Miller BWC-500MAPA Owners manual

August

Effective

1975

with

serial

FORM:

No.

OM-162

HE844784

MODEL

BWC-300M
BWC-500MAPA

APA

STOCK

900

900

NO.
302
311

ADDITIONAL

PRICE

90

CENTS

COPY

MODEL/STOCK

NO.

OWNERS

MILLER

APPLETON,

SERIAL/STYLE

NO.

ELECTRIC

WISCONSIN,

CODE

NWSA

PURCHASED

DATE

MANUAL

Co.

54911

NO.

MFG.

USA

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CERTIFICATE

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EQUIPMENT:________________________

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in

TABLE

OF

CONTENTS

SECTION

SECTION

SECTION

Paragraph

-

1

-

1

-

1

-

1

2-

2-2.
2-3.
2-4.

3-1.

-

3

-

3

-

3
3-
3-

6.

3-

8.

3-

3-

9.

3-10.

No.



1

SAFETY

1.

Introduction

2.

General

Arc

3.

4.

Standards

2

General

1.

Precautions

Welding

INTRODUCTION

Receiving-Handling

Description

Safety

3

INSTALLATION

Location

2.

Electrical

3.

Secondary

Remote

4.

5.

Con

tactor

Water

Valve

7.

Shielding

External-Internal

Automatic-Manual

External

RULES

Booklet

Connections

Input

Connections

Amperage

Control

Connections

Gas

Valve

Start

Switch

FOR

Index

Control

Connections

Connections

High

Frequency

Terminal

Connections

OPERATION

Connections

Strip

OF

Selection

ARC

WELDING

POWER

SOURCE

Page

No.

1

1

3

4

5
5

5

5

5

6

7
7
7

7
7
7
8

8

SECTION

SECTION

SECTION

4

Power

4-1.

-

4

2.

Range

4.

3.

Amperage

-

4

Remote

4.

4-

Start

5.

4-

6.

High-Frequency

4-

7.

High-Frequency

4-8.

High

4-

9.

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4-10.

Post-FlowTimer

4-11.

DutyCycle

4-12.

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MAINTENANCE

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Fan

5-2.

5-3.

Transformer

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Spark

6

FUNCTION

OF

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Switch

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Amperage

Adjustment

Frequency

Control

tactor

Curve

Motor

Gap

TROUBLESHOOTING

CONTROLS

Control

Control

Switch

Intensity

Control

DelayTimer

Receptacle

Receptacle

&

Switch

9
9
9
9
9
9

9

10

10

10

10

10

12
12
12

12

Paragraph

No.

Page

No.

SECTION

PARTS

7

7-1.

General

-

2.

7

General

7-a

PowerService

7-4.

WeldingMachine

5.

7-

Welding

-

6.

7

Wiring

Grounds

7-7.

7-8.

Metal

9.

7-

Individual

Check

7-10.

LIST

CERTIFICATION

Information

Leads

The

In

Building

Installation

List

FOR

Vicinity

FREQUENCY

HIGH

Of

The

Welding

Certification

Area

ARC

WELDING

EQUIPMENT

15
15

15
15

16

16

16

16
17

17

~SECTION

i-SAFETY

RULES

FOR

OPERATION

OF

ARC

WELDING

POWER

SOURCE

1-1.

INTRODUCTION

We

experience

ful,

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ing

opment,

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never

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cover

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by

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instruction

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safety

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PRECAUTIONS

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to

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industrial

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clothing

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wear

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person

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listed

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pitted,

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workpieces

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aid

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on

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illness

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index.

through

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use

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equipment

practices.

usedormain

not

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equipment

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the

equipment

equipment

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and

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on

safety

procedures

in

the

most

and

local

installation,

shirt

avoid

to

with

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(protected

or

cutting,

energy

or

them.

ignite

facilities

for

overhead

when

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used

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enrichment

produce.

in

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NEVER

personal

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you.

weld

of

devel

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the

with

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than

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complete.

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inspection

gauntlet

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or

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ventilate

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lation

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operator

both

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fumes

the

work

wears

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if

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leaks

in

large

ously.

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will

space

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accidently

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heat

of

and

gas,

violet

chloroethylene

gene.
drawn

radiant

minute

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and

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flame,

arc,

of

compressed

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aware

cracks,

wall

or

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prevent

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equipment

electrical

(in

circuits.

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combustibles

if

work

paint

spray

work

can

away

ignition

shields.

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touching

welded

should

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watcher

tinguishing

or

ing

a

a

a.

appreciable

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appreciable

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openings

feet

combustibles

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partitions

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ensure

taken.

been

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work

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when

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be

used,

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wear

be

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with

coated

should

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surface,

air-supplied

in

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a

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quantities

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bring

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the

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DO

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into

the

energy.can

amounts

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of

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along

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parts)

practicable,

rooms,

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reach

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suitable

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within

are

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mercury,

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or

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the

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energy

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WELD

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explosion

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can

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and

explosion:

clean

of

in

are

dip

moved,

combustibles

cut).

by

combustibles

35

combustibles

sparks

combustibles

adjacent

be

ignited

should

approval

check

toxic

or

unless

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and

beryllium

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person

unless

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well

only

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oxygen

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form

to

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the

cut

where

or

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to

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materials

ventilated,

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gas
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arc

atmosphere

atmospheres

fumes.
each

or

air-supplied

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heated

area

respirator.

space

wearing

space

change

cylinders

shut

to

or

and

of

or

Prevention

combustibles

are:

hot

cylinders;

sparksorfalling

Out

35

and

metallic

area,

to

an

tanks,

move

of

sparks

and

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heat-resistant

be

standing

during

feet

or

that

vapors

or

slag

and

windows

of

sight

feet.

operable,

particles

NOT

do

free

area

storage

combustibles

and

snug-fitting,

on

opposite

ceilings,

by

for

and

(including

further

are

in

visible)

to

to

walls,

radiantorconducted

by

be obtained

that

adequate

that

area

held

combustibles,

when

container

listed

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bearing

produce

may

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the

it

is

area

is

being

exhaust

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that

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avoided.

concentration

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supply

downstream

be

decomposed

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products.

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of

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decompose

to

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solvent

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containing

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of

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reached

material;

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slag

or

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or

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sides

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time

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building

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ceilings,

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of

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heated,

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3

in

walls

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sparks,

or

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and

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well

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emit

the

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danger

space.

source.

valves

highly

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form

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where

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pass

and

through

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35

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OM-162

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metal

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be

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index.

Page

1

Page

0.

2

Secure

Passageways

where

such

nets.

This

includes:

solvent

solubility)

carbon

mended

or

dioxide,

in

substitute

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container

paragraph

to

determine

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castings

or

cutting.

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Contain

line),

flammable

Compressed

Standard

manual,

TIONS
IN

1.

Regulator

tor

downstream

more

Never

than

Remove

(first

a

Leaks

Excessive

downstream

Faulty

when
release.

Repair.

repair

special

2,

Cylinders

damage

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rails,

short

1-3C.)

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assurance

Identifying

marked

tent.

name,

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Gas

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listed

Regulators

relief

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a

regulator

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the

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hose)

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valve).

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right

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6.

Electrode

Electrode

of

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trigger

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other

7.

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devices

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wire

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power

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lock-type

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REPLACE

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power

STANDARDS

For

more

latest

their

ANSI

1.

CUTTING

Society,

2.

ANSI
TION

TION,

Institute,

American

3.

AND

COMBUSTIBLES,

NFPA

4.

FOR
National

Avenue,

NFPA

5.

CESSES,

CGA

6.
PRESSED

Compressed
York,

7.

OSHA

ING,

power

emergency,

or

equipment

all

power

information,

revisions

Standard

2501

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AND

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4-1)

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3-8.

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ac

OM-162

Page

7

I

3-9.

AUTOMATIC-MANUAL

4-1)

A

provided

circuit

AUTOMATIC-MANUAL
MANUAL
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4-

4-2.

4-3.

4-4.

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I

OM-162

Page

9

4-

4-9.

A

High-Frequency

front

quency.
increase

8.

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A

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for

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34

4-12.

10

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20

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determine

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4-11.

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the

OM-162

Page

17

August

1975

FORM:

OM162

Effective

with

serial

MODEL

BWC-300M
BWC-500MAPA

No.HF844784

APA

STOCK

900
900

NO.
302
311

MODEL/STOCK

NO.

SERIAL/STYLE

PARTS

MILLER

APPLETON,

ELECTRIC

WISCONSIN,

NO.

LIST

MFG.

USA

DATE

PURCHASED

CO.

54911

NWSA

CODE

NO.

4579

Li

S.

S

29

28-~

26-~

27~

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26

OM-1

62

Page

Front

View

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1

1

6
6

2
2

1

1
6
6

2

1 1

1 1

2
2

I

1

1 1

1 1

1

1

2 2

1

1 1

1 1

1 1
4 4
4 4

1

1 1

1

1

2

1

9

2
6

1 1

1 1

1

2

2 2

1

1

OM.162

1

1

1
1

1

1

8

10

3
2

1

8

10

3

2

1

1

1

1

1

1

1

1

1

2

1

9

2

8

1

2

1

Page

2

Quantity

Model

Item

-

No.

Dia.

Mkgs.

Factory

Part

No.

Description

3~

Amp

~

Amp

43

46

48

~age

16

TD2

17

TD3
18
18

19

20

GS1,WS1

21
22
23

23

24

F4

25
26

F1,3

27 F2

28

29

7T,8T

30

31

RC2

32

Ri

S4

33

34

RC1

35

R10,17

R7

36

37

SR3

38

R2,6

39

SR2,6,8

39

SR2,6,8

40

C8

R8,9,12

41

C4,7

42

SR5

CR3.4

5,9,10

44

CR6

45

CR1,7,8

CR2

47

1T,3T

2T,4T

3

034

701

034

712

038

853

038612
038613
024178
038

900

601

839

601

840

038847

038

900

601

839

010296

003

538

003

539

010

295

014

028

027496

015139

014

105

014

111

*012

606

*012

601

*012611

012602

412

042
038

639

038

620

100

286

035

493

019 602
030654
030

656

*030

041

011

609

039 607

030627

030

626

016 626

016 627

015099
015

100

014

114

037

616

102

363

601

242

617

030

037

568

102

363
242

601

685

000

102363

601

242

611

031

178

604

031

610

037 613

102363

242

601

034

615

034

601

034612
034607

038

601

038

602

power

(Contd)

-

115

ll5voIts

output

volts

Complete Assembly

1

TIMER,

.

TIMER,

.

minute

3

second-

TERMINAL,

TERMINAL

ASSEMBLY,

.TERMINALBOARD

.STUD,brassl/2-13x3

2-1/4

x

1/2-13

1/2-13

jam

2-1/4

1/2-13

standard

pipe

way

volts

ac

standard

pipe

-

valve

lower

volts

250

25OvoIts

volts

250

(F1-4)

plug

-

HF

panel

30

amp

block

HF

changeover

grounded

150

control

6-1/2

watt

10

current

control
control11inches

SPDT

twistlock

NUT,
NUT,

brass

brass

brass

STUD,

-

-

.BUSBAR

ELBOW,

COIL,

brass

brass

brass-
11

valve115

brass

mounting

STUD,

NUT,

VALVE,

.

ELBOW,

ANGLE,

BASE
BASE

PANEL,
DOOR,

FUSE,

FUSE,

FUSE,

front

access

plug

plug

plug

HOLDER,
BAR,

mounting

BLOCK,
LINK,
STRIP,

terminal

jumper

mounting-

RECEPTACLE,

KNOB,
SHAFT,
SHAFT,

pointer

current

current

RHEOSTAT,

SWITCH,

toggle

RECEPTACLE,

1/2-13

-

hex

-

hex

1/2-13x

-

hex

5voltsac2

-

-

front

15

amp

10

amp

3

amp

-

fuse

-

terminal

-

WW

RESISTOR,WWadjlO0watt2ohm

RESISTOR,

CONTROL
CONTROL

PANEL,

.

PANEL,

.

COVER,

.

RECTI

.

BRACKET,

..

INSULATOR,

..

RESISTOR,

.

RECTIFIER,

.

BRACKET,

. .

INSULATOR,

..

RECTIFIER,

.

BRACKET,

. .

INSULATOR,

..

CAPACITOR,

.

RESISTOR,

.

CAPACITOR,

.

RECTIFIER,

.

BRACKET,

.

.

INSULATOR,

..

RELAY,

.

RELAY,

.

RELAY,

-

RELAY,

.

BLOCK,

-

BLOCK,

.

WW

PANEL,

PANEL,

mounting-

mounting

dust-

FIER,

115

volts

24

llOvoItsdc2PDT
llOvoltddc3PDT

terminal

terminal

200

adj

master

master

components

-

components

panel

selenium

mounting-

washer

WW

adj

25

selenium

mounting

washer

selenium

mounting-

washer

electrolytic

2

carbon

watt

electrolytic

selenium

mounting-

washer

dc

30

30

ac

2PDT

DPDT

amp
amp

volts

watt

(consisting

watt

(consisting

-

(consisting

(consisting

60

cycle

60cycle

(consisting

output

power

90

degree

IPS

1/4

90

degree

solenoid

6

pole

30

amp

-

twistlock

inches

15

ohm

l25voIts

amp

3P3W

ohm

250

(consisting

(consisting

2000

100

pole

pole

of)

of)

of)

150

ohm

of)

rectifier

rectifier

rectifier

5uf

40uf250

rectifier

9

3

of)

(consisting

1/4MPT

1/8

port

1/4

3P3W

of)

of)

ohm

volts

dc

volts

orifice

MPT

dc

of)

RH

5/8-18

(consisting

LH

5/8-18

of)

1
1

2

1

1

2

2

2

2

1

2

2
1

1
1 1
1 1

2 2
1

4

1

2 2

4

1

1

1 1
1

1
1
1

2
2

1

1

1

1 1

2

2
2 2
3
2
2

1

3 3

2 2

1

2
2 2

5

1 1

3

1
2

2

1

1

2

1

2
2

4

1

2

4

2

2

1

2

2

1
1

1

4

1

4

1

1

1
1

1
1

2

2

1

1

2

2

3

2

2

1

1

2

5

3

1

2

2

48

43-

46

45~

43---!

45
43

43

37

38

39

i-

~

C

40

41

42

Right

Hand

Side

View

OM-162

Page

4

49

50

51

66

65

64

53

54



57

Page

63

61

62

60

Rear

59

View

58

5

Item

No.

Dia.

Mk~.

Factory

Part

No.

Description

Quantity

Model

300

Amp

500

Amp

49

52

53

60

61

62

63

64
65

65

49

50

51

54

55

55

56
57

58

59

Complete

R3
R3

SR7

SR4

T2

W

W

W

Z

TE2

TE3

CR19

Ti
Ti

MA3

66

MA3

66

030
030
037601

014

037640

101

036782
034679

034
033

*034

034
033

*034

022027
022516

015
036

038 697
038
038848
038850

038602
038890

601

026
038652

038

601
038

038

038620
038
601
038
038
034781
023401

039

**~fl

102263

**033

*

*033

**033

**033

**033

*

*033

*

*033

**o33

022

036
101

660

RESISTOR,

750

RESISTOR,

RECTIFIER,selenium

019

BRACKET,

RECTIFIER,selenium

943

PANEL,
TRANSFORMER,

INTERLOCK,

653

CONTACTOR,

675
662

656

045

784

COIL,

.

KIT,

.

CONTACTO

COIL,

.

KIT,

.

LINK,jumper-contactor

STRIP,jumper-contactor

102

BRACKET,

CHOKE

780

TERMINAL

849

TERMINAL

.TERMINALBOARD

.TERMINALBOARD

BLOCK,

.

STUD,

.

836

754

804
837

651

621

909
841
852
851

NUT,

.

INSULATION,

-

LINK,

-

STUD,

-

NUT,

-

LINK,

.

BLOCK,

.

LINK,

.

STUD,

.

NUT,

.

JUMPER,

-

JUMPER,

RELAY,

TRANSFORMER,

154

TRANSFORMER,

931

TRANSFORMER

-

.TRANSFORMERSUBASSEMBLY

756

757

681
680
749

750

682

994
436

781
936

COIL,

-

.COIL,

.COIL,

COIL,

-

COIL,

.

COIL,

.

COIL,

.

COIL,

-

AMPLIFIER,

AMPLIFI

ANGLE,

Assembly

WW

WW

mounting

mounting

contactor

point,

contactor

-

point

mounting

terminal

brass

-

brass

jumper

brass

brass

connecting

terminal

jumper

brass

-

brass

primary

primary

2pole

primary

primary
primary

primary

secondary
secondary
secondary-

secondary

ER,

support-

(Contd)

fixed

fixed

rectifiers
KVA2

contactor-

1

size

115

contact

2

size

R,

115

contact

ASSEMBLY,
ASSEMBLY,

30

i/4-20x

hex

jam

primary

3/8-16

hex

jam

terminal

30

-

terminal

5/8-11

hex

jam

board

board

12

amp

power-
power

SUBASSEMBLY

LH
RH

-

bottom

-

bottom

LH
RH

bottom

-

bottom

magnetic

magnetic

amplifier

50
220

watt

10

watt

rectifier

and

resistors

30-115-115-190/198

normally

4P

115

volts

volts

ac

4P

115

volts

volts

ac

-

contactor

primary

primary

3

pole

amp

with

2-1/8

1/4-20

-

stud

barrier

2-1/2

x

3/8-16

4

pole

amp

3

x

block

30

5/8-11

main

-

main

RH

top

LH

top

LH

top

RH

control

control

top

(Note

ohm

ohm

1

closed

(consisting

(consisting

terminal

and

(consisting
(consisting

collar

hex

amp

(consisting
(consisting

LH

RH

RH

of)
of)

LH

2)

of)

of)

board

of)
of)

(Note

2)

1

1

1 1

1
1
1
1 1
1
1
1

1

2

1
1

1

1

1

4

16

4

2

2

9

1

1

2 2

1

1

1

1

1

2

1
1

1

1
1

1

1

4

1

2

1

1

1
1

4

16

1

2
7

2

1

1

1

1

2

2

2
2

1

OM-162

Page

6

s~~n

r

~~~~_-

85

84

83



1

69

70

72

74

75

76

77

~

78

I,1

4

3ge

80~

7

I,

Left

Hand

Side

View

Item

No.

Dia.

Mk~.

Factory

Part

No.

Description

Quantity

Model

300

Amp

500

Amp

67

68

69

70

71
72
73 Ri
74
75

76

77

78

79

79

80
80

81

82

83
84

85

81
82

83
84

85

Ci

R13

SR9

SR1O

C9

R16

5
CR11
CR12
5T

6T
CR13

MA1,2

MA

MA2

MA2

MA1

MA1

FM

C5

C5

C5

1,2

025316

025

142

025

141

030 618

102728

016

628

016

629

014

112
113

014

014.118

037616

102

363

601

242

037

568

102

363

601

242

031

610

604178

617

030
034601

034612

038

621
038646
034615

038854

035899

002

992

**036512

0*002993

735

035

033

683

*0022

435

*0033684

014610

014

106

014602
014

771

425

014
032

605

032

606

032

616

765

016

038025

035

266.BUS

035265

608

031

038

027

015

199
015200
015

198
034

527
038025
035

266

035265

608

031

038027

198

015

201

015

015

202

034

529
038026
035266

102265

608

031

015196

015

197

Complete

Assembly

(Contd)

CAPACITOR,paperoil35uf46ovoltsac
BRACKET,
BRACKET,

RESISTOR,
BRACKET,

CONTROL
CONTROL

PANEL,

.

PANEL,

.

.COVER,

RECTIFIER,

.

BRACKET,

..

INSULATOR,

..

RECTIFIER

BRACKET,

..

INSULATOR,

..

CAPACITOR,

.

mounting
mounting

WW

mounting-start

PANEL,
PANEL,

mounting.
mounting.

dust-

selenium

mounting

(consisting

mounting

-

capacitors

-

capacitor

fixed

10

watt

start

(consisting

start

(consisting

components
components

panel

(consisting

-

rectifier

washer

of)

-

rectifier

washer

electrolytic

40

20K

control

uf

250

.RESISTOR,carbon2watti00ohm

RESISTOR,

.

RELAY,

.

RELAY,

.

BLOCK,

.

BLOCK,

.

RELAY,ll5voltsac2PDT

.

TERMINAL

.

AMPLIFIER,
AMPLIFIER,

WW

24

adj

volts

llOvoltsac2PDT

terminal

terminal

BOARD,

magnetic-

magnetic

.AMPLIFIERSUBASSEMBLY
.AMPLIFIERSUBASSEMBLY

COIL,

.

COIL,

-

COIL,

.

control
control
control

ac

ac

dc 2

dc

30

30

25

DPDT

amp
amp

2000

watt

4

pole

10

pole

mounting

main

(consisting

-

main

(consisting

components

.CO(L,controldc
PANEL,
PANEL,

rear

rear

WINDTUNNEL,l8inch

inch

1/4

20

windtunnel

HP

230

60

Hz.

60

Hz.

BANK

BOARD

volts

18

20

inch

inch

1625

ac

3

wing

3

wing

(consisting

of)

WINDTUNNEL,

BAR,

support-

MOTOR,

BLADE,
BLADE,

CAPACITOR

.MOUNTING

fan

fan

BAR

.TERMINALBOARD

uf

CAPACITOR,

STRIP,

.

ANGLE,

.

ANGLE,

.

CHANNEL,

.

CAPACITOR

MOUNTING

.

BUS

BAR

electrolytic

retaining

mounting

mounting

mounting

BANK

BOARD

250

(consisting

of)

.TERMINALBOARD

250

CAPACITOR,

STRIP,

CHANNEL,
ANGLE,

.

ANGLE,

.

CAPACITOR

.MOUNTING

electrolytic

retaining

mounting

support
support

BANK

BOARD

-

front

-

back

(consisting

uf25volts

of)

.BUSBAR

.TERMINALBOARD

250

CAPACITOR,

.

electrolytic

uf25volts

.CHANNEL,mounting

ANGLE,

.

support

ohm

panel

of)

of)(Note

of)

volts

ohm

RPM

22

degree

21

degree

25

volts

of)
of)

6

.

2 2

2

8

1

2

1
1

1)

1

1

1

1 1

1
2

1

2

2 2

1

2

2

dc

1
1

1
2

2

1
1

1

1

1

1 1
1

1

1

1

1

1

2

1

1

2

2

.

2

1

1

1

1

2

1
1

1

1

2
2
2
2

ac

65

2

1

1

2

3

2
2

2

ac

65

2
2

1

1

2

2
2

ac

30

2

OM.162

Page

8

Item

No.

Dia.

Mkgs.

Factory

Part

No.

Description

Quantity

Model

300

Amp

500

Amp

V
A
A

P1
P2
CR14
CT
CT

*

Recommended

**Rl

NOTE:

1.

Start

2.

The

opposite

Spare

at

Factory

Control

Transformer

illustrated.

as

014637

014

014636

014108

010

926

010

876
015712
010

025602
025617

025

618

025

025

034615
036611
036 612

Parts

or

Panel

(12),

Complete

Assembly

PANEL,side

107

PANEL,

side

COVER,top

COVER,top

HANGER,
HANGER,

minerallic

minerallic

GROMMET,

119

TUBING,

Optional

steel

Equipment

METER,voltac0-lOOscale

METER,ampaco-500scale

701

700

METER,

FILTER,
FILTER,

RELAY,

amp

HF

HF

ll5voltsac2PDT

TRANSFORMER,
TRANSFORMER,

Authorized

is

locatedonthe

Item

Service

No.53and

rubber

5/8

ac

dc

ac

Station.

top

the

OD

0-800

volt

amp

current
current

right

Control

(Contd)

No.

2

1

No.

lDx

5/8

x

3/32

scale

and

amp

meter

rear

corner

hole

7/8

wall

x

meter

500/5

800/5

on

Amplifier

1/16

5/8

the

(MA3),

500

groove

Ampere

Item

Model.

No.

66

2

2

1

1

1 1

4 4

2 2
3

3

1

1

1

1 1
1 1

1

the

500

on

Ampere

Model

1

1

1

1

is

the

BE

SURE

TO

PROVIDE

STOCK,

MODEL,

AND

SERIAL

NUMBERS

WHEN

ORDERING

REPLACEMENT

PARTS.

age

9