Miller Electric 500SSX User Manual

Miller

OWNERS

MANUAL

1994

Apri

Effective

With

Form:

Serial

No.

OM-168

KE600689

256

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2-1. 2-2.

SECTION

3-1.

3-2.

3-3.

3-4.

3-5.

SECTION

5-1. 5-2. 5-3.

SECTION

7-1.

7-2.

2

SPECIFICATIONS

Volt-Ampere

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2 2

3

4

5

6

7

9

13

14

17

20

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PARTS

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Main

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PB

SCR

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OM.168

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568

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kg)

OM-168

256

Page

1

2-1.

Volt-Ampere

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screw

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Page

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3-4.

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5-0004-A

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5-0750

OM-168

256

Page

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3-5.

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OM-168

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OM-168

256

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OM-168

ST-000

256

599-H

Page

13

5-2.

Overload

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OM-168

256

Page

15

NOTES

OM-168

256

Page

16

SIECTION

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>

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OM-168

SC-137

256

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Page

17

GND.

OM-168

256

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Figure

18

6-2.

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70-150

125-225

225-360

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25-85

50-160

135-235

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400-500

500-750

750-1000

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PARTS.

OM-168

256

Page

27

Miller

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ELECTRICAL

6-

7

TUNGSTEN

Selecting

Preparing

Tungsten

And

Output

Information

Power

&

TROUBLESHOOTING

DIAGRAMS

ELECTRODE

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

Switch,

Rear

Assembly,

PB

Rectifier,

Panel,

Front

w/Components

SCR

w/Components

Pri

OM-168256-4/94

-

1

SECTION



Read

all

safety

messages



Obey

Learn

all

the

safety

meaning

messagos

of

WARNING

throughout

avoid

to

SAFEETY

this

injury.

CAUTION.

and

manual.

INFORMATION

modl.1

2/93

-

1

~

5

6

2 2

t~!~!f~

;i~ii~ieiI

ELECTRIC



Do



Disconnect

instsiling

a

WA~~

NOTE

not

touci

~

SHOCK

live

input

or

servicing.

~

can

electctdai

power

Turn

~

kill

pacts.

betorejj_4

Off

switch

when

Figure

SECTION

3

CAU

READ

Section

using

1

2

tlI1~~U

MOVING



Keep



Keep

w~

SAFETY

high

-1.

-

BLOCKS

3-1

before

frequency.

Safety

Information

SPECIFICATIONS

-

PARTS

from

away

moving

all

panels

at

and

start

proceeding.

can

covers

injure.

pacts

closed

of

1

I

1

Safety

2

SignaJ

WARNING

serious

or

CAUTION

or

injury

happen.

3

Statement

Result

4

Safety

Hazard

5

Hazard

6

Safety

Read

safety

bol

shown.

7

NOTE

Special



ation

Alert

Symbol

Word

means

possible

can

injury

means

equipment

InstructionsToAvoid

Symbol

Banner

instructions

Of

blocks

happen.

possible

damage

Hazard

(if

for

to

safety.

death

minor

can

And

Available)

each

sym

best

oper

Of

Type

Welding

Max

Open-Circuit

Of

Type

Overall

Amperes

Input

Rated

Weld

KVA/KW

Amperage

Weight

Specifications

Output

Process

Voltage

Power

Input

Dimensions

Rated

At

Output

UsedAtRated

Range

Output

Table

Constant

Shielded

70

Volts

DC

Current/Direct

Metal

Three-Phase;

See

102

59AAt380V,

A

56

54AAt

510

38.8

Low:

High:

Net:

Ship:

3-2

Figure

A

At

220

At

400

415

Amperes,

kVAI25.6

-

20

270

37-510

543

lb

(246

568

lb

V,

V

2-1.

220,

V,

41

kW

A;

A

(258

Arc

Volts

kg);

kg)

Welding

Current

(SMAW)

380,

400,

DC

At

Aid

or

35%

Power

(CC/DC)

Gas

Tungsten

Volts

415

Duty

Source

Description

Arc

50/60

AC,

Cycle

(see

-

(GTAW)

Hz

Section

Welding

2-2)

OM-168

256

Page

1

2-1.

Volt-Ampere

Curves

The

volt-ampere

amperage

the

welding

of

the

Range

500

and

other

curves

600

maximum

output

minimum

and of

Curves

tween

200

B.

300

High

400

DC

AMPERES

A.

Low

Range

70

60

40

0

>

30

C)

a

20

10

0

0 60

100

150

200

DC

250

300

AMPERES

350

400

450

500 550

600

60

40

30

C)

a

20

10

0

100

curves

capabilities

power

settings

shown.

700

800

show

voltage

source.

fall

900

the

be

2-2.

WELDING



Do

Duty

weld

not

Minutes

Cycle

4A

LONGER

rated

at

0

load

10

35%

CAUTION

THAN

Duty

longer

Definition

Duty

minutes rated

Cycle

RATED

than

shown

Cycle

that

load

At

510

DUTY

below.

is

percentage

unit

without

Amperes

Figure

2-1.

CYCLE

of

10

weld

can

at

overheating.

Volt-Ampere

can

damage

1200

Ui

uJ

0.

9

Ui

Curves

unit

I00

400

300

and

void

Chart

ssbl.1

10/91

warranty.

SB-084

850-A/SB-084

wam7.1

845-A

8/93

OM-168

3-1/2

256

Minutes

Page

welding

2

6-1/2

Minutes

Figure

Resting

2-2.

Duty

0

Cycle

30

20

DUTY

z

CYCLE

-

Ref.

.2

8/93

sbl

SB-000

865-D

SECTION

3-

INSTALLATION

3-1.

Movement

Location

Selecting

A

ELECTRIC



Do

not



Disconnect

energized

power

FIRE

O~R

placing

bustible



Do

not

surfaces.



Do

not

BLOCK:ED

heating



Do

not

Warranty

And

Airflow

Location

WARNING

SHOCK

touch

bource.

unit

surfaces.

locate

~nstall

and

Dlock

i:s

void

electrical

live

input

supply

EXPLOSION

on,

unit

near

AIRFLOW

possible

filter

or

if

any

power

line

over,

on,

airflow.

type

And

kill.

can

parts.

conductors

BEFORE

can

or

over,

flammables

causes

damage

of

filter

OR

_______________________________________

Moving

from

moving

result

near

combustible

near

unit.

to

is

used.

Welding

do-

welding

from

com

over

Power

Source

FUMES FRESH

TILATION



Do

not



Place

supply

FALLING

serious

damage.



Use

lifting

cylinders,



Use

equipment

2

-

be

can

AIR

can

breathe

welding

unit

only

and

proper

EQUIPMENT

personal

to

eye

or

any

of

1

2

Use

move

If

beyond

3

Use

power

4

Locate

er

hazardous;

AND

be

harmful.

fumes.

where

there

ventilation.

Injury

lift

unit

only,

other

accessories.

adequate

Ufting

Eye

Forks

Ufting

lifting

unit.

using

lifting

opposite

Rating

label

rating

needs.

Une

Disconnect

unit

supply.

PROPER

is

and

NOT

capacity

or

eye

forks,

side

Label

to

correct

near

LACK

fresh

a

good

can

cause

equipment

running

gear,

lift

to

the

Swamll.l

forks

lifting

extend

of

unit.

determine

Device

input

OF

VEN

air

gas

unit.

3/93

to

forks

Input

pow

in

18

mm)

(460

FIgure

3-1.

Movement

And

LocatIon

Of

Welding

4

(460

18

in

mm)

Power

ssb9.1

Source

12/93

-

5T-800

402

OM-168

/

ST~o00

256

599-H

Page

3

NOTE

~

Overall

dimensions

(A,

B,

and

C)

include

lifting

eye,

handles,

hardware,

etc.

Figure

3-2.



0

Overall

Dim

Front

G

ensions

~

~-

And

Inches

30-1/4

A

B



r-

F

Base

Mounting

Hol

e

22-3/4

C

35-3/4

D

E

32-3/4

F

G

H

7I16Dia.

4

Layout

1-1/2

1-1/8

20

Holes

Millimeters

769

578

908

38

832

29

508

11

Dia.

4

Holes

ST-153

3-2.

Selecting

Needed:

Tools

And

Preparing

Weld

Output

Cables



For

Length

Circuit

Example,

Total

=20

Cable

In

Weld

ft

(6

m)

1

Weld

Output

Determine weld

circuit

cable

shortest

not

use

Terminal

lugs

and

work

to

and

weld

Insulated

GTAW

according

Work

onto

Use

clamp

Clamp

amperes. proper

Use

Do

2

Use

capacity

ing

er,

3

4

Install

instructions.

5

Install

Cable

cable

total

maximum

and

Table

size.

cables

damaged

Lug

of

proper

size

hole

or

output

Electrode

Torch

to

cable.

work

length

welding

3-1

select

to

possible.

cables.

amperage

for

connect

electrode

terminals.

manufacturers

hold

Holder

in

OM-168

256

Page

z=~

3-3.

Figure

4

Selecting

And

Preparing

Weld

Output

Cables

sD6.5

11192



S-0752

100

10To60%

Duty

Cyclie

ft

(30

m)

Or

60

Duty

Thru

Total

Less

Cycle

100%

Table

Cable

3-1.

(Copper)

150ft

(45

m)

Weld

Length

I

Cable

200ft

(60

m)

In

Slze*

Weld

I

J

10

Circuit

250ft

(70

Thru

m)

100%

Not

Exceeding

I

300ft

(90

Duty

m)

Cycle

I

350ft

(105

m)

I

40Qft

(120

m)

Weld

3-3.

cable

size

(AWG)

Connecting

4

3

2

1

1/0

2/0

3/0

4/0

2-2/0

is

b

asedoneither

To

Weld

4

3

2

1

1/0

2/0

3/0

4/0

2-2/0

2-3/0

4

volts

a

Output

4

2

1

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

less

or

drop

Terminals

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

3-3/0

3-4/0

4-4/0

circular

1

mils

3

1

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

3-3/0

current

or

a

density

2

-

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

3-3/0

3-4/0

4-3/0

ofatleast

300

per

1/0

3/0

4/0

2-2/0

2-3/0

2-4/0

3-3/0

3-4/0

4-4/0

ampere.

1/0

3/0

4/0

2-2/0

2-3/0

2-4/0

3-3/0

3-4/0

4-4/0

S-0007-D

~==~

Tools

E

LECTRIC



Needed:

~3/4in

Do

Turn

~JVARNING

I

not

Off

SHOCK

touch

welding

live

electrical

power

can

source,

kill.

parts.

and

1

NJ

Positive

Rout

al/cables

o

disconnect

Negative

under

inpuI~

bar.

2

power

before

making

any

weld

output

Turn

door.

1

2

For

connect

terminal

to

For

reverse

Close

connections.

screw

Positive

minal

Negative

Terminal

Electrode

work

and

(+)

positive

Electrode

cable

door.

and

open

Weld

(+)

Weld

()

Positive

cable

electrode

terminal.

Negative

connections.

swaml2.1

lower

Output

to

negative

holder

Ref.

ST-155

2/93

access

Ter

(DCEP),

()

cable

(DCEN),

048-A

Figure

3-4.

Weld

Output

Connections

OM-168

256

Page

5

3-4.

Remote

14

Receptacle

Information

And

Connections

2

1

2

Keyway

3

Plug

4

Threaded

To

connect

keyway,

threaded

Remote

(See

14

Table

to

insert

collar.

Receptacle

3-2)

Collar

receptacle,

and

plug,

Rd

align

tighten

The

remaining

A

REMOTE

ouTpuT

(CONTACTOR)

AMPERAGE

sockets

are

.-



OR

Table

14

not

used.

Socket*

Figure

A

B

C

0

E

3

3-2.

24

Contact

+10

Remote

0

to

3-5.

Remote

-

volts

+10

Remote

ac.

closure

dc

output

control

volts

14

to

circuit

dc

14

Socket

A

completes

to

remote

common.

command

input

Connections

Information

information

24

volts

control.

signal

sb7.1

-

ac

from

12/93

contactor

remote

-

Ref.

ST-000

control

control.

599-H

circuit.

Ref.

/

S0004-A/S-0750

OM-168

256

Page

6

3-5.

Connectin~i

I

ELECTRIC



Do

touch

not



Off

Turn



Have



Installation

welding

only

Input

Power

WARNING

SHOCK

live

electrical

power

qualified

must

persons

meet

National

can

source,

kill.

parts.

install

Electrical

and

unit.

disconnect

Code

input

and

all

power

other

before

codes.

inspecting

or

installing.

swam3.1

2/93

A.

Positioning

Jumper

Links

input

for

the

input

top

jumper

Voltage

at

jumper

Terminal

Voltage

links

220

top

Figure

allow

operation

voltages

highest

voltage

and

right

links.

Label

links

with

unit

Board

Jumper

match

to

220

use

volts

and

side

3-7.

and

input

available

side

and

label.

input

Jumperlinks

ferent

set

ry

2

Check site.

Remove

check

1

Input

Look link

position

2

Input

3

Input

Move For

example,

when

tion

available.

Reinstall

to

on

are

voltage.

panel

compare

Links

voltage.

volts

power

panel

on

facto

posi

or

dif

at

to

is

go

~oo~

'Li

C~~J1J

220

~oo~

'L2~L3

Tools

VOLTS

Needed:

~3/8in

t~oo~

3/8

in

oo~oo

'L.f

Figure

380

3-6.

VOLTS

oo~OO

2~3

Input

oo~oo

Voltage

ooo~o

~1

Jumper

400

ooo~o

'L~L3

Links

VOLTS

\

~

Location

o~ooo

I

~Li

VOLTS

415

o~ooo

'L2'L3

2192Ref.

ssbs.r

OM-168

o~ooo

S-134

ST-094

256

559-A

782-E

Page

7

B.

Connecting

Input

Power

Tools

-

Needed:

3/8

in

3/8

Have

this

1

2

3

Select

Table

comply

local

properamperage

rect

4

Insert

relief.

5

6

7

Connect

ground

input

8

Install conductor

conduit

gized

Connect

then

Be

to

an

Reinstall

9

Select

Table

in

line

connect

qualified

only

installation.

Disconnect

Line

Proper

Rating

Conductors

Input

Grounding

size

Conductor

3-3.

with

electrical

hole

size.

Relief

Strain

conductors

Terminal

Input

Line

Terminals

grounding

terminal

conductors

and

or

equivalent

line

disconnect

grounding

line

input

grounding

earth

ground.

side

type

Install

3-3.

switch

Power

Terminal

ssba4

Welding

Ground

Disconnect Terminal

sure

Overcurrent

disconnect

persons

Conductor

and

national,

codes.

capacity

Connector

through

Board

Source

first.

line

to

Device

connect

input

conductor

conductors.

conductor

panel.

Protection

and

into

device

shown).

1)94-ST-094

make

Device

Of

length

Then

conductors

rating

state,

Use

lugs

and

conductor

connect

terminals.

Ground

grounding

to

deener

device.

using

must

and

cor

strain

first,

goes

size

using

deenergized

(fused

dis

762-E

of

to

in

Input

Voltage

Input

Amperes

Recommended

Breaker

Conductor

Input

Max

Input

Grounding

These

values

1

Recommended

fuse

allows

2

conductor

Input

31

(Table

Maximum

3

210-19(a)

4

The

grounding

than

input

OM-168

256

Rating

Conductor

are

circuit

or

of

0-16

length

21

and

conductor

Page

At

Rated

Standard

In

Amperes

In

Size

Length

Size

calculated

fuseorcircuit

breaker

sizeisfor

insulated

NEC).

is

to

prevent

5-2(b)ofNEC).

shall

(Article

8

Table

Output

Fuse

Or

Circuit

AWGJKcmiI2

in

Feet

In

AWG/KcmII4

the

from

breaker

sizing

250-95

1993

sizeisthat

200%ofrated

to

up

wire

copper

3%

than

more

be

a

coloredoridentified

of

NEC).

Figure

3-7.

Electrical

3-3.

(MM2)

(Meters)3

(MM2)

editionofthe

closestto150%ofrated

with

voltage

input

75C

drop

as

specified

National

rating

between

Input

130(140)

Electrical

amperage.

with

in

the

Power

Service

220

102

150

4(19)

6(13)

input

not

more

service

NEC.

Connections

Requirements*

380

59

90

8(8)

172(52)

8(8)

Code

(NEC).

of

single

and

input

conductor

the

amperage

three

than

entrance

Grounding

400

56

80

8(8)

190(58)

8(8)

power

for

the

of

copper

source.

conductors

welding

current-carrying

terminals

size

wire

Article

power

is

not

205(62)

630-12(a)

inacable

source

required

415

54

80

8(8)

or

raceway

(Articles

to

be

Ret.

of

NEC

larger

S-0092-G

SECTION

WARNING

4-

OPERATION

ELECTRIC



Always



Insulate



Do

not



Keep

FUMES

to

your



Keep



VentilatEl



Read manufacturers

WELDING



Do

not



Watch



Do

not



Do

not



Allow

wear

yourself

touch

all

panels

AND

health.

head

your

area,

Material

can

weld

for

fire;

locate

weld

work

and

SHOCK

insulating

dry

from

electrical

live

and

GASES

out

or

use

Safety

instructions

cause

flammable

near

keep

unit

over

closed

on

equipment

kill.

can

gloves.

work

and

ground.

parts.

covers

securelyinplace

be

can

of

the

fumes.

Sheets

for

fire

material.

device.

material

or

breathing

Data

extinguisher

combustible

containers.

cool

to

~

hazardous

(MSDS5)

used.

explosion.

nearby.

surfaces.

before

handling.

iiii~

and

~

:~r~

.~

4

,~,

,f

ARC

RAYS

NOISE



-



MOVING



.

can

Wear

welding

Wear

correct

PARTS

Keep

and

from

away

all

doors,

securelyinplace.

MAGNETIC



RENTS



See

sic

Pacemaker Wearers

near

arc

tions.

Safety

welding

7

can

wearers

should

welding,

Precautions

safety

burn

can

damage

with

helmet

and

ear,

eye,

can

moving

panels,

FIELDS

affect

pacemaker

keep

consult

gouging,

at

beginning

information.

1

Range

2

Polarity

3

Voltmeter

4

Ammeter

5

Amperage

6

Power

Pilot

7

8

Output/Contactor

9

Amperage

Control

10

Arc

eyes

hearing.

correct

body

protection.

cause

parts.

and

covers,

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away.

their

doctor

or

spot

of

Switch

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Adjustment

Push

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Light

Control

and

skin;

of

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filter.

injury.

closed

guards

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CUR

operation.

before

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opera

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manual

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ba

~

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4-1.

Figure

1

2 3

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/

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1

2

3

the

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1

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Equipment

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to

close

wire

metalatweld

hammer

welding.

work

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weld

brush

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to

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slag

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to

Figure

4-3.

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OM-168

256

Page

9

AA

WARNING

ELECTRIC



Do

not



Do

not



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not

touch touch

touch

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live

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weld

electrode

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clamp

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1

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4-4.

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same

is

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time

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1

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ling

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to

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output,

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perage

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at

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at

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short-circuit

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position

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of

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place

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257

ST-168

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start

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appli

control

welding.

an

in

OM-168

256

Page

4-5.

Arc

Figure

10

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A

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control

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the

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amperage

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unit,

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tan

S-0769

motor,

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4-7.

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OM-168

256

Page

11

LA

WARNING

ARCING



Do

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damage

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1

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weld

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essarily

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poor

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OM-168

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256

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Figure

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Maintenance

Schedule

OM-168

ST-000

256

599-H

Page

13

5-2.

Overload

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5-3.

When

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4~

ELECTRIC

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and

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15

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OM-168

256

Trouble

output;

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unit

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j.

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fifteen

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push

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tighten

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remote

ohmmeter,

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fuse(s),

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connections.

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jumper

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button

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all

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board

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connections.

switch

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if

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the

position.

replace

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in

the

RC1.

for

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if

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of

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____________________________________________________

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____________________________________________________

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for

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for

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for

proper

for

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fan

for

fan

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type

input

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size

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electrode.

connections.

link

positions.

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7

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256

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15

Page

Increase

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ing

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OM-168

NOTES

OM-168

256

Page

16

SECTION

w

>

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(0

0 0~

6-

ELECTRICAL

DIAGRAMS

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SC-137

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68

256

Page

17

OM-168

256

Page

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Figure

16

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9

0

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clean

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gloves

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to

prevent

ELECTRODE

see

yourdistributorfora

contamination

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of

tungsten

the

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Gas

moQ2.1

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.020

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.

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225.360

360-450

450-720

720-950

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250-400

400-500

500-750

750-1000

.

Electrode

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Electrode

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15

to

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15-80

70-150

25

to

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25-85

50-160

*



Table

7-1.

Amperage

DC

Positive/Reverse

Tungsten



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10-20

15-30

25-40

40-55

55-80

80-125

10-20

15-30

25-40

40-55

55-80

80-125

Range



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*



.

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*

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Size

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Gas

Polarity

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High

-

Polarity



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Frequency

15

to

Up

5-20

10-60

50-100

100-160

150.210

200-275

250-350

325-450

20

to

Up

15-35

20-80

50-150

130-250

225-360

300-450

400-500

600-800

Upto2O

15-35

20-80

50-150

130-250

225-360

300-450

400-550

600-800

Using

AC Wave



Argon

Using

Up

10-20

20-30

30-80

60-130

100-180

160-240

190-300

250-400

Upto

5-20

20-60

60-120

100-180

160-250

200-320

290-390

340-525

Uptol5

5-20

20-60

60-120

100-1

160-250

200-320

290-390

340-525

to



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10

15

80

Balanced

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Typical

*Not

The

manufacturers.

OM-168

argon

Recommended.

figures

256

shielding

listed

Page

are

20

gas

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flow

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rates

a

are

guide

15

and

to

35

are

cfh

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a

composite

feet

per

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from

American

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Preparing

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.

2

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For

with

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can

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cause

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/2

/

~

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eter

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4

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S-0162

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Figure

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Preparing

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Electrode

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OM-168

256

Page

21

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Miller Electric 500SSX User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual