Miller Electric SRH-503 User's Manual
Contents
1. f The indicator lamp on the power Switch remains on A When the unit has cooled down the fan restarts air flow and weld output is present at the weld output terminals and or at the elec trode 2 Amperage Adjustment Control 3 Amperage Range Indicator gt Turn handle clockwise to increase Y amperage as indicated by the am perage range indicator L 1 1 lt lt lt gt lt lt gt lt gt lt gt lt gt lt D cde gt T Ee a L E no cs se OO L C ee OO Q Q 803 026 C OM 2236 Page 18 5 2 Electrode Amperage Selector ELECTRODO AMPERAJE SELECCIONADOR ELECTRODE AMPERAGE SELECTOR ELECTRODO CD POSICI N PENETRACI N UTILIZACI N ELECTRODE DC POSITION PENETRATION USAGE EP Preparaci n Minimo Spatter Alta y Desigual Todo All Hondo Deep Min Prep Rough High Spatter Preparaci n Minimo Spatter Alta y Desigual EP Todo All Hondo Deep Min Prep Rough High Spatter Todo All Bajo Low General Mediano Liso F cil R pido Todo All Medium Smooth Easy Fast Baja Hidr geno Fuerte Todo All Bajo Low Law Hydrogen Strong EP EN Plano Horiz Filete Bajo Low Liso F cil M2. ST 803 137 D Figure 8 1 Main Assembly OM 2236 Page 24 Item Dia Part No Mkgs No Description Quantity Figure 8 1 Main Assembly daa 176254 LABEL GENERAL PRECAUTIONARY WORDLESS INTL 2 PANA AM E 4179430 PANEL SIDE LAN NA hahaa 2 MCN 205910 BAFFLE AIR LOWER coronar ike trot e Rede 2 ests Ae uil ieu 205911 BAFFLE AIR UPPER a IRR RE EHE re aa 2 nhan O wende 4206585 COVER TOP cto distan P 1 Dui Dos ea Ere 206403 LABEL CAUTION DO NOT LIFT WORDLESS 1 wipe a dosis 207866 LABEL ROD TYPE amp SIZE 1 na D enn cient 177279 GASKET LIE T EYE echte dre ete repete hex x et ERIS 1 qae Blaise 162830 LIFT EYE nA ee ane nan e Re Ee x cen ute y Re set e mnc 1 xo AE 162820 BAR MTG LIFT EYE 22220 rei e e a EAE 2 11 FM 208402 MOTOR 1 12HP 230V 1550 RPM 50 60HZ 83A 1 maa de ues ur mu 124274 BRACKET MTG FAN MOTOR 1 pee dO disease 173283 CHAMBER PLENUM 14 IN 1 ai K nata A 180165 BLADE FAN 14 000 3WG 28DEG 375 BORE CCW GAL 1 EM Io AE 162807 PANEL HEAR eene bep Lene EL 1 22s d eorr 168343 HINGE CONT POLYOLEFIN COPOLYMER 2 000 L W 125H 2 ee AAA 4162818 DOOR ACCESS PRIMARY ssseeeeeee eet 1 ES n c 179290 LABEL WARNING ELECTRIC
3. 1 OM 2236 Page 25 Item Dia Part No Mkgs No Description Quantity 8 1 Main Assembly continued SpE OS ai 205885 SPACER STL 500 ID X 625 OD X 1 267 2 or MES 024620 SPROCKET W 1 8 HOLE 00000 cece nh 2 EAs OO Meme 206010 CHAIN ROLLER NO 43 1 4X54 PITCHES LG 1 UROD eas eas 010660 PIN SPRING CS 125 X 1 125 2 OUS eui ad 204960 SPRING CPRSN 625 OD X 123 WIRE X 1 500 4 58 T1 204956 XFMR POWER MAIN 220 440 1 TP1 2 3 208381 THERMOSTAT NC OPEN 135C CLOSE 135C W INSUL LEADS ERA RAN INCIUDEO WD scie rra rr 8 O Ares 604536 SCREW 312 18 X 1 75 HEX HD PLN GR5 PLD 2 wt A 217136 LABEL WARNING ELECTRIC SHOCK 2 Od S ases 217864 LABEL CAUTION DO NOT LIFT FR 1 oO csse 217138 LABEL WARNING ELECTRIC SHOCK INPUT POWER 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2236 Page 26 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributo
4. I Total Cable 4 Work Clamp Length In Wel Crone 20 ft Sm Install onto work cable Tools Needed ED daa gt sb6 1 11 92 S 0653 4 8 Weld Cable Sizes Total Cable Copper Length In Weld Circuit Not Exceeding 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft 30 m Or Less 45 m 60 m 70 m 90m 105m 120m Welding 10 To 60 60 Thru 100 Amperes Duty Cycle Duty Cycle 10 Thru 100 Duty Cycle Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere Contact your distributor for the mm equivalent weld cable sizes S 0007 E OM 2236 Page 14 4 9 Connecting To Weld Output Terminals A Turn off power before con necting to weld output terminals 1 Positive Weld Output Terminal 2 Negative Weld Output Terminal 3 Cable Restraint Route weld cables through cable restraint For DC Electrode Positive DCEP connect work cable to negative terminal and connect electrode holder cable to positive terminal For DC Electrode Negative 3 DCEN reverse cable connections Tools Needed TI 3 4 in Ref 803 026 C 4 10 Electrical Service Guide
5. e Couper l alimentation ou arr ter le moteur avant de proc der l instal lation la r paration ou l entretien de l appareil Couper tiqueter l alimentation selon la norme OSHA 29 CFR 1910 147 voir les nor mes de s curit e Installer et mettre la terre correctement l appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e Toujours v rifier la terre du cordon d alimentation V rifier et s assu rer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e Pour ex cuter les branchements d entr e fixer d abord le conducteur de mise la terre ad quat et contre v rifier les connexions e V rifier fr quemment le cordon d alimentation et s assurer qu il n est ni endommag ni d nud le remplacer imm diatement s il est en dommag tout c ble d nud peut causer une lectrocution e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser de c bles us s endommag s de calibre insuffisant ou mal piss s e Ne pas s enrouler les c bles autour du corps e Sila pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode d une autre machine som fre 8 03 APA Ce groupe d
6. L2 V and L3 W to welding power source line terminals Close and secure access door on welding power source Disconnect Device Input Power Con nections 7 Disconnect Device switch shown in OFF position 8 Disconnect Device Supply Grounding Terminal Connect green or green yellow grounding conductor to disconnect device grounding terminal first 9 Disconnect Device Line Terminals Connect input conductors L1 U L2 V And L3 W to disconnect device line terminals 10 Over Current Protection Select type and size of over current protection using Section 4 10 fused dis connect switch shown Close and secure door on line disconnect device Remove lockout tagout device and place switch in the On position 800 103 C Ref 801 116 A OM 2236 Page 17 SECTION 5 OPERATION 5 1 Controls p b DL 9 1 Power Switch W Indicator Lamp WA Ln When the switch is turned on the lamp lights to indicate power has been applied to the unit A Ifthe indicator lamp does not light when the power switch is turned on replace the switch NOTE This unit has over tempera ture protection If unit becomes hot or if the duty cycle is exceeded see Section 4 2 weld output shuts down and the fan stops running
7. Le rayonnement de l arc g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges suscep tibles de causer des br lures oculaires et cutan es Des tincelles sont projet es pendant le soudage e Porter un masque de soudage muni d un filtre de la nuance ad quate pour se prot ger le visage et les yeux pendant le soudage ou pour re garder voir les normes de s curit ANSI Z49 1 et 287 1 e Porter des lunettes de s curit crans lat raux sous le masque e Utiliser des crans ou des barri res pour prot ger les tiers de l clat blouissant ou aveuglant de l arc leur demander de ne pas regarder l arc e Porter des v tements de protection en mati re durable et ignifuge cuir ou laine et des chaussures de s curit A LE SOUDAGE peut causer un incen die ou une explosion Le soudage effectu sur des r cipients ferm s tels que des r servoirs des f ts ou des conduites peut causer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles les pi ces chaudes et les quipements chauds peuvent causer des incendies et des br lures Le contact accidentel de l lectrode avec tout objet m tallique peut causer des tincelles une explosion un surchauf fement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et prot ger les tiers de la projection d tincel
8. With this procedure The possible hazards are shown in the adjoining symbols EF Means Note not safety related 1 2 Arc Welding Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away a ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if move
9. g Output 60 Hz Three Phase Rated Welding Model Output Amp Range DC Max OCV DC 220 230 V 440 460 V KVA KW 500 A 40 Volts DC 50 525 98 49 38 9 26 SOM 60 Duty Cycle a 4 5 2 2 1 8 0 7 While idling 4 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating A Exceeding duty cycle can damage unit and void warranty in 700 ui 600 c ui 500 z 400 a 300 1 LLI 200 100 10 20 30 40 50 60 70 8090100 DUTY CYCLE 6096 Duty Cycle At 500 Amperes For 500 Ampere Models zm A 685 6 Minutes Welding 4 Minutes Resting Overheating tas 0 V pua NS hs gt OR Minutes Reduce Duty Cycle 205 909 OM 2236 Page 11 4 3 Volt Ampere Curves 80 NJ e o e a e Output Voltage Volts D C A Volt ampere curves show mini mum and maximum voltage and amperage output capabilities of unit Curves of other settings fall be tween curves shown 30 20 10 0 0 100 200 300 400 500 600 700 800 900 1000 Output Current AmpsD C 206 054 4 4 Selecting A Location 1 Lifting Eye SN A CL A Movement Location And Airflow VOLTS AMPERES KW PHASE INPUT SERIAL NO STOCK NO HERTZ 18 in 460 mm 2
10. s et les publications P 1 de la CGA mentionn es dans les normes de s curit 2 3 Autres symboles relatifs l installation au fonctionnement et l entretien de l appareil Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur une surface inflam mable ni au dessus ou proximit d elle Ne pas installer l appareil proximit de produits inflammables Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e N utiliser que l anneau de levage pour lever l ap pareil NE PAS utiliser le chariot les bouteilles de gaz ou tout autre accessoire e Utiliser un engin de capacit ad quate pour lever l appareil e Sion utilise un chariot l vateur pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t op pos de l appareil nn ot i L EMPLOI EXCESSIF peut FAIRE SURCHAUFFER L EQUIPEMENT e e Pr voir une p riode de refroidissement respec ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de reprendre le soudage e Ne pas obstruer les orifices ou filtrer l alimentation en air du poste ee LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s y E ASS o e Mettre un bracelet antistatique AVANT de mani puler des cartes o
11. Er 3 N GND PE Earth Ground T ojo opel mom GND PE Earth Ground Tools Needed 3 3 8 in C ARO 3 8 in A Installation must meet all National and Local Codes have only quali fied persons make this installation A Disconnectand lockout tagout in put power before connecting input conductors from unit A Make input power connections to the welding power source first A Always connect green or green yellow conductor to supply grounding terminal first and never toa line terminal See rating label on unit and check input voltage available at site 1 Input Power Conductors Customer Supplied Cord Select size and length of conductors using Section 4 10 Conductors must comply with national state and local electrical codes If applicable use lugs of proper amperage capacity and correct hole size Welding Power Source Input Power Connections 2 Strain Relief Route conductors cord through strain re lief and tighten screws 3 Machine Grounding Terminal 4 Green Or Green Yellow Grounding Conductor Connect green or green yellow grounding conductor to welding power source groundingterminal first 5 Welding Power Source Line Terminals 6 Input Conductors L1 U L2 V And L3 W Connect input conductors L1 U
12. Input Voltage 220 230 440 460 Input Amperes At Rated Output 98 49 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 100 50 Normal Operating 3 150 70 Min Input Conductor Size In AWG Kcmil 4 8 148 258 Max Recommended Input Conductor Length In Feet Meters 45 79 Min Grounding Conductor Size In AWG Kcmil 6 8 Reference 1999 National Electrical Code NEC 1 Consult factory for circuit breaker applications 2 Time Delay fuses are UL class RKO 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above OM 2236 Page 15 4 11 Placing Jumper Links Her A Disconnectand lockout tag out input power before installing or moving jumper links Check input voltage available at site 1 Jumper Link Label Check label only one is on unit 2 Jumper Link Move jumper links to match input voltage and label on unit Close access door or go on to Sec tion 4 12 Do not overtighten jumper link nuts 220 230 mai VOLTS AAA of Acc coffee fee RAR gt 440 460 voLTS o offoo 208 380 A CFI 3 8 1 2 in Ref ST 800 103 A OM 2236 Page 16 4 12 Connecting Input Power
13. Lifting Forks Use lifting eye or lifting forks to move unit If using lifting forks extend forks beyond opposite side of unit 3 Rating Label Use rating label to determine input power needs Label located under front access door 4 Line Disconnect Device Locate unit near correct input power supply A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 Ref 803 025 D OM 2236 Page 12 4 5 Dimensions And Weights 4 Holes 801 530 Dimensions w Running Gear And Lift Eye Height 35 1 4 in 895 mm Width 28 in 711 mm Depth 33 1 2 in 851 mm A 27 1 2 in 699 mm B 3 4 in 19 mm E 21 1 8 in 537 mm D 1 1 8 in 29 mm E 7 16 in 11 mm Dia Weight 410 Ib 186 kg 4 6 Tipping A ES A Be careful when placing or moving unit over uneven surfaces OM 2236 Page 13 4 7 Selecting And Preparing Weld Output Cables 1 Weld Output Cable Determinetotal cable length in weld circuit and maximum welding am peres See Section 4 8 to select proper cable size Use shortest cables possible Do not use damaged cables 2 Terminal Lug Use lugs of proper amperage capacity and hole size for connect ing to work clamp electrode holder and weld output terminals 3 Insulated Electrode Holder Install according to manufacturer s instructions For Example
14. champs lectriques haute fr quence constitue un risque pour la sant humaine Toutefois les tudes et l examen des preuves se poursuivent En attendant les conclusions finales de la re cherche il serait souhaitable de r duire l exposition aux champs lectromagn tiques pendant le soudage ou le coupage OM 2236 Page 8 Afin de r duire les champs lectromagn tiques en milieu de travail res pecter les consignes suivantes 1 Garder les c bles ensemble en les torsadant ou en les fixant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos l op rateur 3 Ne pas s enrouler les c bles autour du corps 4 Garder le poste de soudage et les c bles le plus loin possible de soi 5 Placer la pince de masse le plus pr s possible de la zone de soudage Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur m decin Si ce dernier les d clare aptes il leur est recom mand de respecter les consignes ci dessus SECTION 3 DEFINITIONS 3 1 General Precautionary Label Warning Watch Out There are possible hazards as shown by the symbols 1 Electric shock from welding electrode or wiring can kill 1 1 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves 1 2 Protect yourself from electric shock by insulating yourself from work and ground 1 3 Disconnect
15. 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 Original main power rectifiers Inverters input and output rectifiers only 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Supplies Unless Otherwise Stated Intellitig Maxstar 150 Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified DS 2 Wire Feeder Motor Driven Guns w exception of Spoolmate Spoolguns Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems Flowgauge and Flowmeter Regulators No Labor HF Units Grids Maxstar 85 140 Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp 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 on
16. person before doing any welding mara FLYING METAL can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 2236 Page 2 a BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away e Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electric
17. r guli rement contr ler et entretenir l installation e Maintenir soigneusement ferm s les panneaux et les portes des sour ces de haute fr quence maintenir le jeu d clatement au r glage ad quat et utiliser une terre et un blindage pour r duire les interf ren ces ventuelles LE SOUDAGE L ARC peut causer des interf rences e L nergie lectromagn tique peut causer des interf rences avec l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compati ble au point de vue lectromagn tique e Pour r duire la possibilit d interf rence maintenir les c bles de sou dage aussi courts que possible les grouper et les poser aussi bas que possible par ex terre e Veiller souder une distance de 100 m tres de tout quipement lectronique sensible e Veiller ce que le poste de soudage soit pos et mis la terre confor m ment au pr sent manuel e En cas d interf rences apr s ex cution des directives pr c dentes il incombe l utilisateur de prendre des mesures suppl mentaires tel les que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardia
18. s R pido Flat Horiz Fillet Smooth Easy Faster Todo All Bajo Low Pieza Fundida Cast Iron Todo All Bajo Low Inoxidable Stainless EP ELECTRODO POSITIVO POLARIDAD REVERSO ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODO NEGATIVO POLARIDAD DERECHO ELECTRODE NEGATIVE STRAIGHT POLARITY 207 866 OM 2236 Page 19 SECTION 6 MAINTENANCE 8 TROUBLESHOOTING 6 1 Routine Maintenance 1 gt gt ES A Disconnect power before maintaining 3 Months ID Replace Et Repair or A 56 tighten weld unreadable replace A ghte labels cracked Vy pa terminals weld AT cable 6 Months Blow out or vacuum inside During heavy service clean monthly 6 2 Fuse F1 A Disconnectand lockout tag out input power before open ing rear access door to change fuse 1 Fuse Holder Cover 2 Fuse F1 See Parts List For Rating p Fuse F1 protects control transform er from overload If F1 opens weld output and fan motor stops Re place F1 Close rear access door Tools Needed CRI 38 in S Pull Out And Replace Fuse Turn Install Flat End Of Fuse Into Cover Ref ST 800 101 C OM 2236 Page 20 6 3 Troubleshooting Table Trouble Remedy No weld output unit completely inoperative Place line disconnect switch in On position see Section 4 12
19. 20 735 4125 Circuit Diag rams European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 Welding Process Handbooks www MillerWelds com Contact the Delivering Carrier to 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 Mill r er PRINTED IN USA 2004 Miller Electric Mfg Co 1 04
20. Check fuse F1 and replace if necessary see Section 6 2 Check and replace line fuse s if necessary see Section 4 12 Check for proper input power connections see Section 4 12 Check for proper jumper link position see Section 4 11 No weld output power switch light on but fan off Unit overheated allow unit to cool see Section 4 2 NOTE When unit has cooled fan starts and weld output is present at the weld output terminals and or at the electrode No weld output but fan on Clean and tighten all weld connections see Section 6 1 Unit provides only low or minimum weld output Check for proper line voltage see Section 4 12 Check for proper input power connections see Section 4 12 Check for proper jumper link position see Section 4 12 Check for open line fuse s and replace if necessary see Section 4 12 Clean and tighten all weld connections see Section 6 1 Select correct size weld cables see Sections 4 7 and 4 8 Have factory authorized Service Agent check rectifier SR1 Erratic or improper weld output Check for proper input power connections see Section 4 12 Use proper size and type weld cables see Sections 4 7 and 4 8 Clean and tighten all weld connections see Section 6 1 Use proper size and type electrodes Have factory authorized Service Agent check rectifier SR1 Excessive line current or line fuse s ope
21. II 00012000 of reliable service with proper maintenance And for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in a He US A bbereg steradio exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard 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 Mill INET Mil Thank 7 03 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 131 Symbols age rt iet te oett de vet eie rd nue exe te 1 1 2 Are Welding Hazards tocan hee vetet er ge xe e t x ias 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 3 1 5 Principal Safety Standards 4 1 03 JEME Informationzs ta den tee ts d
22. Lbs 207663 RECITIFER SI DIODE 500 AMP 1 DO arka aata 181245 TERMINAL PWR OUTPUT RED 1 ROONG Orales 181246 TERMINAL PWR OUTPUT BLACK 1 Na 205976 NAMEPLATE MILLER SRH 503 1 38 81 159039 SWITCH ROCKER SPDT 15A 125VAC 1 MN ME 205914 PANEL FRONT usais al er REA ag Reale tp LE di 1 40 ares 205948 NAMEPLATE MILLER SRH 503 1 WAT ananas 190296 GEAR INDICATOR PINION 1 pan A es ni iti aes 190295 GEAR INDICATOR POINTER 1 Sit 190241 HANDLE CONTROL CURRENT 1 fn AA A 010828 HANDLE 2am Kas NAGA Aa GG PAGG PLAN aan refait ate dd 1 RAD a KN uud 186621 BOOT GENERIC OUTPUT STUD 2 d aces SAG ett 180735 WASHER OUTPUT STUD 2 na LR 181169 SPACER OUTPUT STUD 8 gees ci rado e tds 2 22240 2 oe Gane 195130 KIT LEAD SCREW REPLACEMENT 1 quo stern 205985 ASSEMBLY LAMINATION 45 DEG MOVABLE 1 TCU RM 205912 BRACKET MTG LAMINATION 4 bornes 205986 ASSEMBLY LAMINATION 45 DEG STATIONARY
23. N Du uA a Ert c eeu 13 4 7 Selecting And Preparing Weld Output Cables 14 4 8 Weld Gable Sizes zi xs eser Na DAA Rae ee Rd ie Rae RM set dst Rear RD 14 4 9 Connecting To Weld Output Terminals 15 4 10 Electrical Service Guide 1 nose saunas eut mes 2 RAR a iuh t oe Rd 15 4 11 Placing Jumper Links 2 s milia lzac rar LA LAAL AGA LAGARI AA A e 45 16 4 12 Connecting Input Power sisi RASRRRESERTRERREARR EEUU SEE ER a 17 SECTION 5 OPERATION ul A tg E DOE 18 521 Controls siria ium iste REPARARE AAA AAA RA AA REST NG 18 5 2 Electrode Amperage Selector 19 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 20 6 1 Routine Maintenance c2 a ngn pang GG AA NG NG PAGG LNG GAGA da FAET draw bd 20 6 2 FUSE Fl ECCL 20 6 3 Troubleshooting Table ss 24 0 20x p3h NG ra NAG AA AAA ARA A 21 SECTION 7 ELECTRICAL DIAGRAM occcoccccccccnon cr 23 SECTION 8 PARTSLIST 222 a ik ue ri A eee ces 24 OPTIONS AND ACCESSORIES WARRANTY Notes SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage A Marks a special safety message Means Warning Watch Out There are possible hazards
24. O Visit our website at www MillerWelds com OM 2236 205 982G May 2004 Miller Processes Q la Stick SMAW Welding Air Carbon Arc CAC A Cut ting and Gouging pun Submerged SAW Welding Description Ba Ng E Arc Welding Power Source SRH 503 OWNER S MANUAL 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 1t 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 n U 3 Bl E Kisa 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 Working as hard as you do f every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installation and operation quick business and easy With Miller you can count on years N
25. SHOCK INPUT CONNECTION CEW 1 Ls b et Sad cr eid 010467 CONN CLAMP CABLE 1 250 1 20 TE1 159244 PRIMARY BOX CONSISTING OF 1 ove voies 601835 NUT smi eI eere natalie ads bel DERE en tie dealer HD oie 24 vds Pa arcus 038887 STUD PRI BD BRS 10 32 X 1 375 24 Se deeds a 038618 LINK JUMPER TERM BD PRI 8 rias 601835 oto NUT TO 3ABAS ciar ia de A IIR ed ad aia 010913 WASHER FLAT 218 ID BRS 24 id gei mu 159034 HOLDER FUSE MINTR eeseeeee eee 1 22224 F1 156065 FUSE CRTG 5A 600V TIME DELAY 1 25 W 160793 CONTACTOR DEF PRP 60A 3P 24VAC 1 26 T2 208382 XFMR CONTROL 50VA 24V 220 440 60HZ 1 cu E Tei usas 162816 CHANNEL UPRIGHT ssesessse n 4 NA DEDERE 209869 WHEEL POLY OLEFIN 10 IN DIAX 2 00WIDEX 750 2 S29 pa bana 121614 RING RTNG EXT 750 SHAFT X 085 THK E STYLE PLD 2 EC AA 205998 AXLE RUNNING GEAR 750 DIA X 27 703 1 ess dl sense 008999 CASTER SWVL 4 00 IN POLY OLEFIN 2 Mela 163442 SUPPOR GASTER uo pr 1 Ee ea d 163533 BASE ta ERR A RE e EU Re PENES 1 see
26. al circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance A FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit LU OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e D
27. ations ne doi vent tre confi s qu des personnes qualifi es A Pendant l utilisation de l appareil tenir l cart toute personne en particulier les enfants m LES DECHARGES ELECTRIQUES e peuvent tre mortelles Un simple contact avec des pi ces sous tension peut causer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est en fonctionnement Le circuit d entr e et les circuits internes de l appareil sont galement sous tension En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Tout mat riel mal install ou mal mis la terre pr sente un danger e Ne jamais toucher aux pi ces lectriques sous tension e Porter des gants et des v tements de protection secs et exempts de trous e Sisoler de la pi ce et de la terre au moyen de tapis ou autres disposi tifs isolants suffisamment grands pour emp cher tout contact physique avec la pi ce ou la terre e Ne pas se servir d une source de courant alternatif dans les zones humi des les endroits confin s ou l o on risque de tomber e Ne se servir d une source de courant alternatif QUE si le proc d de souda ge l exige e Sil tilisation d une source de courant alternatif s av re n cessaire se ser vir de la fonction de t l commande si l appareil en est quip
28. d aspiration au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est insuffisante utiliser un respirateur adduction d air agr e Lire les fiches techniques de sant s curit FTSS et les instruc tions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs e Ne travailler dans un espace clos que s il est bien ventil ou porter un respirateur adduction d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent se substituer l air abaisser la teneur en oxyg ne et causer des l sions ou des accidents mortels S assurer que l air est respira ble e Ne pas souder proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irri tants e Ne pas souder de m taux munis d un rev tement tels que la t le d acier galvanis e plomb e ou cadmi e moins que le rev tement n ait t enlev dans la zone de soudage que l endroit soit bien venti l et si n cessaire porter un respirateur adduction d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques lorsqu on les soude OM 2236 Page 5 LES RAYONS DE L ARC peuvent cau ser des br lures oculaires et cuta n es
29. de souder retirer tout produit combustible de ses poches tel qu un briquet au butane ou des allumettes LES PARTICULES PROJET ES peu E d vent blesser les yeux e Le soudage le burinage le passage de la pi ce la brosse m tallique et le meulage provoquent l mission d tincelles et de particules m talli ques Pendant leur refroidissement les soudures risquent de projeter du laitier e Porter des lunettes de s curit crans lat raux agr s m me sous le masque de soudage OM 2236 Page 6 a LES ACCUMULATIONS DE GAZ peu vent causer des blessures ou m me la mort e Couper l alimentation en gaz protecteur en cas de non utilisation e Veiller toujours bien ventiler les espaces confin s ou porter un respira teur adduction d air agr z LES PI CES CHAUDES peuvent cau ser des br lures graves e Nepas toucher les pi ces chaudes main nue e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche LES CHAMPS MAGN TIQUES peuvent perturber le fonctionnement des stimu lateurs cardiaques e Les personnes qui portent un stimulateur cardiaque doivent se tenir distance e lis doivent consulter leur m decin avant de s appro cher d un lieu o on ex cute des op rations de sou dage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ouie Le bruit de certains processus et quipements peut affecter l ouie e Po
30. e de ss co tU a dw 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Signification des symboles 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Autres symboles relatifs l installation au fonctionnement et l entretien de l appareil 7 2 4 Principales normes de s curit 8 2 5 Information sur les champs lectromagn tiques 8 SECTION 3 DEFINITIONS eiiim eR xe Ee Re pee Ue RE Ro EUER etant ae 9 3 1 General Precautionary Label nuaran rarua r ranana a nannaa naana 9 3 2 Input Connection Label 10 3 3 Nameplate Safety Symbols 10 3 4 DO NOULITE 2 c zn He IM ree a Ue e ete ade UT ev ed der e 10 SECTION A INSTALLATION inspre xiv Aie DING ieee tenant n one Perse ewes 11 4 1 Specifications cci cm ier eR dead PI An A daar edad RN ERE E DR S 11 4 2 Duty Gycle And Overheating anna kaa p A DRE DE d 11 4 35 Vol Ampere CUrves in seen A E PR ER RIAM E ee yaa NS 12 4 4 Selecting A Location e ur ixi A ISIN eSI RE RM REED 12 4 5 Dimensions And Weights akan A ch Saws NATN DRE EU I EN 18 4 6 TIPPING 8 una nee hi on 2 AM a us OR Ae DR EUR IRE Rom NA Dis E PAR N
31. e symboles signifie Mise en garde Faire preuve de vigi lance ll y a des dangers li s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Se reporter aux symboles et aux directives ci dessous afin de conna tre les me sures prendre pour viter tout danger e N utiliser que du mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment au pr sent manuel e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le c ble de retour de fa on obtenir un bon contact m tal sur m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure Ne pas connecter plus d une lectrode ou plus d un c ble de masse un m me terminal de sortie Il subsiste un COURANT CONTINU IMPORTANT dans les convertisseurs apr s la suppression de l alimentation lectrique e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions nonc es la section Entretien avant de toucher les pi ces b LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz dont l inhalation peut tre dangereuse pour la sant e Setenir distance des fum es et ne pas les inhaler e l int rieur ventiler la zone et ou utiliser un dispositif
32. e work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding
33. e year whichever is greater 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns 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 Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 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 wri
34. fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 2236 Page 1 ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather and wool and foot protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the we
35. gional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 2 1 Signification des symboles identifie un message de s curit particulier Signifie Mise en garde Faire preuve de vigilance Cette proc dure pr sente des risques identifi s par les symboles adjacents aux directives Signifie NOTA n est pas relatif la s curit 2 2 Dangers relatifs au soudage l arc A Les symboles ci apr s sont utilis s tout au long du pr sent manuel pour attirer l attention sur les dangers potentiels et les identifier Lorsqu on voit un symbole faire preuve de vigilance et suivre les directives mentionn es afin d viter tout danger Les consignes de s curit nonc es ci apr s ne font que r sumer le contenu des normes de s curit mentionn es la section 2 4 Lire et respecter toutes ces normes L installation l utilisation l entretien et les r par
36. input plug or power before working on machine 2 Breathing welding fumes can be hazardous to your health 2 1 Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Do not weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use it 3 3 Do not weld on drums or any closed containers 4 Arcrays can burn eyes and injure skin 4 1 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection 5 Become trained and read the instructions before working on the machine or welding 6 Do not remove or paint over cover the label OM 2236 Page 9 3 2 Input Connection Label 1 96 1 Warning Watch Out There are possible hazards as shown by the symbols Electric shock from wiring can kill Disconnect input plug or power before working on machine Read the Owner s Manual before working on this machine Consult rating label for input power requirements and check power available at the job site they must match Read Owner s Manual and inside labels for connection points and proced
37. lding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers e Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your
38. les et de m tal chaud e Ne pas souder un endroit o des tincelles peuvent tomber sur des substances inflammables e Placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneuse ment avec des protections agr es e Des tincelles et des mati res en fusion peuvent facilement passer m me par des fissures et des ouvertures de petites dimensions e Surveiller tout d clenchement d incendie et tenir un extincteur proxi mit Le soudage effectu sur un plafond un plancher une paroi ou une cloison peut d clencher un incendie de l autre c t e Ne pas souder des r cipients ferm s tels que des r servoirs des f ts ou des conduites moins qu ils n aient t pr par s conform ment l AWS F4 1 voir les normes de s curit e Brancher le c ble sur la pi ce le plus pr s possible de la zone de sou dage pour viter que le courant ne circule sur une longue distance par des chemins inconnus et ne cause des risques d lectrocution et d in cendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil au raz du tube contact e Porter des v tements de protection exempts d huile tels que des gants en cuir une chemise en tissu pais des pantalons sans revers des chaussures montantes et un masque e Avant
39. m this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipment at once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of Califo
40. ment is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill e Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body som _8 03 e se PF i This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e f earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with th
41. n repeatedly Check for proper input power connections see Section 4 12 Check for proper jumper link position see Section 4 11 Fan not operating and or over heating Check for and remove anything blocking fan movement Have factory authorized Service Agent check fan motor OM 2236 Page 21 Notes OM 2236 Page 22 SECTION 7 ELECTRICAL DIAGRAM For Primary Circuit Diagram Portion refer to Circuit Diagram located inside wrapper of welding power source pun SIU solas Jo asn psu suosiad paijijonb Ao SAD e PSAOUUSI S18A09 Yjim a DIado jou oq e bulolajas asojeq sulbua dois Jo Jamod jndu j2euuoosiQg e sod b2ujoe e e uonoj jou og e QNVZVH 20HS 941931 ININYYM Y TO tO 97 67 99 SO 9 9q Sq a e La LYA 4 A 2 TO LO Vv Ne v NY Y ML ea za iq e LYS MMOD 08007 DIS 00107 8 8 COITO TIITH E 8 o oO w N O Co mq sg BR a 0 oO D OCT 09h OFZ 0cc Ovv Occ Occ 09v OFZ 0cc Ovy OTZ ocz 09v OFZ 0cc 0vr 03Z YEL BRN 205 900 C Figure 7 1 Circuit Diagram O O OW I 1 uo OM 2236 Page 23 SECTION 8 PARTS LIST E Hardware is common and not available unless listed
42. o not block or filter airflow to unit ar nn o 7 STATIC ESD can damage PC boards y e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards GS N MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body other people or any metal when threading welding wire LE 3 1 4 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health 8 Safety Code Section 25249 5 et seq A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling a MOVING PARTS can cause injury e Keep away from moving parts such as fans Ng e Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perfor
43. que restez dis tance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s appro cher des op rations de soudage l arc de gou geage ou de soudage par points OM 2236 Page 7 2 4 Principales normes de s curit Safety in Welding Cutting and Allied Processes norme ANSI 749 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping norme American Welding Society AWS F4 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org National Electrical Code norme NFPA 70 de la National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 sites Web www nfpa org et www sparky org Safe Handling of Compressed Gases in Cylinders brochure CGA P 1 de la Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Web www cganet com Code for Safety in Welding and Cutting norme CSA W117 2 de la Ca nadian Standards Association Standards Sales 178 boulevard Rexdale Rexdale Ontario Canada M9W 1R3 t l phone 800 463 6727 ou Toronto 416 747 4044 site Web www csa interna tional org Practice For Occ
44. r 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 7 Miller Effective January 1 2004 Equipment with a serial number preface of LE or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied 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
45. rnia to cause cancer birth defects and other reproductive harm OM 2236 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 phone 305 443 9353 website www aws org Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Ra Mi ami FL 33126 phone 305 443 9353 website www aws org National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 web site www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a
46. rter des protecteurs d oreille agr s si le niveau sonore est trop lev Les BOUTEILLES endommag es peuvent exploser Les bouteilles de gaz protecteur contiennent du gaz sous haute pression Toute bouteille endommag e peut exploser Comme les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim de la chaleur excessive des chocs m caniques du laitier des flammes nues des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres cir cuits lectriques e Ne jamais poser une torche de soudage sur une bouteille de gaz e Ne jamais mettre une lectrode de soudage en contact avec une bou teille de gaz e Ne jamais souder une bouteille contenant du gaz sous pression elle risquerait d exploser e N utiliser que les bouteilles de gaz protecteur r gulateurs tuyaux et raccords ad quats pour l application envisag e les maintenir en bon tat ainsi que les pi ces connexes e D tourner la t te lorsqu on ouvre la soupape d une bouteille e Laisser le capuchon protecteur sur la soupape sauf en cas d utilisa tion ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz compri m les quipements associ
47. special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 2236 Page 4 Boulevard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa in ternational org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 518B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Re
48. ting 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 conseq
49. u des pieces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprim s LES PI CES MOBILES peuvent cau ser des blessures e Se tenir l cart des pi ces mobiles e Se tenir l cart des points de coincement tels que les d vidoirs LES FILS DE SOUDAGE peuvent cau ser des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi vers d autres personnes ou vers toute pi ce m canique en en gageant le fil de soudage PAL N LES ORGANES MOBILES peuvent causer des blessures NG e Se tenir l cart des organes mobiles comme les ventilateurs e Maintenir fermes et bien fixes les portes panneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de causer des interf rences e Le rayonnement haute fr quence peut causer des interf rences avec les quipements de radio navigation et de communication les services de s curit et les ordinateurs e Ne demander qu des personnes qualifi es familiaris es avec les quipements lectroniques de faire fonctionner l installation e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences caus es par l installation e Sila Federal Communications Commission signale des interf ren ces arr ter imm diatement l appareil e Faire
50. uential 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 3 04 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 sovice and Mapai Miller Electric Mfg Co Replacement Parts An Illinois Tool Works Company 1635 West Spencer Street Training Schools Videos Books Appleton WI 54914 USA ae International Headquarters USA Technical Manuals Servicing Information USA Phone 920 735 4505 Auto Attended and Parts USA amp Canada FAX 920 735 4134 International FAX 9
51. upational And Educational Eye And Face Protection norme ANSI Z87 1 de l American National Standards Institute 11 West 42nd Street New York NY 10036 8002 t l phone 212 642 4900 site Web www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work norme NFPA 51B de la National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Web www nfpa org et www sparky org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de l U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux T l phone pour la R gion 5 Chicago 312 353 2220 site Web www osha gov 2 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et les effets des champs magn ti ques basse fr quence sur l organisme En parcourant les c bles de soudage le courant cr e des champs lec tromagn tiques Les effets potentiels de tels champs restent pr occupants Cependant apr s avoir examin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit de sp cialistes du National Research Council a conclu L accumula tion de preuves n a pas d montr que l exposition aux champs magn tiques et aux
52. ures Move jumper links as shown on inside label to match voltage at job site Having a loop of extra length connect grounding conductor first Connect line input conductors as shown on inside label double check all connections jumper link positions and input voltage before applying power 3 3 Nameplate Safety Symbols Warning Watch Out There are possible hazards as shown by the symbols Electric shock from welding electrode or wiring can kill Sparks from arcing electrode can cause explosion or fire disconnect cable for process not in use Read Owner s Manual for connection procedures Electric shock from wiring can kill Disconnect input power before working on unit or making terminal strip connections Nameplate D 179 389 3 4 Do Not Lift 1 2 T S my 206 403 Warning Watch Out There are possible hazards as shown by the symbols Falling equipment can cause serious personal injury and equipment damage Do not use handles to lift system Handles are not designed to support weight of system Use lifting eye to lift unit only Not running gear Lift only with proper equipment and correct procedures Use handle only to move unit OM 2236 Page 10 SECTION 4 INSTALLATION 4 1 Specifications Amperes Input at Rated Load
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