Deltaweld Series DC16 2
User Manual: Deltaweld Series
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Issued Jan. 2015 • Index No. DC/16.2 ® Deltaweld Series Quick Specs Heavy Industrial Applications Processes Heavy Equipment Manufacturing Truck and Trailer Manufacturing Ship and Boat Building Tank/Pressure Vessel Fabrication Manufacture of Automotive Equipment Railcar/Locomotive Fabrication and Repair Furniture Manufacture Structural Steel Fabrication Sheet Metal Fabrication Maintenance MIG (GMAW) Flux Cored (FCAW) Air Carbon Arc (CAC-A) Cutting and Gouging Submerged Arc (SAW) MIG Welding Power Source Input Power 3-Phase Power on all models Rated Output 302/402: 300 A at 32 VDC, 100% Duty Cycle 452/602: 450 A at 38 VDC, 100% Duty Cycle 652/852: 650 A at 44 VDC, 100% Duty Cycle Net Weight 302/402: 323 lb. (147 kg) 452/602: 384 lb. (174 kg) 652/852: 472 lb. (214 kg) Superior arc welding performance with MIG welding. Internal digital voltage control (DVC) enables operator to preset weld voltage before striking an arc. Build your own system at MillerWelds.com/equiptoweld or see the Stationary and MIGRunner™ Packages (page 5). Line voltage compensation ensures consistent weld performance by keeping output power constant even if primary input power varies by ±10 percent. Digital voltmeter and ammeter are easy to read, even at 30 feet (9.2 m). Power efficient for exceptional value and return on your investment. Simple control panel provides easy, efficient operation. Two positive output terminals provide high/low stabilizer selection. Allows operator to optimize arc performance. 14-pin receptacle provides quick, direct connection to Miller 14-pin wire feeders and accessories. 115 VAC duplex receptacle provides 15 amps of auxiliary power. Remote on/off capabilities allow operator to turn power source on and off from a distance. Thermal overload protection light indicates power shutdown. Helps prevent machine damage if the duty cycle is exceeded or airflow is blocked. Remote voltage control allows operator to change voltage from feeder. Deltaweld 452 MIGRunner ™ Package shown ® Power cord strain relief provided for your convenience at installation. Fan-On-Demand™ operates only when needed reducing noise, power consumption, and the amount of airborne contaminants pulled through the machine. Enclosed circuit boards provide additional protection from contaminants resulting in longer service life. PC board protection prevents the wire feeder power or other stray voltages (less than 115 VAC) from harming the power source PC board. Power source is warranted for 3 years, parts and labor. Original main power rectified parts are warranted for 5 years. Miller Electric Mfg. Co. Equipment Sales US and Canada An ITW Company 1635 West Spencer Street P.O. Box 1079 Appleton, WI 54912-1079 USA Phone: 866-931-9730 FAX: 800-637-2315 International Phone: 920-735-4554 International FAX: 920-735-4125 MillerWelds.com Deltaweld 302/402 Specifications (Subject to change without notice.) ® Voltage Range Recommended Welding Range Rated Output Amps Input at Rated Output, 50/60 Hz 200 V 230 V 380 V 400 V 440 V 460 V 575 V KVA KW Max. OpenCircuit Voltage 10–32 V 15–32 V 48 42 VDC 300 A at 32 VDC, 100% duty cycle 42 27 25 23 21 17 16.9 12.9 Net Weight Dimensions H: 30 in. (762 mm) (including lift eye) W: 23 in. (585 mm) D: 30.5 in. (775 mm) (including strain relief) Note: For input conductor and fuse size information consult the Owner’s Manual. Control Panel 1 4 2 5 3 6 1. Voltage Adjustment Control 2. Output Switch 3. Remote Voltage Control Switch 4. Digital Meters 5. Power Switch with Indicator Light 6. High Temperature Shutdown Light Performance Data DUTY CYCLE CHART VOLT/AMP CURVE CV RATED OUTPUT 600 80 GMAW FCAW 70 60 DC VOLTS WELDING AMPS 500 400 300 50 40 MAX. 30 MED. 20 MIN. 10 200 40 50 60 70 % DUTY CYCLE 2 80 90 100 0 0 50 100 150 DC AMPS 200 250 300 323 lb. (147 kg) Deltaweld 452/602 Specifications (Subject to change without notice.) ® Voltage Range Recommended Welding Range Rated Output Amps Input at Rated Output, 50/60 Hz 200 V 230 V 380 V 400 V 440 V 460 V 575 V KVA KW Max. OpenCircuit Voltage 10–38 V 15–38 V 72 48 VDC 450 A at 38 VDC, 100% duty cycle 63 39 37 33 32 25 25.1 21.1 Net Weight Dimensions H: 30 in. (762 mm) (including lift eye) W: 23 in. (585 mm) D: 38 in. (966 mm) (including strain relief) 384 lb. (174 kg) Note: For input conductor and fuse size information consult the Owner’s Manual. Control Panel 1 4 2 5 3 6 1. Voltage Adjustment Control 2. Output Switch 3. Remote Voltage Control Switch 4. Digital Meters 5. Power Switch with Indicator Light 6. High Temperature Shutdown Light Performance Data DUTY CYCLE CHART VOLT/AMP CURVE CV RATED OUTPUT 800 80 GMAW FCAW 70 60 DC VOLTS WELDING AMPS 600 400 300 50 MAX. 40 MED. 30 20 MIN. 10 200 40 0 50 60 70 % DUTY CYCLE 80 90 100 0 100 200 300 400 500 DC AMPS 3 Deltaweld 652/852 Specifications (Subject to change without notice.) ® Voltage Range Recommended Welding Range 10–44 V 15–44 V Rated Output 650 A at 44 VDC, 100% duty cycle Amps Input at Rated Output, 50/60 Hz 230 V 380 V 400 V 440 V 460 V 575 V KVA KW Max. OpenCircuit Voltage 96 34.2 54 VDC 58 54 50 48 38 38.2 Net Weight Dimensions H: 30 in. (762 mm) (including lift eye) W: 23 in. (585 mm) D: 38 in. (966 mm) (including strain relief) Note: For input conductor and fuse size information consult the Owner’s Manual. Control Panel 1 4 2 5 3 6 1. Voltage Adjustment Control 2. Output Switch 3. Remote Voltage Control Switch 4. Digital Meters 5. Power Switch with Indicator Light 6. High Temperature Shutdown Light Performance Data DUTY CYCLE CHART VOLT/AMP CURVE CV RATED OUTPUT 1000 80 GMAW FCAW 70 800 600 DC VOLTS WELDING AMPS 60 50 MAX. 40 MED. 30 20 400 MIN. 10 300 40 0 50 60 70 % DUTY CYCLE 4 80 90 100 0 100 200 300 400 DC AMPS 500 600 700 472 lb. (214 kg) Packages ® Option #1: Deltaweld Power Source Only Purchase components separately. Deltaweld 302 #903 376 (200-208/230/460 V, 60 Hz) #903 392 (230/460/575 V, 60 Hz) Build your own system at MillerWelds.com/equiptoweld Deltaweld 452 #903 377 (200-208/230/460 V, 60 Hz) #903 394 (230/460/575 V, 60 Hz) Deltaweld 652 #903 396 (230/460/575 V, 60 Hz) ® Option #2: Deltaweld Stationary Package Comes complete with: Deltaweld power source S-74D wire feeder Bernard™ Q-Gun™ Industrial MIG 4/0 kit consisting of flowmeter regulator with 10-ft. (3 m) gas hose, 10-ft. (3 m) 4/0 feeder weld cable with lugs, and 15-ft. (4.6 m) work cable with 600-amp C-clamp Stationary display without running gear or cylinder rack. Deltaweld 302 Stationary Package #951 235 (200-208/230/460 V, 60 Hz) Deltaweld 452 Stationary Package #951 237 (200-208/230/460 V, 60 Hz) #951 301 (230/460/575 V, 60 Hz) ® Option #3: Deltaweld MIGRunner Package MIGRunner system with factory-installed standard running gear and cylinder rack. Deltaweld 302 MIGRunner Package #951 234 (200-208/230/460 V, 60 Hz) #951 300 (230/460/575 V, 60 Hz) Deltaweld 452 MIGRunner Package #951 236 (200-208/230/460 V, 60 Hz) #951 302 (230/460/575 V, 60 Hz) Deltaweld 652 MIGRunner Package #951 238 (230/460/575 V, 60 Hz) ™ Comes complete with: Deltaweld power source S-74D wire feeder Bernard™ Q-Gun™ Industrial MIG 4/0 kit consisting of flowmeter regulator with 10-ft. (3 m) gas hose, 10-ft. (3 m) 4/0 feeder weld cable with lugs, and 15-ft. (4.6 m) work cable with 600-amp C-clamp Factory-installed standard running gear and cylinder rack 5 Genuine Miller Options and Accessories ® Ground Current Sensor #195 048 Field Disables power source if weld current is present on primary ground. Extension Cables for 14-Pin Plugs to 14-Pin Sockets* #242 208 025 25 ft. (7.6 m) #242 208 050 50 ft. (15.2 m) #242 208 080 80 ft. (24.4 m) Extension cables make a direct connection between the power source and remote control or 24 VAC wire feeder. No messy splicing or adapting required. *For additional lengths visit MillerWelds.com/equiptoweld. Coolant Systems For more information, see the Miller Coolant Systems literature sheet, Index No. AY/7.2. Standard Running Gear #042 886 The large 10-inch (254 mm) rear wheels and 5-inch (127 mm) front casters on this running gear provide excellent mobility on the shop floor, making it easier to move the power source. Very easy to install. Handles double as weld cable holder. Coolmate™ 3 #043 007 115 VAC #043 008 230 VAC For use with water-cooled torches rated up to 500 amps. Unique paddle-wheel indicator, external filter and easy-fill spout. Standard Cylinder Rack #042 887 Holds two cylinders. Only installs on Standard Running Gear. Industrial MIG 4/0 Kit #300 390 Includes flowmeter regulator with 10-foot (3 m) gas hose, 10-foot (3 m) 4/0 feeder weld cable with lugs, and 15-foot (4.6 m) work cable with 600-amp C-clamp. Polarity Control #042 871 This dual-function control is designed for use with dual wire feeders or any application where electrical isolation and/or polarity reversing of weld current is required. Both functions can be used at the same time. Process Control Selector #042 872 Allows you to easily change weld processes. Also includes features of Polarity Control. 6 Coolmate™ 4 #042 288 115 VAC For use with water-cooled torches rated up to 600 amps. Tough molded polyethylene case with carrying handle. Coolant #043 810 Sold in cases of four one-gallon recyclable plastic bottles. Miller coolants contain a base of ethylene glycol and deionized water to protect against freezing to -37 degrees Fahrenheit (-38° C) or boiling to 227 degrees Fahrenheit (108° C). Also contains a compound that resists algae growth. Wire Feeder Options Bench-Style Feeders 22A 24A S-74S S-74D S-74DX S-74 MPa Plus Lit. Index No. M/11.0 M/11.0 M/3.0 M/3.0 M/3.0 M/3.0 Bench-Style Dual Feeders D-74S D-74D D-74DX D-74 MPa Plus M/3.0 M/3.0 M/3.0 M/3.0 Boom-Style Feeders SS-74S12 SS-74S16 SS-74D12 SS-74D16 SS-74DX12 SS-74DX16 SS-74 MPa Plus M/13.11 M/13.11 M/13.11 M/13.11 M/13.11 M/13.11 M/13.11 Boom-Style Dual Feeders DS-74S12 DS-74S16 DS-74D12 DS-74D16 DS-74DX12 DS-74DX16 DS-74 MPa Plus M/13.11 M/13.11 M/13.11 M/13.11 M/13.11 M/13.11 M/13.11 Portable Feeders SuitCase® 12RC M/6.5 Portable Voltage-Sensing Feeders SuitCase® X-TREME™ 8VS SuitCase® X-TREME™ 12VS M/6.42 M/6.42 Aluminum Push-Pull Feeders XR™-S and XR™-D Controls Guns available: XR-Aluma-Pro™ XR-Pistol XR-Pistol-Pro M/1.7 M/1.71 M/1.73 M/1.74 Hard Automation 70 Series Remote Configurations M/3.0 7 Ordering Information Equipment and Options Stock No. Description Deltaweld 302 Power Source Only #903 376* #903 392* 200-208/230/460 V, 60 Hz 230/460/575 V, 60 Hz Deltaweld® 302 Stationary Package #951 235* 200-208/230/460 V, 60 Hz Deltaweld® 302 MIGRunner ™ Package #951 234* #951 300* 200-208/230/460 V, 60 Hz 230/460/575 V, 60 Hz Deltaweld® 402 Power Source Only #907 357** 380/400/440 V, 50 Hz w/CE Deltaweld® 452 Power Source Only #903 377* #903 394* 200-208/230/460 V, 60 Hz 230/460/575 V, 60 Hz Deltaweld® 452 Stationary Package #951 237* #951 301* 200-208/230/460 V, 60 Hz 230/460/575 V, 60 Hz Deltaweld® 452 MIGRunner ™ Package #951 236* #951 302* 200-208/230/460 V, 60 Hz 230/460/575 V, 60 Hz Deltaweld® 602 Power Source Only #907 358** 380/400/440 V, 50 Hz w/CE Deltaweld® 652 Power Source Only #903 396* 230/460/575 V, 60 Hz Deltaweld® 652 MIGRunner ™ Package #951 238* 230/460/575 V, 60 Hz Deltaweld® 852 Power Source Only #907 359** 380/400/440 V, 50 Hz w/CE 22A #951 190 See Lit. Index No. M/11.0 24A #951 193 See Lit. Index No. M/11.0 #951 580 See Lit. Index No. M/6.5 ® Qty. Wire Feeders 70 Series SuitCase® 12RC See Lit. Index No. M/3.0 SuitCase® X-TREME™ 8VS #951 583 See Lit. Index No. M/6.42 SuitCase® X-TREME™ 12VS #951 543 See Lit. Index No. M/6.42 XR™ Controls #300 601 #300 687 XR-S model. See Lit. Index No. M/1.7 XR-D model. See Lit. Index No. M/1.7 Swingarc™ Boom Feeders See Lit. Index No. M/13.11 Options and Accessories Ground Current Sensor #195 048 Extension Cables Industrial MIG 4/0 Kit #300 390 Polarity Control #042 871 Process Control Selector #042 872 Standard Running Gear #042 886 Standard Cylinder Rack #042 887 Coolant Systems Coolant Field See page 6 Includes flowmeter regulator with 10-ft. (3 m) gas hose, 10-ft. (3 m) 4/0 feeder weld cable with lugs, and 15-ft. (4.6 m) work cable with 600-amp C-clamp See page 6 #043 810 Primary Power Cable Secondary Welding Cables Work Cable and Clamp Date: * ** Total Quoted Price: Certified by Canadian Standards Association to both the Canadian and U.S. Standards. 50 Hz models with CE Specifications are manufactured according to the Standards IEC-974-1 and EN-60974-1. Conforms with NEMA EW 1 “Electric Arc Welding Power Source,” Class I (100). Distributed by: © 2014 Miller Electric Mfg. Co. Price
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