Miller PARALLEL BOX Owners manual

OWNER’S MANUAL

For Paralleling Control

1. Safety Symbol Definitions

OMĆ201 344

March 2001

Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.

Beware of electric shock from wiring. Keep all panels
and covers closed.

Welding sparks can cause fire or explosion. Move
flammables away. Do not weld on closed tanks or
barrels – they can explode. Clean tanks or barrels
properly.

Wear safety glasses with side shields. Static electricity can damage parts on circuit boards. Put

2. Specifications

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.

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.

Arc rays can burn eyes and skin – wear face protection
(helmet or face shield) with correct shade of filter, and
cover exposed skin with nonflammable clothing.

on grounded wrist strap before touching circuit board.

Allows Easy Connection Of Two Welding Power Sources For Increased Amperage Applications

Welding Power Source Must Have Full Remote 14 Capability

802 737

Uses 24 volts AC, 60 Hz Input Power Supplied Through Master 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)

3. Setting DIP Switch S1

Turn Off welding power sources.
Remove control cover.
1 DIP Switch S1
2 DIP Switch Settings
Place switches in positions shown

for the type of slave welding power
source you are using.

. For DIP switch settings for weld-

ing power sources not listed,
see Section 4.

Install cover or proceed to Section 4.

Summit Arc

5678

4

23

Dimension/

Dimension 1000

OFF

1

5678

OFF

23

1

4

Goldstar 652

5678

4

23

OFF

1

Dimension/

Goldstar 452

5678

4

23

OFF

1

2

1

Ref. 802 741

OM-201 344 Page 2

4. Fine Tuning Adjustment Procedure For Better Load Sharing (Optional)

Summit Arc

5678

4

2

23

Other Machines
Than Those Listed

23

5678

1

4

4

OFF

Turn Off welding power sources.
Remove cover.
1P2
2 DIP Switch S1
3 DIP Switch Settings For Units

Listed

If you are using this parallel control
with a Summit Arc, Dimension 1000,
Dimension 452 or 652, or Gold Star
452 or 652, set DIP switch(s) as

Dimension 1000

Dimension/

Goldstar 452 Or 652

shown, and adjust P2 to match the

OFF

1

5678

OFF

23

1

4

5678

OFF

23

1

4

slave machine current output to that
of the master machine.

4 DIP Switch Settings For Ma-

chines Not Listed Above

3

1

If you are using this parallel control
with a machine not listed, set DIP
switch as shown, and adjust P2 to
match the slave machine current
output to that of the master machine.

Install cover.

5. Mounting Control On Welding Power Source

1

2

Ref. 802 741

Turn Off welding power source.
1 Welding Power Source
2 Paralleling Control
Control can be mounted on top or

on right side of welding power
source.

To secure control, loosen sheet
metal screw at desired location.
Place control center mounting hole
over screw as shown. Tighten
screw.

802 738

OM-201 344 Page 3

6. Connecting Control Cords To Welding Power Sources

1

4

2

6

From remote

3

control device.

Turn off welding power sources.
Make connections as shown.
1 Master Welding Power Source
2 Paralleling Control
3 Interconnecting Cable And 14-Pin

Plug PLG4

This is the larger diameter of the two inter­connecting cables.

4 Slave Welding Power Source
5 Interconnecting Cable And 14-Pin

Plug PLG5
6 Remote 14 Receptacle
A remote control device must be used to

control the welding power sources contac­tor and output.

The Output Contactor control and Output
Adjustment control switches on the weld-

7. Welding Power Source Output Connections

1

+

CC+CV

6

7

2

–

3

8

++

CC CV

5

ing power sources must be placed in the
Remote position.

Connect plug from remote control device
to receptacle as follows: align keyway, i n­sert plug, and tighten threaded collar.

See Section 7 for socket information if re­mote control device plug does not match
receptacle.

Turn off welding power sources.

Y Do not use different polari-

ties at the same time on a
common workpiece when
more than one welding pow­er source is used.

1 Master Welding Power

Source
2 Paralleling Control
3 Slave Welding Power Source
4 Negative Weld Output Cables
5 Paralleled Negative Weld

Output Cable
6 Positive Weld Output Cables

–

4

5

. The master welding power

source can be in the CC or CV

mode, depending on the par-

ticular application. The slave

welding power source must be

in the CC mode since it will be

duplicating the current put out

by the master power source.

7 Paralleled Positive Weld

Output Cable
Paralleled weld output cables need

to be sized for the largest amount
of weld output available from the
paralleled welding power sources.
See Section 9.

8 Remote 14 Receptacle
Connect remote control device to

Remote 14 receptacle.

802 739

OM-201 344 Page 4

. Be sure paralleled weld cables are connected

postive-to-positve and negative-to-negative.

802 740

8. Remote 14 Receptacle RC3 Information

Socket Information

A 24 volts ac from master welding power source.

24 VOLTS AC

REMOTE OUTPUT CONTROL

115 VOLTS AC

GND

B Contact closure to A completes 24 volts ac contactor control circuit.
C Command reference from master welding power source.
D Remote control circuit common.

E 0 to +10 volts dc input command signal from remote control.

F Total current feedback of master and slave machines, 1 volt per 200 am-

H Voltage feedback; 1 volt per 10 arc volts.

I 115 volts, 60 Hz ac from master machine.
J Contact closure to I completes 115 volts ac contactor control circuit.
K

G

peres.

Chassis common.
Circuit common for 24 and 115 volts ac circuits.

9. Weld Cable Size*

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less

Welding

Amperes

100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 3/0 4/0 4/0
250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0
400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0
500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0
600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0
700 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0 4-4/0
800 4/0 2-2/0 2-3/0 2-4/0 3-4/0 3-4/0 4-4/0 4-4/0

900 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 4-4/0 4-4/0
1000 2-2/0 2-3/0 2-4/0 3-3/0 4-3/0 4-4/0
1250 2-3/0 2-4/0 3-3/0 4-3/0 4-4/0
1500 2-4/0 3-3/0 3-4/0 4-4/0

*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of not more than 300 circular mils per ampere. Contact your
distributor for the mm

10 To 60%

Duty Cycle

2

equivalent weld cable sizes.

60 Thru 100%

Duty Cycle

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

10 Thru 100% Duty Cycle

350 ft

(105 m)

400 ft

(120 m)

OM-201 344 Page 5

10. Circuit Diagram

201 330

OM-201 344 Page 6

11.Parts List

5

4

3

2

1

6

7

8

10

9

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

1 200 874 COVER, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 PLG1 201 331 PLUG ASSY, elect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 PC1 200 433 CIRCUIT CARD ASSY, parallel box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 115 440 STAND-OFF, no 6-32 x .687 lg .250 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 200 873 CASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 RC3 134 735 CONN, circ ms/cpc 14 skt size 20 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 019 663 MOUNT, nprn 15/16 OD x 3/8 rec 3/16 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 010 916 CONN, clamp cable .750 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 PLG5 201 266 CABLE, interconnecting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 PLG4 201 265 CABLE, interconnecting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

802 741

OM-201 344 Page 7

OM-201 344 Page 8