Documente Academic
Documente Profesional
Documente Cultură
May 2004
205 982G
Processes
Stick (SMAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Submerged (SAW) Welding
Description
SRH-503
www.MillerWelds.com
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.
Mil_Thank 7/03
TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Autres symboles relatifs linstallation, au fonctionnement et lentretien de lappareil. . . . . . . . . . . . 2-4. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Information sur les champs lectromagntiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. General Precautionary Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Input Connection Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Nameplate Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Do Not Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Selecting And Preparing Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. Weld Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11. Placing Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Electrode/Amperage Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Fuse F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIES WARRANTY 1 1 1 3 3 4 4 5 5 5 7 8 8 9 9 10 10 10 11 11 11 12 12 13 13 14 14 15 15 16 17 18 18 19 20 20 20 21 23 24
Notes
D If earth grounding of the workpiece is required, ground it directly with a separate cable. D Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. D Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. D Wear a safety harness if working above floor level. D Keep all panels and covers securely in place. D Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. D Insulate work clamp when not connected to workpiece to prevent contact with any metal object. D Do not connect more than one electrode or work cable to any single weld output terminal.
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D Pacemaker wearers keep away. D Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations.
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D D D D
D D
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. Signifie NOTA ; nest pas relatif la scurit. 2-2. Dangers relatifs au soudage larc
Y Les symboles ci-aprs sont utiliss tout au long du prsent manuel pour attirer lattention sur les dangers potentiels et les identifier. Lorsquon voit un symbole, faire preuve de vigilance et suivre les directives mentionnes afin dviter tout danger. Les consignes de scurit nonces ci-aprs ne font que rsumer le contenu des normes de scurit mentionnes la section 2-4. Lire et respecter toutes ces normes. Y Linstallation, lutilisation, lentretien et les rparations ne doivent tre confis qu des personnes qualifies. Y Pendant lutilisation de lappareil, tenir lcart toute personne, en particulier les enfants.
D Nutiliser que du matriel en bon tat. Rparer ou remplacer surle champ les pices endommages. Entretenir lappareil conformment au prsent manuel. D Porter un harnais de scurit quand on travaille en hauteur. D Maintenir solidement en place tous les panneaux et capots. D Fixer le cble de retour de faon obtenir un bon contact mtal sur mtal avec la pice souder ou la table de travail, le plus prs possible de la soudure.
D Ne pas connecter plus dune lectrode ou plus dun cble de masse un mme terminal de sortie.
Il subsiste un COURANT CONTINU IMPORTANT dans les convertisseurs aprs la suppression de lalimentation lectrique.
D Arrter les convertisseurs, dbrancher le courant lectrique et dcharger les condensateurs dalimentation selon les instructions nonces la section Entretien avant de toucher les pices.
D Se tenir distance des fumes et ne pas les inhaler. D lintrieur, ventiler la zone et/ou utiliser un dispositif daspiration au niveau de larc pour lvacuation des fumes et des gaz de soudage. D Si la ventilation est insuffisante, utiliser un respirateur adduction dair agr. D Lire les fiches techniques de santscurit (FTSS) et les instructions du fabricant concernant les mtaux, les consommables, les revtements, les nettoyants et les dgraisseurs. D Ne travailler dans un espace clos que sil est bien ventil ou porter un respirateur adduction dair. Demander toujours un surveillant dment form de se tenir proximit. Des fumes et des gaz de soudage peuvent se substituer lair, abaisser la teneur en oxygne et causer des lsions ou des accidents mortels. Sassurer que lair est respirable. D Ne pas souder proximit doprations de dgraissage, de nettoyage ou de pulvrisation. La chaleur et les rayons de larc peuvent ragir en prsence de vapeurs et former des gaz hautement toxiques et irritants. D Ne pas souder de mtaux munis dun revtement, tels que la tle dacier galvanise, plombe ou cadmie, moins que le revtement nait t enlev dans la zone de soudage, que lendroit soit bien ventil, et si ncessaire, porter un respirateur adduction dair. Les revtements et tous les mtaux renfermant ces lments peuvent dgager des fumes toxiques lorsquon les soude.
D Couper lalimentation ou arrter le moteur avant de procder linstallation, la rparation ou lentretien de lappareil. Couper/tiqueter lalimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de scurit). D Installer et mettre la terre correctement lappareil conformment son manuel dutilisation et aux codes nationaux, provinciaux et municipaux. D Toujours vrifier la terre du cordon dalimentation Vrifier et sassurer que le fil de terre du cordon dalimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccorde une prise correctement mise la terre. D Pour excuter les branchements dentre, fixer dabord le conducteur de mise la terre adquat et contrevrifier les connexions. D Vrifier frquemment le cordon dalimentation et sassurer quil nest ni endommag ni dnud ; le remplacer immdiatement sil est endommag tout cble dnud peut causer une lectrocution. D Mettre lappareil hors tension quand on ne lutilise pas. D Ne pas utiliser de cbles uss, endommags, de calibre insuffisant ou mal pisss. D Ne pas senrouler les cbles autour du corps. D Si la pice soude doit tre mise la terre, le faire directement avec un cble distinct. D Ne pas toucher llectrode quand on est en contact avec la pice, la terre ou une lectrode dune autre machine.
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endommages
Les bouteilles de gaz protecteur contiennent du gaz sous haute pression. Toute bouteille endommage peut exploser. Comme les bouteilles de gaz font normalement partie du procd de soudage, les manipuler avec prcaution. D Protger les bouteilles de gaz comprim de la chaleur excessive, des chocs mcaniques, du laitier, des flammes nues, des tincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un portebouteilles pour les empcher de tomber ou de se renverser. D Tenir les bouteilles loignes des circuits de soudage ou autres circuits lectriques. D Ne jamais poser une torche de soudage sur une bouteille de gaz. D Ne jamais mettre une lectrode de soudage en contact avec une bouteille de gaz. D Ne jamais souder une bouteille contenant du gaz sous pression elle risquerait dexploser. D Nutiliser que les bouteilles de gaz protecteur, rgulateurs, tuyaux et raccords adquats pour lapplication envisage ; les maintenir en bon tat, ainsi que les pices connexes. D Dtourner la tte lorsquon ouvre la soupape dune bouteille. D Laisser le capuchon protecteur sur la soupape, sauf en cas dutilisation ou de branchement de la bouteille D Lire et suivre les instructions concernant les bouteilles de gaz comprim, les quipements associs et les publications P1 de la CGA, mentionnes dans les normes de scurit.
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SECTION 3 DEFINITIONS
3-1. General Precautionary Label
Warning! Watch Out! There are possible hazards as shown by the symbols. 1 1.1 Electric shock from welding electrode or wiring can kill. Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Protect yourself from electric shock by insulating yourself from work and ground. Disconnect input plug or power before working on machine. Breathing welding fumes can be hazardous to your health. Keep your head out of the fumes. Use forced ventilation or local exhaust to remove the fumes. Use ventilating fan to remove fumes. Welding sparks can cause explosion or fire. Keep flammables away from welding. Do not weld near flammables. Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. Do not weld on drums or any closed containers. Arc rays can burn eyes and injure skin. Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection. Become trained and read the instructions before working on the machine or welding. Do not remove or paint over (cover) the label.
1.2
1.3
3.2
3.3 4 4.1
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2 3
5 1 2 3 ?
V
6
? ?
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4 8
5 3
S-179 290
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 Owners 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 Owners Manual and inside labels for connection points and procedures. 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.
4 5 5 6 6
206 403
SECTION 4 INSTALLATION
4-1. Specifications
Amperes Input at Rated Load Output, 60 Hz, Three-Phase Amp Range DC 50 525 Max OCV DC 220-230 V 98 4.5* 440-460 V 49 2.2* KVA KW
Model
500 Amp
77
38.9 1.8*
26 0.7*
*While idling
WELD AMPERES
100 10 20 30 40 50 60 70 80 90100
% DUTY CYCLE
60% Duty Cycle At 500 Amperes For 500 Ampere Models
4 Minutes Resting
V
15
Minutes
205 909
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206 054
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. 2 4 Line Disconnect Device Locate unit near correct input power supply.
OR
Y Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20.
18 in (460 mm)
18 in (460 mm)
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35-1/4 in (895 mm) 28 in (711 mm) 33-1/2 in (851 mm) 27-1/2 in (699 mm) 3/4 in (19 mm)
4-6. Tipping
Y Be careful when placing or moving unit over uneven surfaces.
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10 ft (3 m) 3
10 ft (3 m) Tools Needed:
2
sb6.1 11/92 S-0653
150 ft (45 m)
200 ft (60 m)
250 ft (70 m)
300 ft (90 m)
350 ft (105 m)
400 ft (120 m)
*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 mm2 equivalent weld cable sizes. S-0007-E
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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. 3 For DC Electrode (DCEN), reverse connections. Negative cable
Reference: 1999 National Electrical Code (NEC) 1 Consult factory for circuit breaker applications. 2 Time-Delay fuses are UL class RK5 . 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).
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220230 VOLTS
440460 VOLTS
208 380A
3/8, 1/2 in
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3
= GND/PE Earth Ground 8
Y Disconnect and lockout/tagout input power before connecting input conductors from unit. Y Make input power connections to the welding power source first. Y Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal. See rating label on unit and check input voltage available at site. 1 Input Power Conductors (Customer Supplied Cord)
10 9 2 4 6
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 relief and tighten screws. 3 4 Machine Grounding Terminal Green Or Green/Yellow Grounding Conductor
IMPORTANT
5
L1 (U) 3 Input Contactor
Connect green or green/yellow grounding conductor to welding power source grounding terminal first. 5 Welding Power Source Line Terminals Input Conductors L1 (U), L2 (V) And L3 (W)
6 L2 (V)
L3 (W)
Connect input conductors L1 (U), L2 (V) and L3 (W) to welding power source line terminals. Close and secure access door on welding power source.
4 3
= GND/ PE Earth Ground
Disconnect Device Input Power Connections 7 8 Disconnect Device (switch shown in OFF position) 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. Tools Needed: 3/8 in 3/8 in 10 Over-Current Protection Select type and size of over-current protection using Section 4-10 (fused disconnect switch shown). Close and secure door on line disconnect device. Remove lockout/tagout device, and place switch in the On position.
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SECTION 5 OPERATION
5-1. Controls
1 Power Switch W/Indicator Lamp
When the switch is turned on, the lamp lights to indicate power has been applied to the unit. Y If the indicator lamp does not light when the power switch is turned on, replace the switch. NOTE: This unit has over-temperature 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. The indicator lamp on the power switch remains on. 1 Y 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 electrode. 2 3 Amperage Adjustment Control Amperage Range Indicator
Turn handle clockwise to increase amperage as indicated by the amperage range indicator. 2
803 026-C
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3 Months
6 Months
Or
6-2. Fuse F1
Y Disconnect and lockout/tagout input power before opening rear access door to change fuse. 1 2 Fuse Holder Cover Fuse F1 (See Parts List For Rating)
Fuse F1 protects control transformer from overload. If F1 opens, weld output and fan motor stops. Replace F1. Close rear access door.
Turn
Pull Out And Replace Fuse (Install Flat End Of Fuse Into Cover)
Turn
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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. No weld output, but fan on. Unit provides only low or minimum weld output. 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. Clean and tighten all weld connections (see Section 6-1). 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) open repeatedly. Fan not operating and/or over heating. Check for proper input power connections (see Section 4-12). Check for proper jumper link position (see Section 4-11). Check for and remove anything blocking fan movement. Have factory authorized Service Agent check fan motor.
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Notes
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205 900-C
16
17
23
24
25
15
22
14
20
21
26
13
12
59
10
11
27
28 30
61
34
29
60
56
55
33
32
53 54
37
38
31
57
52
58
35
36
41 42 1 48 49 49 47 45 60 51 50 44
ST-803 137-D
40
39 43
Item No.
Dia. Mkgs.
Part No.
Quantity
. . . 1 . . . . . . . . . . 176254 . . . 2 . . . . . . . . . +179430 . . . 3 . . . . . . . . . . 205910 . . . 4 . . . . . . . . . . . 205911 . . . 5 . . . . . . . . . +206585 . . . 6 . . . . . . . . . . 206403 . . . 7 . . . . . . . . . . 207866 . . . 8 . . . . . . . . . . 177279 . . . 9 . . . . . . . . . . 162830 . . . 10 . . . . . . . . . . 162820 . . . 11 . . . FM . . 208 402 . . . 12 . . . . . . . . . . 124274 . . . 13 . . . . . . . . . . 173283 . . . 14 . . . . . . . . . . 180165 . . . 15 . . . . . . . . . . 162807 . . . 16 . . . . . . . . . . 168343 . . . 17 . . . . . . . . . +162818 . . . 18 . . . . . . . . . . 179290 . . . 19 . . . . . . . . . . 010467 . . . 20 . . . TE1 . . 159244 . . . 21 . . . . . . . . . . 601835 . . . 22 . . . . . . . . . . 038887 . . . . . . . . . . . . . . . . 038618 . . . . . . . . . . . . . . . . 601835 . . . . . . . . . . . . . . . . 010913 . . . 23 . . . . . . . . . . 159034 . . . 24 . . . . F1 . . *156065 . . . 25 . . . . W . . . 160793 . . . 26 . . . . T2 . . 208382 . . . 27 . . . . . . . . . . 162816 . . . 28 . . . . . . . . . . 209869 . . . 29 . . . . . . . . . . 121614 . . . 30 . . . . . . . . . . 205998 . . . 31 . . . . . . . . . . 008999 . . . 32 . . . . . . . . . . 163442 . . . 33 . . . . . . . . . . 163533 . . . 34 . . . . . . . . . . 207663 . . . 35 . . . . . . . . . . 181245 . . . 36 . . . . . . . . . . 181246 . . . 37 . . . . . . . . . . 205976 . . . 38 . . . . S1 . . 159039 . . . 39 . . . . . . . . . . 205914 . . . 40 . . . . . . . . . . 205948 . . . 41 . . . . . . . . . . 190296 . . . 42 . . . . . . . . . . 190295 . . . 43 . . . . . . . . . . 190241 . . . 44 . . . . . . . . . . 010828 . . . 45 . . . . . . . . . . 186621 . . . 47 . . . . . . . . . . 180735 . . . 48 . . . . . . . . . . . 181169 . . . 49 . . . . . . . . . . 195130 . . . 50 . . . . . . . . . . 205985 . . . 51 . . . . . . . . . . 205912 . . . 52 . . . . . . . . . . 205986
. . . . . LABEL,GENERAL PRECAUTIONARY WORDLESS,INTL . . . . . . . . . . . . . . . . . PANEL,SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BAFFLE,AIR LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BAFFLE,AIR UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COVER,TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL,CAUTION DO NOT LIFT WORDLESS . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL,ROD TYPE&SIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKET,LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT EYE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BAR,MTG LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOTOR,1/12HP 230V 1550 RPM 50/60HZ .83A . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET,MTG FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHAMBER,PLENUM 14 IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLADE,FAN 14.000 3WG 28DEG .375 BORE CCW GAL . . . . . . . . . . . . . . . . . . PANEL,REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HINGE,CONT POLYOLEFIN COPOLYMER 2.000 L W/.125H . . . . . . . . . . . . . . DOOR,ACCESS PRIMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL,WARNING ELECTRIC SHOCK INPUT CONNECTION CE W . . . . . . . CONN,CLAMP CABLE 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRIMARY BOX, (CONSISTING OF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STUD, PRI BD BRS 10-32 X 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LINK, JUMPER TERM BD PRI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, 10-32 BRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, FLAT .218 ID BRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOLDER, FUSE MINTR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE, CRTG .5A 600V TIME DELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTACTOR, DEF PRP 60A 3P 24VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XFMR, CONTROL 50VA 24V 220/440 (60HZ) . . . . . . . . . . . . . . . . . . . . . . . . . . . CHANNEL,UPRIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL,POLYOLEFIN 10 IN DIAX 2.00WIDEX.750 . . . . . . . . . . . . . . . . . . . . . . RING,RTNG EXT .750 SHAFT X .085 THK E STYLE PLD . . . . . . . . . . . . . . . . . AXLE,RUNNING GEAR .750 DIA X 27.703 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CASTER,SWVL 4.00 IN POLYOLEFIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SUPPORT,CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BASE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECITIFER,SI DIODE 500 AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TERMINAL,PWR OUTPUT RED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TERMINAL,PWR OUTPUT BLACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE,MILLER SRH503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH,ROCKER SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL,FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE,MILLER SRH503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEAR,INDICATOR PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEAR,INDICATOR POINTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLE,CONTROL CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOT,GENERIC OUTPUT STUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER,OUTPUT STUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPACER,OUTPUT STUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KIT, LEAD SCREW REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY,LAMINATION 45 DEG MOVABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET,MTG LAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY,LAMINATION 45 DEG STATIONARY . . . . . . . . . . . . . . . . . . .
2 2 2 2 1 1 1 1 1 2 1 1 1 1 1 2 1 1 1 1 24 24 8 24 24 1 1 1 1 4 2 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 1 4 1
OM-2236 Page 25
Item No.
Dia. Mkgs.
Part No.
Quantity
. . . 53 . . . . . . . . . . 205885 . . . . . . . . 54 . . . . . . . . . . 024620 . . . . . . . . 55 . . . . . . . . . . 206010 . . . . . . . . 56 . . . . . . . . . . 010660 . . . . . . . . 57 . . . . . . . . . . 204960 . . . . . . . . 58 . . . . T1 . . 204956 . . . . . . . . . . . . TP1, 2, 3 208381 . . . . . .............................. . . . 59 . . . . . . . . . . 604536 . . . . . . . . 60 . . . . . . . . . . 217136 . . . . . . . . 61 . . . . . . . . . . 217864 . . . . . . . . 62 . . . . . . . . . . 217138 . . . . .
SPACER,STL .500 ID X .625 OD X 1.267 . . . . . . . . . . . . . . . . . . . . . . . . . . . SPROCKET,W/1/8 HOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHAIN,ROLLER NO 43 1/4X54 PITCHES LG . . . . . . . . . . . . . . . . . . . . . . . PIN,SPRING CS .125 X 1.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPRING,CPRSN .625 OD X .123 WIRE X 1.500 . . . . . . . . . . . . . . . . . . . . XFMR,POWER MAIN 220/440 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTAT,NC OPEN 135C CLOSE 135C W/INSUL LEADS (included w/T1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREW, 312-18 X 1.75 HEX HD-PLN GR5 PLD . . . . . . . . . . . . . . . . . . . . LABEL, WARNING ELECTRIC SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, CAUTION DO NOT LIFT (FR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, WARNING ELECTRIC SHOCK/INPUT POWER . . . . . . . . . . . . .
2 2 1 2 4 1 3 2 2 1 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 Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2236 Page 26
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1.
Induction Heating Coils and Blankets APT & SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts (No labor) Spoolmate Spoolguns Canvas Covers
Millers True Blue Limited Warranty shall not apply to: 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.) Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturers warranty, if any. 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.
2.
3.
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2.
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 (Unless Otherwise Stated) Intellitig Maxstar 150 Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) 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 & Arc Stud Guns Racks 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.)
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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 Millers 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 customers risk and expense. Millers 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 3/04
3.
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4. 5.
Owners Record
Please complete and retain with your personal records.
Model Name Purchase Date Distributor Address City State Zip Serial/Style Number
(Date which equipment was delivered to original customer.)
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.
PRINTED IN USA
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