Miller Electric Wire Feeder Users Manual
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OM-877 Form: 108 026 November 1995 OWNER’S MANUAL 10KW AUXILIARY POWER BANK Read and follow these instructions and all safety blocks carefully. Give this manual to the operator. Have only trained and qualified persons install, operate, or service this unit. For help, call your distributor Call your distributor if you do not understand the directions. or: MILLER Electric Mfg. Co., P.O. Box 1079, Appleton, WI 54912 414-734-9821 cover 1/94 – ST-108 014-A 1995 MILLER Electric Mfg. Co. PRINTED IN USA From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you Miller is the first welding figure out what the problem is. The parts list equipment manufacturer in will then help you to decide which exact part the U.S.A. to be registered to the ISO 9001 Quality System you may need to fix the problem. Warranty and Standard. service information for your particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web. Working as hard as you do – every power source from Miller is backed by the most hassle-free warranty in the business. Miller offers a Technical Manual which provides more detailed service and parts information for your unit. To obtain a Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P. TABLE OF CONTENTS SECTION 1 – SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE . . . . . . . 1-1. 1-2. 1-3. 1-4. 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standards Booklet Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 4 5 SECTION 2 – SAFETY PRECAUTIONS AND SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. General Information And Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Safety Alert Symbol And Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 6 6 SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3-1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SECTION 4 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4-1. 4-2. Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interconnecting Cord Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 7 5 – OPERATOR CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Volt Load/240 Volt Load Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Amperage Load Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hertz Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual-Scale AC Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 9 9 9 10 10 10 SECTION 6 – SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SECTION 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 6-1. 6-2. Loading Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shutting Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 11 SECTION 7 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Inspection And Upkeep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Internal Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 11 11 SECTION 8 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Figure 8-1. Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-2. Panel, Front w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8-3. Resistor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 14 15 OM-877 – 11/95 SECTION 1 – SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1-1. INTRODUCTION We learn by experience. Learning safety through personal experience, like a child touching a hot stove is harmful, wasteful, and unwise. Let the experience of others teach you. Safe practices developed from experience in the use of welding and cutting are described in this manual. Research, development, and field experience have evolved reliable equipment and safe installation, operation, and servicing practices. Accidents occur when equipment is improperly used or maintained. The reason for the safe practices may not always be given. Some are based on common sense, others may require technical volumes to explain. It is wiser to follow the rules. Read and understand these safe practices before attempting to install, operate, or service the equipment. Comply with these procedures as applicable to the particular equipment used and their instruction manuals, for personal safety and for the safety of others. Failure to observe these safe practices may cause serious injury or death. When safety becomes a habit, the equipment can be used with confidence. These safe practices are divided into two Sections: 1-General Precautions, common to arc welding and cutting; and 2-Arc Welding (and Cutting) (only). Reference standards: Published Standards on safety are also available for additional and more complete procedures than those given in this manual. They are listed in the Standards Index in this manual. ANSI Z49.1 is the most complete. The National Electrical Code, Occupational Safety and Health Administration, local industrial codes, and local inspection requirements also provide a basis for equipment installation, use, and service. 1-2. GENERAL PRECAUTIONS Different arc welding processes, electrode alloys, and fluxes can produce different fumes, gases, and radiation levels. In addition to the information in this manual, be sure to consult flux and electrode manufacturers Material Safety Data Sheets (MSDSs) for specific technical data and precautionary measures concerning their material. A. Burn Prevention Wear protective clothing-gauntlet gloves designed for use in welding, hat, and high safety-toe shoes. Button shirt collar and pocket flaps, and wear cuffless trousers to avoid entry of sparks and slag. Wear helmet with safety goggles and glasses with side shields underneath, appropriate filter lenses or plates (protected by clear cover glass). This is a MUST for welding or cutting, (and chipping) to protect the eyes from radiant energy and flying metal. Replace cover glass when broken, pitted, or spattered. See 1-3A.2. Avoid oily or greasy clothing. A spark may ignite them. Hot metal such as electrode stubs and workpieces should never be handled without gloves. Medical first aid and eye treatment. First aid facilities and a qualified first aid person should be available for each shift unless medical facilities are close by for immediate treatment of flash burns of the eyes and skin burns. Ear plugs should be worn when working on overhead or in a confined space. A hard hat should be worn when others work overhead. Flammable hair preparations should not be used by persons intending to weld or cut. B. Toxic Fume Prevention Severe discomfort, illness or death can result from fumes, vapors, heat, or oxygen enrichment or depletion that welding (or cutting) may produce. Prevent them with adequate ventilation as described in ANSI Standard Z49.1 listed in Standards Index. NEVER ventilate with oxygen. Lead -, cadmium -, zinc -, mercury -, and beryllium-bearing and similar materials, when welded (or cut) may produce harmful concentrations of toxic fumes. Adequate local exhaust ventilation must be used, or each person in the area as well as the operator must wear an air-supplied respirator. For beryllium, both must be used. Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed from the work surface, the area is well ventilated and, if necessary, while wearing an air-supplied respirator. Work in a confined space only while it is being ventilated and, if necessary, while wearing an air-supplied respirator. Gas leaks in a confined space should be avoided. Leaked gas in large quantities can change oxygen concentration dangerously. Do not bring gas cylinders into a confined space. Leaving confined space, shut OFF gas supply at source to prevent possible accumulation of gases in the space if downstream valves have been accidentally opened or left open. Check to be sure that the space is safe before re-entering it. Vapors from chlorinated solvents can be decomposed by the heat of the arc (or flame) to form PHOSGENE, a highly toxic gas, and other lung and eye irritating products. The ultraviolet (radiant) energy of the arc can also decompose trichloroethylene and perchloroethylene vapors to form phosgene. DO NOT WELD or cut where solvent vapors can be drawn into the welding or cutting OM-877 Page 1 atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichloroethylene or perchloroethylene. C. Fire and Explosion Prevention Causes of fire and explosion are: combustibles reached by the arc, flame, flying sparks, hot slag or heated material; misuse of compressed gases and cylinders; and short circuits. BE AWARE THAT flying sparks or falling slag can pass through cracks, along pipes, through windows or doors, and through wall or floor openings, out of sight of the goggled operator. Sparks and slag can fly 35 feet. To prevent fires and explosion: Keep equipment clean and operable, free of oil, grease, and (in electrical parts) of metallic particles that can cause short circuits. If combustibles are in area, do NOT weld or cut. Move the work if practicable, to an area free of combustibles. Avoid paint spray rooms, dip tanks, storage areas, ventilators. If the work cannot be moved, move combustibles at least 35 feet away out of reach of sparks and heat; or protect against ignition with suitable and snugfitting, fire-resistant covers or shields. Walls touching combustibles on opposite sides should not be welded on (or cut). Walls, ceilings, and floor near work should be protected by heat-resistant covers or shields. Fire watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if: a. appreciable combustibles (including building construction) are within 35 feet b. appreciable combustibles are further than 35 feet but can be ignited by sparks c. openings (concealed or visible) in floors or walls within 35 feet may expose combustibles to sparks d. combustibles adjacent to walls, ceilings, roofs, or metal partitions can be ignited by radiant or conducted heat. Hot work permit should be obtained before operation to ensure supervisor’s approval that adequate precautions have been taken. After work is done, check that area is free of sparks, glowing embers, and flames. An empty container that held combustibles, or that can produce flammable or toxic vapors when heated, must never be welded on or cut, unless container has first been cleaned as described in AWS Standard A6.0, listed 7 in Standards Index. This includes: a thorough steam or caustic cleaning (or a solvent or water washing, depending on the combustible’s solubility) followed by purging and inerting with nitrogen or carbon dioxide, and using protective equipOM-877 Page 2 ment as recommended in A6.0. Waterfilling just below working level may substitute for inerting. A container with unknown contents should be cleaned (see preceding paragraph). Do NOT depend on sense of smell or sight to determine if it is safe to weld or cut. Hollow castings or containers must be vented before welding or cutting. They can explode. Explosive atmospheres. Never weld or cut where the air may contain flammable dust, gas, or liquid vapors (such as gasoline). D. Compressed Gas Equipment Standard precautions. Comply with precautions in this manual, and those detailed in CGA Standard P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, listed 11 in Standards Index. 1. Pressure Regulators Regulator relief valve is designed to protect only the regulator from overpressure; it is not intended to protect any downstream equipment. Provide such protection with one or more relief devices. Never connect a regulator to a cylinder containing gas other than that for which the regulator was designed. Remove faulty regulator from service immediately for repair (first close cylinder valve). The following symptoms indicate a faulty regulator: Leaks-if gas leaks externally. Excessive Creep-if delivery pressure continues to rise with downstream valve closed. Faulty Gauge-if gauge pointer does not move off stop pin when pressurized, nor returns to stop pin after pressure release. Repair. Do NOT attempt to repair. Send faulty regulators for repair to manufacturer’s designated repair center, where special techniques and tools are used by trained personnel. 2. Cylinders Cylinders must be handled carefully to prevent leaks and damage to their walls, valves, or safety devices: Avoid electrical circuit contact with cylinders including third rails, electrical wires, or welding circuits. They can produce short circuit arcs that may lead to a serious accident. (See 1-3C.) ICC or DOT marking must be on each cylinder. It is an assurance of safety when the cylinder is properly handled. Identifying gas content. Use only cylinders with name of gas marked on them; do not rely on color to identify gas content. Notify supplier if unmarked. NEVER DEFACE or alter name, number, or other markings on a cylinder. It is illegal and hazardous. Empties: Keep valves closed, replace caps securely; mark MT; keep them separate from FULLS and return promptly. Prohibited use. Never use a cylinder or its contents for other than its intended use, NEVER as a support or roller. Locate or secure cylinders so they cannot be knocked over. outlet away from people and sources of ignition. Wipe with a clean lintless cloth. Passageways and work areas. Keep cylinders clear of areas where they may be struck. Match regulator to cylinder. Before connecting, check that the regulator label and cylinder marking area, and that the regulator inlet and cylinder outlet match. NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas. Transporting cylinders. With a crane, use a secure support such as a platform or cradle. Do NOT lift cylinders off the ground by their valves or caps, or by chains, slings, or magnets. Do NOT expose cylinders to excessive heat, sparks, slag, and flame, etc. that may cause rupture. Do not allow contents to exceed 130°F. Cool with water spray where such exposure exists. Protect cylinders particularly valves from bumps, falls, falling objects, and weather. Replace caps securely when moving cylinders. Stuck valve. Do NOT use a hammer or wrench to open a cylinder valve that can not be opened by hand. Notify your supplier. Mixing gases. Never try to mix any gases in a cylinder. Never refill any cylinder. Cylinder fittings should never be modified or exchanged. 3. Hose Tighten connections. When assembling threaded connections, clean and smooth seats where necessary. Tighten. If connection leaks, disassemble, clean, and retighten using properly fitting wrench. Adapters. Use a CGA adapter (available from your supplier) between cylinder and regulator, if one is required. use two wrenches to tighten adapter marked RIGHT and LEFT HAND threads. Regulator outlet (or hose) connections may be identified by right hand threads for oxygen and left hand threads (with grooved hex on nut or shank) for fuel gas. 5. Pressurizing Steps: Drain regulator of residual gas through suitable vent before opening cylinder (or manifold valve) by turning adjusting screw in (clockwise). Draining prevents excessive compression heat at high pressure seat by allowing seat to open on pressurization. Leave adjusting screw engaged slightly on single-stage regulators. Stand to side of regulator while opening cylinder valve. Prohibited use. Never use hose other than that designed for the specified gas. A general hose identification rule is: red for fuel gas, green for oxygen, and black for inert gases. Use ferrules or clamps designed for the hose (not ordinary wire or other substitute) as a binding to connect hoses to fittings. No copper tubing splices. Use only standard brass fittings to splice hose. Avoid long runs to prevent kinks and abuse. Suspend hose off ground to keep it from being run over, stepped on, or otherwise damaged. Coil excess hose to prevent kinks and tangles. Protect hose from damage by sharp edges, and by sparks, slag, and open flame. Examine hose regularly for leaks, wear, and loose connections. Immerse pressured hose in water; bubbles indicate leaks. Repair leaky or worn hose by cutting area out and splicing (1-2D3). Do NOT tape. 4. Proper Connections Clean cylinder valve outlet of impurities that may clog orifices and damage seats before connecting regulator. Except for hydrogen, crack valve momentarily, pointing Open cylinder valve slowly so that regulator pressure increases slowly. When gauge is pressurized (gauge reaches regulator maximum) leave cylinder valve in following position: For oxygen, and inert gases, open fully to seal stem against possible leak. For fuel gas, open to less than one turn to permit quick emergency shutoff. Use pressure charts (available from your supplier) for safe and efficient, recommended pressure settings on regulators. Check for leaks on first pressurization and regularly there-after. Brush with soap solution (capfull of Ivory Liquid* or equivalent per gallon of water). Bubbles indicate leak. Clean off soapy water after test; dried soap is combustible. E. User Responsibilities Remove leaky or defective equipment from service immediately for repair. See User Responsibility statement in equipment manual. F. Leaving Equipment Unattended Close gas supply at source and drain gas. G. Rope Staging-Support Rope staging-support should not be used for welding or cutting operation; rope may burn. *Trademark of Proctor & Gamble. OM-877 Page 3 1-3. ARC WELDING Comply with precautions in 1-1, 1-2, and this section. Arc Welding, properly done, is a safe process, but a careless operator invites trouble. The equipment carries high currents at significant voltages. The arc is very bright and hot. Sparks fly, fumes rise, ultraviolet and infrared energy radiates, weldments are hot, and compressed gases may be used. The wise operator avoids unnecessary risks and protects himself and others from accidents. Precautions are described here and in standards referenced in index. A. Burn Protection Comply with precautions in 1-2. The welding arc is intense and visibly bright. Its radiation can damage eyes, penetrate lightweight clothing, reflect from light-colored surfaces, and burn the skin and eyes. Skin burns resemble acute sunburn, those from gasshielded arcs are more severe and painful. DON’T GET BURNED; COMPLY WITH PRECAUTIONS. 1. Protective Clothing Wear long-sleeve clothing (particularly for gas-shielded arc) in addition to gloves, hat, and shoes (1-2A). As necessary, use additional protective clothing such as leather jacket or sleeves, flame-proof apron, and fire-resistant leggings. Avoid outer garments of untreated cotton. Bare skin protection. Wear dark, substantial clothing. Button collar to protect chest and neck and button pockets to prevent entry of sparks. 2. Eye and Head Protection Protect eyes from exposure to arc. NEVER look at an electric arc without protection. Welding helmet or shield containing a filter plate shade no. 12 or denser must be used when welding. Place over face before striking arc. Protect filter plate with a clear cover plate. Cracked or broken helmet or shield should NOT be worn; radiation can pass through to cause burns. Cracked, broken, or loose filter plates must be replaced IMMEDIATELY. Replace clear cover plate when broken, pitted, or spattered. Flash goggles with side shields MUST be worn under the helmet to give some protection to the eyes should the helmet not be lowered over the face before an arc is struck. Looking at an arc momentarily with unprotected eyes (particularly a high intensity gas-shielded arc) can cause a retinal burn that may leave a permanent dark area in the field of vision. 3. Protection of Nearby Personnel Enclosed welding area. For production welding, a separate room or enclosed bay is best. In open areas, surround the operation with low-reflective, non-combustible screens or panels. Allow for free air circulation, particularly at floor level. OM-877 Page 4 Viewing the weld. Provide face shields for all persons who will be looking directly at the weld. Others working in area. See that all persons are wearing flash goggles. Before starting to weld, make sure that screen flaps or bay doors are closed. B. Toxic Fume Prevention Comply with precautions in 1-2B. Generator engine exhaust must be vented to the outside air. Carbon monoxide can kill. C. Fire and Explosion Prevention Comply with precautions in 1-2C. Equipment’s rated capacity. Do not overload arc welding equipment. It may overheat cables and cause a fire. Loose cable connections may overheat or flash and cause a fire. Never strike an arc on a cylinder or other pressure vessel. It creates a brittle area that can cause a violent rupture or lead to such a rupture under rough handling. D. Compressed Gas Equipment Comply with precautions in 1-2D. E. Shock Prevention Exposed hot conductors or other bare metal in the welding circuit, or in ungrounded, electrically-HOT equipment can fatally shock a person whose body becomes a conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wet surface when welding, without suitable protection. To protect against shock: Wear dry insulating gloves and body protection. Keep body and clothing dry. Never work in damp area without adequate insulation against electrical shock. Stay on a dry duckboard, or rubber mat when dampness or sweat can not be avoided. Sweat, sea water, or moisture between body and an electrically HOT part or grounded metal reduces the electrical resistance, and could enable dangerous and possibly lethal currents to flow through the body. A voltage will exist between the electrode and any conducting object in the work circuit. Examples of conducting objects include, but are not limited to, buildings, electrical tools, work benches, welding power source cases, workpieces, etc. Never touch the electrode and any metal object unless the welding power source is off. 1. Grounding the Equipment Arc welding equipment must be grounded according to the National Electrical Code, and the work must be grounded according to ANSI Z49.1 “Safety In Welding And Cutting.” When installing, connect the frames of each unit such as welding power source, control, work table, and water circulator to the building ground. Conductors must be ade- quate to carry ground currents safely. Equipment made electrically HOT by stray current may shock, possibly fatally. Do NOT GROUND to electrical conduit, or to a pipe carrying ANY gas or flammable liquid such as oil or fuel. ject in contact with the electrode circuit unless the welding power source is off. b. Equipment without output on/off control (no contactor) Welding power sources used with shielded metal arc welding (SMAW) and similar processes may not be equipped with welding power output on-off control devices. With such equipment the electrode is electrically HOT when the power switch is turned ON. Never touch the electrode unless the welding power source is off. Three-phase connection. Check phase requirements of equipment before installing. If only 3-phase power is available, connect single-phase equipment to only two wires of the 3-phase line. Do NOT connect the equipment ground lead to the third (live) wire, or the equipment will become electrically HOT-a dangerous condition that can shock, possibly fatally. Before welding, check ground for continuity. Be sure conductors are touching bare metal of equipment frames at connections. If a line cord with a ground lead is provided with the equipment for connection to a switchbox, connect the ground lead to the grounded switchbox. If a three-prong plug is added for connection to a grounded mating receptacle, the ground lead must be connected to the ground prong only. If the line cord comes with a threeprong plug, connect to a grounded mating receptacle. Never remove the ground prong from a plug, or use a plug with a broken off ground prong. 2. Electrode Holders Fully insulated electrode holders should be used. Do NOT use holders with protruding screws. 3. Connectors Fully insulated lock-type connectors should be used to join welding cable lengths. 4. Cables Frequently inspect cables for wear, cracks and damage. IMMEDIATELY REPLACE those with excessively worn or damaged insulation to avoid possibly-lethal shock from bared cable. Cables with damaged areas may be taped to give resistance equivalent to original cable. Keep cable dry, free of oil and grease, and protected from hot metal and sparks. 5. Before installation, inspection, or service, of equipment, shut OFF all power and remove line fuses (or lock or red-tag switches) to prevent accidental turning ON of power. Disconnect all cables from welding power source, and pull all 115 volts line-cord plugs. Do not open power circuit or change polarity while welding. If, in an emergency, it must be disconnected, guard against shock burns, or flash from switch arcing. Leaving equipment unattended. Always shut OFF and disconnect all power to equipment. Power disconnect switch must be available near the welding power source. F. Protection For Wearers of Electronic Life Support Devices (Pacemakers) Magnetic fields from high currents can affect pacemaker operation. Persons wearing electronic life support equipment (pacemaker) should consult with their doctor before going near arc welding, gouging, or spot welding operations. 1-4. STANDARDS BOOKLET INDEX For more information, refer to the following standards or their latest revisions and comply as applicable: 1. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126. 2. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. 3. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. 4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018. Electrode a. Equipment with output on/off control (contactor) Welding power sources for use with the gas metal arc welding (GMAW), gas tungsten arc welding (GTAW) and similar processes normally are equipped with devices that permit onoff control of the welding power output. When so equipped the electrode wire becomes electrically HOT when the power source switch is ON and the welding gun switch is closed. Never touch the electrode wire or any conducting ob- Safety Devices Safety devices such as interlocks and circuit breakers should not be disconnected or shunted out. Terminals And Other Exposed Parts Terminals and other exposed parts of electrical units should have insulating covers secured before operation. 6. 7. OM-877 Page 5 5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE FOOTWEAR obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018. 6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018. 7. 8. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING, AND ALLIED PROCESSES obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. 9. NFPA Standard 70, NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. 10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. 11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. 12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3. 13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103. 14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126. 15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018. SECTION 2 – SAFETY PRECAUTIONS AND SIGNAL WORDS 2-1. GENERAL INFORMATION AND SAFETY A. General Information presented in this manual and on various labels, tags, and plates on the unit pertains to equipment design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed for the safe and effective use of this equipment. The nameplate of this unit uses international symbols for labeling the front panel controls. The symbols also appear at the appropriate section in the text. B. Safety The installation, operation, maintenance, and troubleshooting of arc welding equipment requires practices and procedures which ensure personal safety and the safety of others. Therefore, this equipment is to be installed, operated, and maintained only by qualified persons in accordance with this manual and all applicable codes such as, but not limited to, those listed at the end of Section 1 – Safety Rules For Operation Of Arc Welding Power Source. OM-877 Page 6 2-2. SAFETY ALERT SYMBOL AND SIGNAL WORDS The following safety alert symbol and signal words are used throughout this manual to call attention to and identify different levels of hazard and special instructions. This safety alert symbol is used with the signal words WARNING and CAUTION to call attention to the safety statements. WARNING statements identify procedures or practices which must be followed to avoid serious personal injury or loss of life. CAUTION statements identify procedures or practices which must be followed to avoid minor personal injury or damage to this equipment. IMPORTANT statements identify special instructions necessary for the most efficient operation of this equipment. SECTION 3 – SPECIFICATIONS Rated Load For SinglePhase AC Input 50/60 Hertz 100% Duty Cycle 10 kW At 120 Volts, 83 Amperes 240 Volts, 42 Amperes Weight Net Ship 125 lb (57 kg) 145 lb (66 kg) Figure 3-1. Specifications 3-1. DESCRIPTION This unit is designed to provide an adjustable load during output testing procedures for any single-phase 120 or 240 volts ac power source. This unit is equipped with analog meters which provide simple and accurate readings of voltage, amperage, and frequency. 37-3/4 in (959 mm) 22 in (559 mm) 30 in (762 mm) ST-108 014 Figure 3-2. Dimensional View SECTION 4 – INSTALLATION 4-1. • LOCATION (Figure 3-2) Do not place any filtering device over the intake air passages. Warranty is void if any type of filtering device is used. CAUTION: IMPROPER LIFTING OF EQUIPMENT can result in personal injury and equipment damage. • Use equipment of adequate capacity to lift the unit. • If using lift forks to handle this unit, be sure the lift forks are long enough to extend out of the opposite side of the base. This unit is equipped with rubber casters to allow easy movement. Using lift forks too short will expose internal components to damage should the tips of the lift forks penetrate the bottom of unit. 4-2. RESTRICTED AIRFLOW can cause improper cooling and unit damage; ENTRY OF OBJECTS THROUGH TOP can damage unit. • Maintain at least 12 in (305 mm) of unrestricted space on all sides of the unit, and keep air intakes on sides and outlet openings on top free of obstructions. • Do not place tools, parts, etc. on top of unit. • Do not allow any objects to fall into top of unit. The service life and operating efficiency of this unit are reduced when the unit is subjected to high levels of dust, dirt, moisture, corrosive vapors, and extreme heat. INTERCONNECTING CORD INSTALLATION A. Cord Selection It is necessary to obtain a proper 3-conductor cord for making 120 volt and/or 240 volt input connections inside the unit. Select a cord of adequate amperage capacity and proper wire size for the rated amperage output of the power source. In most applications, it should not be necessary for the required cord length to exceed 25 ft (7.6 m). Table 4-1 provides a guide for selecting proper size cord for single-phase power sources based on ampacity rating. OM-877 Page 7 securely onto stripped ends of conductors for both cords. Table 4-1. Cord Size By Ampacity Rating Cord Size–AWG* Ampacity Of Cord 18 10 14 18 12 25 10 30 8 40 6 50 4 70 2 95 4. Insert cords up through strain reliefs in bottom of front access opening. Be sure cords are in correct locations for 120 volt and 240 volt connections (see unit nameplate and Figure 4-1). IMPORTANT: Do not remove existing leads from terminal studs. *Cord sizes are based on National Electrical Code (1984 Edition) specifications for allowable ampacity for not more than two thermoset or thermoplastic insulated current-carrying copper conductors in a cord (see Article 400 in NEC for specific information.) 5. Remove only the outside nut from each terminal board stud for 120 and 240 volt connections. Remove top nut from ground terminal stud (see Figure 4-1). 6. Install conductor ring terminals onto studs as indicated in Figure 4-1, and secure with nuts removed in Step 5. 7. Secure cords by tightening strain relief clamp screws. 8. Reinstall front access panel onto unit. B. Cord Connections Using proper cords of desired length, make connections to the load bank as follows: 1. Remove front access panel from unit (see Figure 5-1). 2. Strip cord jacket back approximately 5 in (127 mm) and separate conductors; strip 1/4 in (6 mm) of insulation from end of each conductor. 9. Obtain and install a proper plug that matches the power source receptacle onto remaining end of cords. 3. Obtain ring terminals of proper capacity and size to fit 1/4 in (6 mm) terminal studs. Install terminals 10. Place cords in storage area while unit is not in use. 120V Terminal L2 – Connect Black Conductor Input Terminal Board Front Control Panel 120V Terminal L1 – Connect White Conductor 240V Terminal L2 – Connect Black Conductor 240V Terminal L1 – Connect White Conductor Front Access Panel Removed Strain Relief Opening – Insert 120V Cord Up From Cord Storage Area Strain Relief Opening – Insert 240V Cord Up From Cord Storage Area Ground Terminal – Connect Ground Conductors Cord Storage Area ST-108 013-A Figure 4-1. Input Terminal Board And Ground Connectors OM-877 Page 8 SECTION 5 – OPERATOR CONTROLS Hertz Meter Pilot Light For 240VAC Load AC Voltmeter Pilot Light For 120VAC Load Load Selector Switch 120/240VAC Dual Scale AC Ammeter Front Access Panel Amperage Load Switches Cord Storage Area ST-108 014-A Figure 5-1. Front Panel Controls And Component Locations 5-1. 120 VOLT LOAD/240 VOLT LOAD SELECTOR SWITCH (Figure 5-1) CAUTION: ARCING can damage switch contacts. • Do not change the position of the selector switch under load. IMPORTANT: Always place both AMPERAGE load switches in the OFF position before connecting a power source, when changing the 120 VOLT LOAD/240 VOLT LOAD selector switch position, and after completing power source output checking procedures. Arcing causes the contacts to become pitted and eventually inoperative. AMPERAGE OFF The 120 VOLT LOAD/240 VOLT LOAD selector switch is used to select the proper voltage load terminals inside the unit, and to disconnect and isolate the other voltage load terminals. Before making selection with selector switch, be sure that the AMPERAGE load switches are placed in the OFF positions (see Section 5-3). 5-2. PILOT LIGHTS (Figure 5-1) Two pilot lights are provided on the unit. The pilot light for the corresponding voltage load will illuminate when input voltage is present at the Load Bank. 5-3. OFF 5 5 10 10 45 45 40 15 15 + 40 20 35 35 30 30 20 25 25 Ref. SC-096 625 AMPERAGE LOAD SWITCHES (Figure 5-1) CAUTION: INCORRECT SWITCH POSITIONS can damage internal components. • When operating on 240 volts, set amperage switches at same position or within one position of another. A balanced load setting at both amperage load switches is necessary to prevent resistor damage inside the unit. Figure 5-2. Amperage Load Switch Scales Two AMPERAGE load switches provide the selection of resistance values when checking output from an ac power source. The scales around each switch are calibrated in amperes with the inside scale for 120 vac input and the outside scale for 240 vac input (see Figure 5-2). OM-877 Page 9 The voltmeter displays the voltage of the ac power source. The scale range is 0–300 in increments of 2.5 volts. Table 5-1. Power Requirements For Load Amperage At Input Voltage KW 1 1.5 2 2.5 3 4 5 6 7 7.5 9 10 AMPERES AT 120V 8 8 12 17 21 25 33 42 50 58 62 67 75 83 AMPERES AT 240V 4 6 8 10 12 17 21 25 29 31 33 37 42 Power requirements up to 10kw at 120 or 240 vac input for various ampere load values are shown in Table 5-1 and on the unit nameplate. Ampere values selected at the two AMPERAGE load switches differ between 120 and 240 VAC input as follows: 120 Volt Operation: When this unit is used as a 120 volt load, AMPERAGE load switch settings are added together to obtain the approximate load value. For example, if one switch is set at 20 amperes and the other switch at 20 amperes, the result would be a total load of approximately 40 amperes. 5-5. CAUTION: DC (DIRECT CURRENT) SOURCES will damage unit. • Do not connect unit to any dc source. The hertz meter displays the frequency of the power being supplied by the ac power source. The scale range is 45–65 in increments of 0.5 Hz. 5-6. 240 Volt Operation: When this unit is used as a 240 volt load, both Amperage load switches must be set at the same value to obtain that approximate load value. For example, if one switch is set at 20 amperes and the other switch at 20 amperes, the result would be a total load of approximately 20 amperes. Figure 5-3. Dual-Scale AC Ammeter CAUTION: DC (DIRECT CURRENT) SOURCES will damage unit. • Do not connect unit to any dc source. VOLTMETER (Figure 5-1) CAUTION: DC (DIRECT CURRENT) SOURCES will damage unit. • Do not connect unit to any dc source. DUAL-SCALE AC AMMETER (Figure 5-1) SN-107 796 IMPORTANT: Do not change either switch setting more than one position higher or lower from the setting on the other switch (see CAUTION at beginning of Section 5-3 and on the unit nameplate). 5-4. HERTZ METER (Figure 5-1) The ammeter is a dual-scale meter that displays ac amperes for the 120 volts input on the top scale and ac amperes for the 240 volts input on the bottom scale. SECTION 6 – SEQUENCE OF OPERATION WARNING: ELECTRIC SHOCK can kill. • Do not touch live electrical parts. • ENGINE EXHAUST GASES can kill. • Use in open, well ventilated areas or vent exhaust out of doors, if applicable. Shut down auxiliary power source before connecting load bank. MAGNETIC FIELDS FROM HIGH CURRENTS can affect pacemaker operation. • Wearers should consult with their doctor before going near equipment producing auxiliary power during load bank operation. See Section 1 – Safety Rules For Operation Of Arc Welding Power Source for basic information. HOT SURFACES can cause burns and melt or ignite materials. • Do not touch load bank panels while operating. • Do not place any objects on load bank. ARCING AND EXHAUST SPARKS can cause fire. • Watch for fire. • • Have a fire extinguisher nearby and know how to use it. Disconnect welding cables from power source, if applicable, before testing auxiliary power output. OM-877 Page 10 6-1. LOADING PROCEDURE 1. Make required connections to unit according to Section 4-2. 2. Place AMPERAGE load switches in the OFF position (see Section 5-3). 3. Connect Load Bank cord to the ac power source. Be sure to use appropriate cord when Load Bank has both 120 and 240 volt cords installed. 8. 4. Place 120 VOLT LOAD/240 VOLT LOAD selector switch in proper position (see Section 5-1). 6-2. Compare meter readings with ac power source Owner’s Manual to check for compliance with specifications. SHUTTING DOWN 1. Rotate AMPERAGE load switches to the OFF position. 5. Turn on or start the ac power source. 6. Check pilot lights for proper input voltage load selection (see Section 5-2). 2. Shut down the power source. 7. Rotate AMPERAGE load switches to select desired ampere load value (see Section 5-3). 3. Disconnect Load Bank cord from power source, and place cord in the Load Bank cord storage. SECTION 7 – MAINTENANCE IMPORTANT: Every six months inspect the labels on the unit for legibility. All precautionary labels must be maintained in a clearly readable state and replaced when necessary. See Parts List for part number of precautionary labels. 7-1. Remove grease and grime from components; remove moisture from electrical parts and cords. 2. Check cord terminal connections. Be sure that connections are clean and tight. 7-2. INSPECTION AND UPKEEP Usage and shop conditions will determine the frequency and type of maintenance. Inspect equipment every six months as follows: WARNING: ELECTRIC SHOCK can kill. • Do not touch live electrical parts. • 1. Shut down and disconnect Load Bank from auxiliary power source before inspecting, maintaining, or servicing. MOVING PARTS can cause serious injury. • Keep clear of moving parts. HOT SURFACES can cause severe burns. • Allow cooling period before servicing. Maintenance to be performed only by qualified persons. INTERNAL CLEANING WARNING: ELECTRIC SHOCK can kill. • Do not touch live electrical parts. • Shut down and disconnect Load Bank from auxiliary power source before inspecting, maintaining, or servicing. HOT SURFACES can cause severe burns. • Allow cooling period before servicing. Blow out or vacuum the dust and dirt from around the internal components. Do this annually depending on the location of the unit and the amount of dust and dirt in the atmosphere. If dirty or dusty conditions are present, clean unit monthly. The outer enclosure should be removed and a clean, dry airstream or vacuum suction should be used for this cleaning operation. SN-106 867-A Figure 7-1. Circuit Diagram OM-877 Page 11 11 3 14 1 13 12 2 Fig 8-2 Fig 8-3 4 10 9 5 8 7 6 SECTION 8 – PARTS LIST ST-108 016 Figure 8-1. Main Assembly OM-877 Page 12 Item No. Part No. Description Quantity Figure 8-1. Main Assembly ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 . . . 106 661 . . Figure 8-2 . . . 106 870 . . . 082 136 . . . 123 154 . . +082 129 . . . 082 139 . . . 106 659 . . . 138 049 . . . 138 168 . . . 073 310 . . . 106 674 . . . 082 138 . . . 090 398 .. .. .. .. .. .. .. .. .. .. .. .. .. .. PANEL, LH side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front-w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR ASSEMBLY (Figure 8-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, rear-top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, rear-lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, RH side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CASTER, rbr sta 3 in bolt down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAN, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CASTER, swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, retaining-cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front-lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front-center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 1 1 1 1 1 2 1 2 1 1 1 +When ordering a component originally displaying a precautionary label, the label should also be ordered. BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. OM-877 Page 13 Item No. Dia. Mkgs. Part No. Description Quantity Figure 8-2. Panel, Front w/Components (Fig 1 Item 2) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ........................ . . . . . . . . . . . . . 106 673 . . . . . S1,2 . . . . . 059 734 . . . . . . . . . . . . . . . 106 671 . . . . . . . . . . . . . . . 106 672 . . . . . CT1 . . . . . 036 282 . . . . . . S3 . . . . . 106 670 . . . . . . . . . . . . . . . 088 838 . . . . . . . . . . . . . . . 006 790 . . . . . . A . . . . . . 106 665 . . . . . PL2 . . . . . 099 001 . . . . . . . . . . . . . . . 059 773 . . . . . PL1 . . . . . 027 645 . . . . . . HZ . . . . . 088 225 . . . . . . V . . . . . . 085 631 . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH, current 10 positon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, baffle air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSFOARMER, current 100/5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH, selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXTENSION, handle switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KNOB, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . METER, amp dual scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIGHT, indicator red lens 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIGHT, indicator red lens 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . METER, hertz 45-65 scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . METER, volt ac 0-300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 2 2 1 1 1 1 2 1 1 1 1 1 1 5 4 3 2 1 15 8 7 6 14 13 12 11 10 9 ST-108 015-A Figure 8-2. Panel, Front w/Components +When ordering a component originally displaying a precautionary label, the label should also be ordered. BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. OM-877 Page 14 Item No. Part No. Description Quantity Figure 8-3. Resistor Assembly (Fig 1 Item 3) ... 1 ... ... 2 ... ... 3 ... ......... ... 4 ... ......... ... 5 ... ......... ... 6 ... ... 7 ... ... 8 ... ... 9 ... . . . 10 . . . . . . 11 . . . . . . 12 . . . 106 667 059 800 059 726 059 724 059 728 059 725 059 727 059 724 070 270 106 669 106 666 059 779 059 797 059 798 106 668 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. BUS BAR, connecting resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, 25A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSULATOR, end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RING, retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSULATOR, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RING, retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSULATOR, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RING, retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUS BAR, connecting resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUS BAR, connecting resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUS BAR, connecting resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, 5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, 10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUS BAR, connecting resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4 48 48 20 20 28 28 6 2 6 6 4 10 2 6 7 5 4 6 3 8 2 1 9 10 11 9 11 12 9 10 2 6 1 12 ST-108 012-A Figure 8-3. Resistor Assembly BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. OM-877 Page 15 Notes OM-877 Page 16 Notes OM-877 Page 17 Notes OM-877 Page 18 Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way. * LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS. Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor. 1. 5 Years Parts – 3 Years Labor * * 2. 3 Years — Parts and Labor * * * * * * 3. Original main power rectifiers Inverters (input and output rectifiers only) Transformer/Rectifier Power Sources Plasma Arc Cutting Power Sources Semi-Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) 1 Year — Parts and Labor * * * * * * * * * * * * * * * * * DS-2 Wire Feeder Motor Driven Guns (w/exception of Spoolmate 185 & Spoolmate 250) Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HF Units Grids Maxstar 140 Spot Welders Load Banks Miller Cyclomatic Equipment Running Gear/Trailers Plasma Cutting Torches (except APT & SAF Models) Field Options (NOTE: Field options are covered under True Blue for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.) 4. 6 Months — Batteries 5. 90 Days — Parts * * MIG Guns/TIG Torches Induction Heating Coils and Blankets * * * * * APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts (No labor) Spoolmate 185 & Spoolmate 250 Canvas Covers Miller’s True Blue Limited Warranty shall not apply to: 1. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. 2. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any. 3. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment. MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province. miller_warr 7/00 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA Replacement Parts Training (Schools, Videos, Books) International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 Technical Manuals (Servicing Information and Parts) Circuit Diagrams European Headquarters – United Kingdom Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066 Welding Process Handbooks www.MillerWelds.com Contact the Delivering Carrier for: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00
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