Miller Electric 500SSX User Manual

Miller
OWNERS
MANUAL
1994
Apri
Effective
With
Form:
Serial
No.
OM-168
256
cover
1/94
ST-cOO
599-H
Read
and
blocks
safety
Have
only
install,
operate,
Call
your
the
directions.
CC/DC
For
510
Requires
Overheating
Arc
follow
these
carefully.
trained
or
distributor
Gold
Welding
SMAW
Amperes,
Three-Phase,
Control
(Dig)
instructions
and
service
if
you
Power
and
GTAW
Volts
41
Protection
qualified
this
unit.
do
understand
not
'
Starfi
Source
Welding
At
35%
DC,
Hz
50/60
all
and
persons
MILLER
1994
500SSX
Duty
Power
Input
Electric
Mfg.
Cycle
Co.
Give
For
or:
Appleton,
this
help,
MILLER
manualtothe
call
WI
your
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54912
distributor
Mfg.
operator.
P.O.
Co.,
414-734-9821
Box
1079,
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away
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or
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3.
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Allow
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Do
engine
not
flames.
engine
to
cold
not
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4.
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intakes.
hazardous.
well-ventilated
engine
can
area,
checkingoradding
if
unit
smoking
before
before
people
troubleshooting
cable
loose
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beginning
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spilled,
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starting
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clothing,
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for
as
during
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and
exhaust
fuel.
is
near
possible,
job.
fuel
to
clean
up
guards
necessary.
servicing,
tools
away
areas.
outside
any
check
expand.
before
or
covers
disconnect
from
and
sparks
and add
starting
moving
I
or
for
parts.
6.
1.
2.
3.
4.
5.
Reinstall
finished
Always
Stop
engine
cables.
Do
not
Do
not
Observe
panels
and
wear
allow
use
correct
before
a
before
tools
welder
or
face
to
polarity
and
guards
starting
engine.
shield
when
disconnecting
cause
sparks
charge
(+
batteries
and
to
close
working
when
on
)
doors
when
on
or
connecting
working
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servicing
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battery.
on
start
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a
battery.
vehicles.
is
r~.
~
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.~
~
Safetyin
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and
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dent
of
Documents,
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20402.
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of
Cutting
can
Welding
550
ciety,
National
tection
Association,
Sri
9/92
STEAM
COOLANT
.
skin.
The
under
Welding
Society.
Health
Safe
Containers
Society
N.W.
LeJeune
Electrical
coolantinthe
pressure.
and
Cutting,
N.W.
550
Standards,
U.S.
Government
Practices
That
Have
Standard
Rd,
NFPA
Code,
Batterymarch
AND
can
ANSI
LeJeune
OSHA
AWS
Miami,
PRESSURIZED
burn
adiator
r
Standard
Rd,
29
for
the
Held
Hazardous
F4.1,from
FL
Standard
Park,
face,
be
can
PRINCIPAL
Z49.i,
Miami
FL
33126
CFR
1910,
Office,
Printing
Preparation
33126
American
from
70,
Quincy,
Substances,
National
MA
eyes,
h
very
from
from
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Washington,
for
Welding
Welding
02269.
HOT
and
and
ot
SAFE.:TY
American
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Fire
Pro
and
So
1.
Donotremoveradiatorcapwhenengineishot.Allowengine
cool.
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and
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gloves
pressuretoescape
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rag
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cap
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removing
STANDARDS
Safe
Handling
from
P-i,
Suite
way,
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for
Canadian
levard,
Safe
Practices
ANSI
tion,
Institute,
Cutting
Fire
Protection
Compressed
501,
Safety
Standards
Rexdale,
For
Standard
1430
Broadway,
And
Welding
of
Compressed
Gas
Welding
VA
and
Arlington,
in
Association,
Ontario,
Canada
Occupation
Z87.1,
New
Processes,
Association,
in
Gases
Association,
22202.
GSA
Cutting,
Standards
I
M9W
And
Educational
from
American
NY
NFPA
10018.
Standard
York,
Batterymarch
Cylinders,
1235
Jefferson
Standard
Sales,
R3.
EyeAnd
National
51
Park,
Quincy,
178
CGA
B,
Davis
Wi Rexdale
Face
from
MA
cap.
cap.
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High
from
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Protec
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02269.
PRECAUTIONS
SECURITE
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EN
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A
LARC
PROTEGEZ-VOUS,
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precautions.
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ii,cedernier,
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circuit
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information
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ou
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une
produit
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produits
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vapeurs
portez
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produits
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les
fumŁesetles
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peut
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sante.
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vapeurs
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nettoyage
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11.
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pas
ou
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et
irritants.
pas
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pas
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pas
le
pour
pas
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protecteurs
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plafond,unplancher,
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termŁ,
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courant
les
risques
avec
non
un
pantalon
casque.
de
et
des
plaquŁes
car
fond,
alors
nØcessaire.
extincteur
un
lautre
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prŁs
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suivre
chalumeau.
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ou
coupez
huileux,
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hautement
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piquage
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blessures.
le
et
meulage
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peuvent
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metal.
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2.
de
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vŒtements
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facialoudes
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recommandØs.
de
protection
soudure
lunettes
peut
projeter
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coques
individuelle
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laitier.
approuvØes.
appropriØs.
du
partie
procedØ
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Les
chaleur
2.
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cadre
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Assurez-vous
protecteurs
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Avant
moteur.
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3.
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Les
exploser.
Les
bouteilles
haute
pression.
exploser.
bouteilles
intense,
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Les
PEUVENT
Les nocifs.
Le
une
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Des
des
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explosion.
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plein
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blessures.
en
piŁces
des
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que
sont
personries
mains,
les
bien
de
ou
ou
portes,
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connecter
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bouteilles
les
bouteilles
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protegees
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circuit
tout
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produisent
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en
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mouvement,
courroies accrocher
les
panneaux,
qualifiees
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gaz
endommagees
font
soin.
avec
contre
de
soudage.
a
un
electrique
DES
des
gaz
causer
un
inflammable.
de
verifier
le
plein.
ou
proche
telles
peuvent
vŒtements
des
un
systŁme,
doivent
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protecteurs
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de
soudage.
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incendie
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les
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et
capots
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des
ou
les
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6.
de
louvrant.
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comprime
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amples
RØinstallez
6.
aprŁs
moteur.
tout
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que
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des
matØriels
Øtat.
pas
le
chapeau
et
aux
CGA,
le
ØnumØrŁes
mettez
et
respectez
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des
machines
ventilØes.
utilisez
vous
des
dØchappement
dair
prises
carburantouden
faites
attention
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des
du
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pour
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renversØ
des
ou
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pas elles
outils.
des
et
les
capots
travaux
laissez
plein
entre
bouteilles
les
matØriels
raccords
les
et
visage
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consignes
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devant
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le
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avant
capots
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cable
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nue.
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de
faire
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chaque
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robinet
ainsi
doivent
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bouteille
utilisation.
bouteilles
aux
Ia
que
ci-dessous.
dangereux.
des
aires
confine,
a
lextØrieur,
de
avant
du
bord
ras
carburant.
cheveux
dun
et
de
:
prØvoyez
Nettoyez
le
moteur.
systŁme
de
des
fermez
faire
dŁmarrer
electrode.
dØtendeurs,
application
Œtre
en
en
de
gaz
publication
ouvertes
faire
soudage.
le
et
les
loin
plein
de
tout
depannage
pendant
a
Ia
borne
en
piŁces
vŒtements
les
portes
le
in
Safety
Society,
Safety
and
of
Documents,
20402.
Recommended
GuthnQof
AWS
F4.i,
Miami
FL
National
Association,
srlf
9/91
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INFORMATION
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The
following
of
the
Effects
Background
Government
large
cellular
establish
produce
of
very
understanding
single
allow
risk
or
avoid
or
SECTION
is
U.S.
Congress,
of
Power
Paper,
Printing
volumeofscientific
level
and
that
low
changes
high
quality,
coherent
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to
us
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to
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-
1
SAFETY
from
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of
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OTA-BP-E-53
May
findings
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results
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yet
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conclusions
~based
Considerations
Magnetic
General
Electric
1989):
based
animals
are
us
more
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Conclusions
Assessment,
&
(Washington,
.
.
.
on
and
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complex.
to
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questionsofpossible
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TABLE
INFORMATION
About
Fields
Biological
Magnetic
there
Fields
DC:
is
now
experiments
which
people
interact
with,
of
this
most
Current
the
evidence
it
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minimize
to
Welding
Section
U.S.
a
very
the
at
clearly
and
work
is
scientific
in
a
not
yet
OF
The
And
To
reduce
magnetic
procedures:
1.
2.
3.
4.
cables
Keep
Arrange
Do
not
Keep
welding
cables
coil
practical.
5.
Connect
work
possible.
About
Pacemakers:
The
above
recommended
complete
information.
CONTENTS
Effects
fieldsinthe
close
together
to
one
or
drape
power
clamp
procedures
for
pacemaker
Low
Of
side
cables
source
to
workpiece
are
Frequency
workplace,
by
twistingortaping
and
around
and
away
cables
among
wearers.
as
the
from
body.
as
close
Consult
the
far
to
those
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the
use
them.
operator.
as
away
weld
the
also
your
modlO
And
following
as
normally
for
doctor
1
4/93
SECTION
2-1. 2-2.
SECTION
3-1.
3-2.
3-3.
3-4.
3-5.
SECTION
SECTION
5-1. 5-2. 5-3.
SECTION
SECTION
7-1.
7-2.
2
SPECIFICATIONS
Volt-Ampere
Cycle
Duty
INSTALLATION
3
Selecting
Selecting
Connecting
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4-
OPERATION
MAINTENANCE
5
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Location
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And
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14
Receptacle
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ELECTRICAL
6-
7
TUNGSTEN
Selecting
Preparing
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And
Output
Information
Power
TROUBLESHOOTING
&
DIAGRAMS
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Electrode
Moving
Weld
Terminals
Welding
Output
And
Power
Cables
Connections
Source
2 2
3
4
5
6
7
9
13
14
14
17
20
21
SECTION
Figure Figure Figure
Figure
Figure
Figure
8
8-1. 8-2. 8-3.
8-4. 8-5.
8-6.
PARTS
LIST
Main
Assembly
Panel,
Terminal
Swil:ch,
Rectifier, Panel,
Rear
Assembly,
PB
SCR
Front
w/Components
Pri
w/Components
OM.168
22
24
24 25
25
26
256
4/94
SECTION
-
1
SAFE~TY
INFORMATION
modl.1
2/93
1
!
-~_________
/
5
6
7-H
2
Read
Obey
Learn
all
all
thi?
safety
safety
meaning
messages
messages
:
not
touch
D~
SHOCK
live
input
electrical
power
ELECTRIC
Do
Disconnect
installingorservicing.
a
WARNIF~
NOTE
can
Turn
of
WARNING
kIII.~
parts.
before
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throughout
to
avoid
and
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high
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Information
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from
at
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moving
and
start
parts.
covers
of
Injure.
closed
I
1
2
WARNING
or
CAUTION
injury
Safety
Signal
serious
or
Alert
Word
means
injury
means
equipment
happen.
StatementOfHazard
3
Result
4
5
6
Read bol
7
Special
ation
InstructionsToAvoid
Safety
Hazard
Hazard
Symbol
Banner
Safety
blocks
safety
shown.
NOTE
instructions
related
not
Symbol
possible
can
happen.
possible
damage
(If
for
for
to
safety.
death
minor
can
And
Available)
each
sym
best
oper
Specifications
Of
Type
Welding
TypeOfInput
Overall
Output
Process
Max
Open-Circuit
Power
Dimensions
Amperes
Input
Rated
Weld
Output
KVAJKW
UsedAtRated
Amperage Range
Voltage
At
Rated
Output
Output
SECTION
Constant
Shielded
Volts
70
Three-Phase;
See
Figure
A
102
AAt380
59
A
At
56
AAt415
54
510
Amperes,
kVN25.6
38.8
Low:
20-270
37-510
High:
Table
2-1.
Current/Direct
Metal
Arc
DC
220,
3-2
At
220
V,
V,
400
V,
V
41
kW
A;
A
2
Welding
(SMAW)
380,
VoltsDCAt
SPECIFICATIONS
Tungsten
Volts
Duty
Cycle
Source
Description
Arc
(GTAW)
50/60
(see
Hz
Section
AC,
Currerlt
And
Or
400,
Power
(CC/DC)
Gas
415
~I5%
Welding
2-2)
Weight
Net:
Ship:
543
568
lb
lb
(246
(258
kg);
kg)
OM-168
256
Page
1
2-1.
Volt-Ampere
Curves
0
>
C.)
The
volt-ampere
minimum
and
amperage
of
the
Curvesofother
the
tween
Low
A~.
70
60
50
40
30
20
10
0
0
100
150
50
2D0
DC
250
Range
300
AMPERES
350
400
450
500
650
600
0
>
C.)
70
60
50
40
30
20
10
0
100
0
200
B.
300
High
400
DC
Range
600
AMPERES
maximum
and
output
welding
curves
600
show
curves
capabilities
power
settings
shown.
700
800
the
voltage
source.
fall
be
900
2-2.
WELDING
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LONGER
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rated
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At
shown
is
that
without
510
Figure
DUTY
below.
percentage
unit
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overheating.
Amperes
2-1.
CYCLE
of
weld
Volt-Ampere
can
damage
10
at
1200
(1)
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unit
and
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Chart
.110/91SB-084
ssbl
warranty.
850-A/SB-084
warn7.1
845-A
8/93
OM-168
Minutes
Page
~
Welding
2
ii~
3-1/2
256
6-1/2
Minutes
Figure
Resting
2-2.
Duty
Cycle
Z
DUTY
CYCLE
sbl
8/93Aol.
.2
SB-000
865-D
SECTION
3-
INSTALLATION
3-1.
Movement
Location
Selecting
£~
ELECTRIC
Do
not
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energized
power
FIRE
placing
bustible
Do
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surfaces.
Do
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heating
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not
Warranty
And
Airflow
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A
And
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touch
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parts.
conductors from
BEFORE
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damage
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of
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OR
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or
or
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near
is
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Welding
de
welding
from
com
combustible
over
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to
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I
Source
FUMES
FRESH
TILATION
Do
not
Place
supply
FALLING
serious
be
can
AIR
can
breathe
unit
only
and
proper
EQUIPMENT
hazardous;
AND
be
harmful.
fumes.
welding
where
there
ventilation.
Injury
PROP
is
a
good
can
and
equipment
LACK
ER
VEN
fresh
cause
OF
air
damage.
Use
lifting
cylinders,
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equipmentofadequate
eye
or
to
any
1
2
Use
move
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beyond
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power
4
Locate
er
lift
unit
other
Lifting Lifting
using
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Use
Line
supply.
only,
accessories.
Eye
Forks
lifting
eye
unit.
lifting
opposite
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labeltodetermine
rating
needs.
Disconnect
unit
near
NOT
running
capacity
or
lifting
forks,
sideofunit.
correct
lift
to
cwarnhil
extend
Device
input
gear,
the
forks
gas
unit.
3/93
to
forks
input
pow
in
18
~460
mm)
Figure
3-1.
Movement
And
Location
Of
Welding
4
(460
l8in
mm)
Power
ssb9.1
Source
12193-
ST-BOO
OM-168
402
I
ST-000
256
599-H
Page
3
NOTE
LI~ii~
Overall
dimensions
(A,
B,
and
C)
include
lifting
eye,
handles,
hardware,
etc.
:igure
3-2.
/
H
Overal
Front
G
Dimensions
And
Inches
I
D
~-
E
1~
F
Base
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A
B
C
D
E
F
G
H
Layout
30-1/4
22-3/4
35-3/4
1-1/2
32-3/4
1-1/8
20
7/l6Dia.
Holes
4
Millimeters
769
578
908
38
832
29
508
11
D~a.
4
Holes
ST-153
600
3-2.
Selecting
Tools
Needed:
Arid
Preparing
~
10
ft
Weld
(3m)
Output
Cables
For
Example,
Total
Length
Circuit=20
Cable
In
Weld
ft
(6
m)
1
Weld
Output
Determine
weld
circuit
cable
shortest
not
use
Terminal
lugs
work
to
and
weld
Insulated
GTAW
according
Work
onto
Use
and
clamp
Torch
Clamp
amperes. proper
Use
Do
2
Use
capacity
ing
er,
3
4
Install instructions.
5
Install
Cable
total
cable
and
maximum
Table
size.
cables
damaged
Lug
of
proper
hole
size
or
output
Electrode
to
work
cable.
length
welding
3-1toselect
possible.
cables.
amperage
for
connect
electrode
terminals.
manufacturers
hold
Holder
in
OM-168
256
Page
c,~
th6.5
3-3.
Figure
4
Selecting
And
Preparing
Weld
Output
Cables
11/92
S~0752
-
-
-
p
-~-,
-
Table
3-1.
Weld
Cable
Size*
Welding
Amperes
100
150
200
250
300
350
400
500
600
700
800
900
1000
*Weldcable
size
To
10
Duty
(AWG)
100
Cycle
4
3
3
2
1
1/0
1/0
2/0
3/0
4/0
4/0
2-2/0
2-2/0
ft
(30
60%
isbased
m)
on
60
Duty
Less
Or
Thru
2-2/0
2-2/0
2-3/0
2-3/0
either
Total
100%
Cycle
4
3
2
1
1/0
2/0
2/0
3/0
4/0
4
a
Cable
voltsorless
(Copper)
150ff
m)
(45
4
2
1
1/0
2/0
3/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
2-4/0
or
drop
Length
I
(60
current
a
200ft
3
1
1/0
2/0
3/0
4/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
3-3/0
3-3/0
In
Weld
m)
10
density
Circuit
I
250ff
(70
Thru
1/0
2/0
3/0
4/0
2-210
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
4-3/0
ofatleast
Not
Exceeding
1/0
3/0
4/0
I
400ft
1/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
3-3/0
3-4/0
4-4/0
4-4/0
5-0007-c
I
300ff
m)
100%
2
300
(90
Duty
210
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
4-4/0
4-4/0
circular
m)
Cycle
1
mils
I
350ff
(105_m)_j~120_m)
2-2/0
2-3/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
4-4/0
4-4/0
per
ampere.
3-3.
Connecting
4A
LECTRIC
E
Do
not
S
Turn
Off
Tools
Needed:
To
Weld
Output
Terminals
~JVARNING
SHOCK
touch
welding
electrical
live
power
can
source,
kill.
parts.
and
1
disconnect
input
2:
power
before
making
any
weld
output
Turn door.
1
2
For
connect
terminal
to
For
reverse
Close
connections.
screw
Positive
minal
Negative
Electrode
work
and
positive
(+)
Electrode
cable
door.
and
open
Weld
(+)
Weld
(-)
Positive
cable
electrode
terminal.
Negative
connections.
swarnl2.1
lower
Output
Output
to
negative
holder
2193
access
Ter
(DCEP),
()
cable
(DCEN),
~==~
3/4in
Figure
3-4.
Weld
Oiitput
Connections
OM-168
Rel.
ST-155
256
048-A
Page
5
3-4.
Remote
14
Receptacle
Information
And
Connections
1
Remote
(See
2
Keyway
3
Plug
4
Threaded
To
connect
keyway,
threaded
14
Table
to
insert
collar.
Receptacle
3-2)
Collar
receptacle,
and
plug,
Rd
align
tighten
*The
A
AMPERAGE
remaining
REMOTE
OUTPUT
(CONTACTOR)
sockets
are
~
OR
3
>
12193
sbl.1
Remote
3-2.
24
Contact
+10
Remote
0
3-5.
Remote
volts
volts
+10
to
ac.
closuretoA
dc
control
volts
Figure
Table
14
used.
not
Socket*
A
B
C
D
E
14
output
ciircuit
do
input
14
Socket
Socket
completes
remote
to
common.
command
Connections
Information
Information
24
volts
control.
signal
ac
from
contactor
remote
ST-coo
Ret.
control
control.
599-H
circuit.
/
Ret.
5-0004-A
/
5-0750
OM-168
256
Page
6
3-5.
Connecting
Input
Power
WARNING
A.
Positioning
ELECTRIC
Do
not
Off
Turn
Have
Installation
Jumper
1
touch
welding
only
SHOCK
live
electrical
power
qualified
must
persons
meet
Links
kill.
can
parts.
source,
install
National
and
disconnect
unit.
Electrical
Code
input
and
all
power
other
before
inspectingorinstalling.
codes
Jumper
ferent
input
for
set
ry
Check
input
site.
Remove
check
jumper
1
Input
Look
at
link
position
2
Input
3
Input
links
Move
For
example,
tion
when
available.
Reinstall
to
on
Figure
links
allow
voltages
the
highest
and
top
Voltage
jumper
with
Terminal
Voltage
to
220
top
3-7.
operation
voltage
right
links.
Label
links
unit
Board
Jumper
match
220
use
volts
and
side
swam3.1
and
are
input
available
side
and
label.
input
volts
input
panel
2/93
dif
on
facto
voltage.
at
to
panel
compare
Links
voltage.
posi
power
or
go
is
~oo~
~L1
Tools
cIJ===~u
220
'L2
~oo~
Needed:
VOLTS
'L3
~
~
3/Biii
3/8
0
I
VOLTS
380
oo~Oo
in
oo~oo
~L~
~
'L3
oo~oo~
~j
ooO~O
'L~
400
~
VOLTS
ooo~o
~L3
\
OOO~~1
o~ooo
'L1
415
'L2
ssb5.1
VOLTS
o~ooo
0L3
2/92
Ref.
O~OOo
S-134
5T.094
559-A
762-E
Figure
3-6.
Input
Voltage
Jumper
Links
Location
OM-168
256
Page
7
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