Miller Electric 500SSX Specifications

MillerApri1994Form:OM-168256EffectiveWithSerialNo.KE600689OWNERSMANUALReadandfollowtheseinstructionsandallsafetyblockscarefully.Haveonlytrainedand

I00)01a)-op3(a0101%)2Fig8-5211(0C-Im-SDPIn U)mB0C23Cl)rnC)0z-ICl)Cl)-IFig8-310I-,1711611151413

Figure8-1.MainAssemblyWhenorderingacomponentoriginallydisplayingaprecautionarylabel,thelabelshouldalsobeordered.**Includedw/PC1.BESURETOPROVIDEMODELA

ItemDia.No.Mkgs.PartNo.DescriptionFigure8-2.Panel,Rearw/Components(Fig8-1Item7)Quantity..1...FM..234116190131361032611158289..1111Figure8-2.Panel,Rear

itemPartNo.No.Description046745Figure8-4.Switch,PB(Fig8-6Item11)BUTTON,pushresetred1SPRING,cprsn.430ODx.040wirex1.500stnIs1PUSHBUTTONSET,w/cable&h

-n(aC-ICDCD-n-I0IC)acD(I,30r~)C.)0/////A////-pC.)I)\--\N(1~(0-~F)~

Figure8-6.Panel,Frontw/Components(Fig8-1Item20)+Whenorderingacomponentoriginallydisplayingaprecautionarylabel,thelabelshouldalsobeordered.BESURETOPROV

LesBOUTEILLESendommageespeuventexploser.Lesbouteillescontiennentdesgazprotecteurssoushautepression.Desbouteillesendommageespeuventexploser.C;ommelesbo

EMFINFORMATIONTABLEOFCONTENTSSECTION1-SAFETYINFORMATIONSECTION2SPECIFICATIONS2-1.Volt-AmpereCurves2-2.DutyCycleSECTION3INSTALLATION3-1.SelectingALoc

SECTION1-SAFE~TYINFORMATIONReadallsafetymessagesthroughoutthismanual.Obeyallsafetymessagestoavoidinjury.Learnthi?meaningofWARNINGandCAUTION.modl.12

2-1.Volt-AmpereCurvesFigure2-1.Volt-AmpereCurves2-2.DutyCycleL~AUTIONWELDINGLONGERTHANRATEDDUTYCYCLEcandamageunitandvoidwarranty.Donotweldatratedloa

SECTION3-INSTALLATION3-1.SelectingALocationAndMovingWeldingPowerSource£~~NARNINGELECTRICSHOCKcankill.Donottouchliveelectricalparts.Disconnectinputpo

NOTELI~ii~Overalldimensions(A,B,andC)includeliftingeye,handles,hardware,etc.IDInchesMillimetersA30-1/4769FrontB22-3/4578D1-1/238E32-3/4832~-C35-3/49

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Table3-1.WeldCableSize*4A~JVARNINGToolsNeeded:3/4in~==~Figure3-4.WeldOiitputConnectionsWeldingAmperesTotalCable(Copper)LengthInWeldCircuitNotExceeding

3-4.Remote14ReceptacleInformationAndConnectionsFigure3-5.Remote14ConnectionsTable3-2.Remote14SocketInformationREMOTE14Socket*SocketInformationOUTPUT(C

3-5.ConnectingInputPowerWARNINGELECTRICSHOCKcankill.Donottouchliveelectricalparts.TurnOffweldingpowersource,anddisconnectinputpowerbeforeinspectingo

MILLERSTRUEBLUETMLIMITEDWARRANTYEffective,January1,1992(EquipmentwithaserialnumberprefaceofKCornewer)ThislimitedwarrantysupersedesallpreviousMtLLER

B.ConnectingInputPowerFigure3-7.InputPowerConnectionsTable3-3.ElectricalServiceRequirements*InputVoltage220380400415InputAmperesAtRatedOutput1C2595654

SECTION4-OPERATIONWARNINGELECTRICSHOCKcankill.Alwaysweardryinsulatinggtoves.Insulateyourselffromworkandground.Donottouchliveelectricalparts.Keepal

WARNINGELECTRICSHOCKcankill.Donottouchliveelectricalparts.Donottouchweldoutputterminalswhencontactorisenergized.Donottouchelectrodeandworkclampatth

RANGESWITCHHIGHAAMPERAGE14PANEL1RangeSwitchUseswitchtochooseoutputrange.Lowgivesbetterlowamperageadjustment(usewithLowscaleonAmperageAdjustmentcontrol

I

a~JVARNINGARCINGcandamagoswitchcontacts.DonotchangePolaritySwitchpositionwhilewelding.Arcinginsideswitchcandamagecontacts,causingswitchtofail.LiFigur

SECTION5-MAINTENANCE&TROUBLESHOOTING~WARNINGELECTRICSHOCKcankill.Donottcuchliveelectricalparts.TurnOffweldingpowersource,anddisconnectinputpower

5-2.OverloadProtectionaWARNING~IVARNINGREADSectioSAFETYn5betorBLOCKSatstartofeproceeding.~-~ffIj-~Whenoverheated,thermostatLetfanrunforStartwelding.op

Maximumweldoutput.--~__Erraticweldoutput.I-..-.-~3-5B--Excessivelinecurrentorlinefuse(s)-~opensrepeatedly.CheckforshortedtanmotorFMleads,andrepa

NOTESOM-168256Page16

SIECTION6-ELECTRICALDIAGRAMSu~~0.~.~I~E~.~.~)~U(.).~0~.Q)g)0LL~~SC-137779-Aw>IU)00~Ui>F00Figure6-1.CircuitDiagramForWeldingPowerSourceOM-168256

ARCWELDINGSAFETYPRECAUTIONS5.ProperlyinstallandgroundthisequipmentaccordingtoitsOwnersManualandnational,state,andlocalcodes.6.Whenmakinginputconnecti

GND.Figure6-2.WiringDiagramForWeldingPowerSourceGND.OM-168256Page18

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SECTION7-TUNGSTENELECTRODENOTEForadditionalinformation,seeyourdistributorforahandbookontheGasTungstenIArcWelding(GTAW)process.Wearcleanglovestoprevent

7-2.PreparingTLungsten1TungstenElectrode12BalledEndBallendoftungstenbeforeweldingbyapplyingeitheranacamperageslightlyhigherthanwhatisrecommendedforagi

00)0)1%)0)(0cDF)r%)2411C-ImP-~a(a, (a,3a.25,~Fig8-521Cl)mC,0zCo-ICl)!C/)-I19II--181716)1413Fig8-620

Figure8-1.MainAssemblyWhenorderingacomponentoriginallydisplayingaprecautionarylabel,thelabelshouldalsobeordered.**lncludedw/PC1.BESURETOPROVIDEMODELA

..1...FM...234116190131361032611158289Figure8-2.Panel,Rearvt/Components(Fig8-1Item7)1111Figure8-2.Panel,Rearw/Components4-Figure8-3.TerminalAssembly,

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BUTTON,pushresetredSPRING,cprsn.430ODx.040wirex1.SOOstnlsPUSHBUTTONSET,w/cable&housingBRACKET,mtgswitchPBSWITCH,JimleafactgSPDT1\~~5Figure8-4.Swit

00)0)010)-uCD CD1~)0)-nCDC-ICDC)D)CD-n0NC)CCDCl)CD30\N)C~)/I)0////////I/~/~?L__N)-96N)\--

3.+1582584...S3...089085Ri...08420651302576...014...1439356...C15...1439346...C17...1439336...C18...1439367...RC1...143976079 5341347341347310797398.

aWARNINGPRINCIPALSAFE.:TYSTANDARDSSafetyinWeldingandCutting,ANSIStandardZ49.i,fromAmericanWeldingSociety.550N.W.LeJeuneRd,MiamiFL33126SafetyandHealthS

April1994Form:OM-168256EffectiveWithSerialNo.KE600689OWNERSMANIUALGoldStarfi500SSXReadandfollowtheseinstructionsandallsafetyblockscarefully.Haveonly

IJMILLERSTRUEBLUETMLIMITEDWARRANTYEffectiveJanuary1.1992(EquipmentwithaserialnumberprefaceofKC~ornewer)-ThislimitedwarrantysupersedesallpreviousMI

ARCWELDINGSAFETYPRECAUTIONSELECTRICSHOCKcankill.Touchingliveelectricalpartscancausefatalshocksorsevereburns.Theelectrodeandworkcircuitiselectricallyli

CYLINDERScanexplodeifdamaged.Shieldinggascylinderscontaingasunderhighpressure.Ifdamaged,acylindercanexplode.Sincegascylindersarenormallypartoftheweldi

PRECAUTIONSDESECURITEENSOUDAGEALARCEENGARDELESOUDAGEALARCestdangereux.PROTEGEZ-VOUS,AINSIQUELESAUTRES,CONTRELESBLESSURESGRAVESPOSSIBLESOULAMOnT.NELA

PROJECTIONSBRULANTESpeuvent>LESETINCELLESETLEScauserdesblessures.LepiquageetlemeulageproduisentdesØclatsdeLesBOUTEILLESendommagØespeuventexploser.L

EMFINFORMATIONTABLEOFCONTENTSSECTION1-SAFETYINFORMATIONSECTION2-SPECIFICATIONS2-1.Volt-AmpereCurves2-2.DutyCycleSECTION4-OPERATION9SECTION6-ELECTRICAL

SECTION1-SAFEETYINFORMATIONmodl.12/936aWA~~CAUObeyallsafetymessagostoavoidinjury.LearnthemeaningofWARNINGandCAUTION.Readallsafetymessagesthroughou

2-1.Volt-AmpereCurvesFigure2-1.Volt-AmpereCurves2-2.DutyCycle0120010DutyCycleispercentageof10minutesthatunitcanweldatratedloadwithoutoverheating.Minut

SECTION3-INSTALLATION3-1.SelectingALocationAndMovingWeldingPowerSourceWARNINGELECTRICSHOCKcankill.Donottouchliveelectricalparts.Disconnectinputpower

Figure3-2.OverallDimensionsAndBaseMountingHoleLayout3-2.SelectingAndPreparingWeldOutputCables1WeldOutputCableDeterminetotalcablelengthinweldcircuitand

Table3-1.WeldCableSlze*I~JVARNINGFigure3-4.WeldOutputConnectionsTotalCable(Copper)LengthInWeldCircuitNotExceeding150ftI200ftI250ftI300ftI350ftI40Qft10

3-4.Remote14ReceptacleInformationAndConnectionsFigure3-5.Remote14Connections-Table3-2.Remote14SocketInformationREMOTE14Socket*-SocketinformationouTpuT

3-5.Connectin~iInputPowerWARNINGELECTRICSHOCKcankill.Donottouchliveelectricalparts.TurnOffweldingpowersource,anddisconnectinputpowerbeforeinspecting

B.ConnectingInputPowerFigure3-7.InputPowerConnectionsTable3-3.ElectricalServiceRequirements*InputVoltage220380400415InputAmperesAtRatedOutput102 59565

SECTION4-OPERATIONWARNINGELECTRICSHOCKcankill.Alwaysweardryinsulatinggloves.Insulateyourselffromworkandground.Donottouchliveelectricalparts.Keepal

AAWARNINGELECTRICSHOCKcankill.Donottouchliveelectricalparts.Donottouchweldoutputterminalswhencontactorisenergized.Donottouchelectrodeandworkclampat

RAN~SWITCH2.AAMPERN3E1RangeSwitchUseswitchtochooseoutputrange.Lowgivesbetterlowamperageadiustment(usewithLowscaleonAmperageAdjustmentcontrol).Highgive

PRECAUTIONSDESECURITEENSOUDAGEALARCMISEENGARDELESOUDAGEALARCestdangereux.PROTEGEZ-VOUS,AINSIQUELESAUTRES,CONTRELESBLESSURESGRAVESPOSSIBLESOULAMORT.N

LAWARNINGARCINGcandamageswitchcontacts.DonotchangePolaritySwitchpositionwhilewelding.Arcinginsideswitchcandamagecontacts,causingswitchtofail.)IFigure

SECTIONI5MAINTENANCE&TROUBLESHOOTINGWARNINGELECTRICSHOCKcankill.Donottouchliveelectricalparts.TurnOfiweldingpowersource,anddisconnectinputpcwer

5-2.OverloadProtection\~READSectioSAFETYn5beforBLOCKSatstartofeproceeding.minutesWhenoverheated,thermostatLetfanrunforStartwelding.opens,outputstops,a

TroubleRemedySectionLoworminimumweldoutput.-~Checkforproperlinovoltage.-~ Checkforopenlineruse(s),andreplaceifnecessary.Check-~3-58andresetcirc

NOTESOM-168256Page16

SECTION6-ELECTRICALDIAGRAMSU~0.0~~a().~0Cq~a~2~SC-137779Aw>-II(000~<UaCaFigure6-1.CIrcuitDiagramForWeldingPowerSourceCM-i68256Page17

OM-168256Page16Figure6-2.WiringDiagramForWeldingPowerSource

00) 0) N)010)-D(0C(0zmC~)In9

SECTION7-TUNGSTENELECTRODENOTEForadditionalinformation,seeyourdistributorforahandbookontheGasTungstenArcWelding(GTAW)process.Wearcleanglovestopreventc

7-2.PreparingTungstenAUTION43Figure7-2.PreparingTungstenForDCElectrodeNegative(DCEN)Welding1TungstenElectrode.1ElectrodeDiameter~iI~IjE~1-1/2Times22