Reference
Only.
Ret.
802
483-A
/
199
3431199
348
/199
350
OM-2227
Page
14
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
5-1.
Routine
Maintenance
__
Trouble
Remedy
No
weld
output;
unit
completely
inoperative.
Place
line
disconnect
switch
in
On
position
(see
Section
3-12).
Check
and
replace
line
fuse(s),
if
necessary,
or
reset
circuit
breaker
(see
Section
3-12).
Check
for
proper
input
power
connections
(see
Section
3-12).
Check
for
proper
jumper
link
position
(see
Section
3-12).
No
weld
output;
Power
switch
pilot
light
on.
Check,
repair,
or
replace
feeder
(see
wire
feeder
Owners
Manual).
Unit
overheated.
Allow
unit
to
cool
with
fan
On
(see
Section
3-2).
Have
Factory
Authorized
Service
Agent
check
control
board
PCi
and/or
motor
drive
board
PC2.
Unit
provides
only
maximum
or
minimum
weld
output.
Have
Factory
Authorized
Service
Agent
check
control
board
PCi,
motor
drive
board
PC2
and
Hall
Device
HD1.
Erratic
or
improper
weld
output.
Use
proper
size
and
type
of
weld
cable
(see
Section
3-8).
Clean
and
tighten
all
weld
connections.
Check
wire
feeder
installation
according
to
Owners
Manual.
Use
proper
tap
on
stabilizer
(see
Section
3-9)
Have
Factory
Authorized
Service
Agent
check
control
board
PCi,
motor
drive
board
PC2
and/or
SCR
in
main
rectifier.
No
115
volts
ac
output
at
duplex
re-
ceptacle.
Reset
circuit
breaker
CB1
(see
Section
3-7).
Fan
not
operating.
Note:
fan
runs
only
when
cooling
is
necessary.
Check
for
and
remove
anything
blocking
fan
movement.
Have
Factory
Authorized
Service
Agent
check
fan
motor.
3
Months
A
Disconnect
power
before
maintaining.
Replace
unreadable
labels.
6
Months
Blow
out
or
vacuum
inside.
During
heavy
service,
clean
monthly
-~
Or
OM-2227
Page
15
.
Trouble
Remedy
Wire
does
not
feed,
feeder
completely
inoperative.
Check
9-pin
plug
PLG8
connections
(see
Section
3-10).
Check
input
power.
Wire
does
not
feed.
Check
circuit
breaker
CB2
on
welding
power
source,
and
reset
if
necessary
(see
Section
3-7).
Check
gun
trigger
connection
at
wire
feeder
(see
wire
feeder
owners
manual).
Check
gun
trigger
leads
and
trigger
switch.
Have
Factory
Authorized
Service
Agent
check
drive
motor,
control
board
PCi,
and
motor
board
PC2.
Wire
feeds
erratically.
Readjust
hub
tension
and
drive
roll
pressure
(see
wire
feeder
owners
manual).
Use
correct
size
drive
roll
(see
wire
feeder
owners
manual).
Clean
or
replace
dirty
or
worn
drive
roll
(see
wire
feeder
owners
manual).
Remove
weld
spatter
around
nozzle
opening.
Replace
contact
tip
or
liner.
Have
Factory
Authorized
Service
Agent
check
drive
motor
and
control
board
PCi.
Wire
feeds
when
Jog
switch
is
pressed
but
not
when
gun
trigger
is
pressed.
Check
gun
trigger
connection
at
wire
feeder
(see
wire
feeder
owners
manual).
Check
gun
trigger
leads
and
trigger
switch.
Wire
feeds
as
soon
as
power
is
applied.
Check
gun
trigger.
Wire
does
not
feed
until
trigger
is
pressed,
but
continues
to
feed
after
trigger
is
released.
Check
position
of
Mode
switch
on
welding
power
source.
This
is
normal
operation
when
switch
is
in
Crater
Fill
On
or
Trigger
Hold
On
positions
(see
Section
4-1).
Check
for
short
between
gun
trigger
leads
and
weld
cable.
Repair
or
replace
gun
trigger
leads.
Gas
valve
rattles
loudly
and
wire
feeds
slowly
or
erratically.
Check
for
short
between
gun
trigger
leads
and
weld
cable.
Repair
or
replace
gun
trigger
leads.
Gas
does
not
flow;
wire
feeds.
Check
gas
valve
and
flowmeter.
OM-2227
Page
16
SECTION
6-
ELECTRICAL
DIAGRAM
-o
0
(I,
-,
P1
I?
I
I
~
~Jo
~>--(~
~-)4
~3-)F~3-)
;--~~~--
~
000000
m
j~t;
:fl~:f!:~f~
11
~
~AAA
RCI-8>>
~(RC36
I I
I
RC1-5>>
~
-~
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r~i
I,
-
~(Rcs13
__________________________________
-
_______
Sc,
______I
~Fc,
~
-
RC3-12
~:J
<<RC3-l1
>
24
VAC
GAS
VALVE
~NTAC1OR
~-
.9
aPOJIr
~MMON
RCl-4>
RC1
-3>
RCI
2
>
>
~
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~
I
~
UT~
~
Rd-I
RCI-7)>
RC1-8>>
RC1-R>>
-~-1
~
1-~~
i~\1
RCI-1O>>-
RC31O>>~-
RdS8>>~-
RC3-2>>-
RC3-18>>~
~
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~
~x,._____!~ki
~)>~J
~.T~<
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~<RC3-7
~
~
OUTPUT
COMMRNO
~_)C~~
>~+1O
VOC
REFU~1~E
(cOMMAND
&
WFS)
~j~<4--
~
-~r7
~
~
9<RCII12
$<RCII-IO
A
RCI
1-16
<RCII-9
JOG
<601-13
~~~~_uOTOR
~<RCIO-6
POWER
Rd1UW9
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r
______
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V
i~
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A
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RCII-4>
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L
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RC1O-3>~
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Figure
6-1.
Circuit
Diagram
197
032-C
OM-223
Page
17
Hardware
is
common
and
not
available
unless
listed.
SECTION
7-
PARTS
LIST
Figure
7-1.
Main
Assembly
ST-802
606
OM-2227
Page
18
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