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Miller Electric SRH-503 manual

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Table of contents for the manual

  • Page 1

    Processes Description Stick (SMAW ) W elding OM-2236 205 982G May 2004 Air Carbon Arc (CAC-A) Cut- ting and Gouging Arc Welding Power Source Submerged (SAW) W elding SRH-503 Visit our website at www.MillerWelds.com[...]

  • Page 2

    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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

  • Page 4

    Notes[...]

  • Page 5

    OM-2236 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means W arning! Watch Out[...]

  • Page 6

    OM-2236 Page 2 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. ARC RA YS can burn eyes and skin. D 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 Z8[...]

  • Page 7

    OM-2236 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. F [...]

  • Page 8

    OM-2236 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American W elding Society , 550 N.W . LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www .aws.org). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Weld[...]

  • Page 9

    OM-2236 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE A V ANT UTILISA TION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Y Identifie un message de sécurité particulier . . Signifie « NOT[...]

  • Page 10

    OM-2236 Page 6 Le rayonnement de l’arc génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) suscep- tibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage. LES RA YONS DE L ’ARC peuvent ca u- ser des brûlures oculaires et cuta- nées. D Porter u n masque de soudage[...]

  • Page 11

    OM-2236 Page 7 2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- SION D Ne pas placer l’appareil sur une surface inflam- mable, ni au−dessus ou à proximité d’elle. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surchar[...]

  • Page 12

    OM-2236 Page 8 2-4. Principales normes de sécurité Safety in W elding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American W elding Society , 550 N. W . LeJeune Rd, Miami FL 33126 (téléphone : (305) 443−9353, site Web : www .aws.org). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Pipi[...]

  • Page 13

    OM-2236 Page 9 SECTION 3 − DEFINITIONS 3-1. General Precautionary Label W arning! W atch Out! There are possible hazards as shown by the symbols. 1 Electric shock from welding electrode or wiring can kill. 1.1 W ear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect yourself from electric [...]

  • Page 14

    OM-2236 Page 10 3-2. Input Connection Label 1 W arning! W atch Out! There are possible hazards as shown by the symbols. 2 Electric shock from wiring can kill. 3 Disconnect input plug or power before working on machine. 4 Read the Owner ’ s Manual before working on this machine. 5 Consult rating label for input power requirements, and check power [...]

  • Page 15

    OM-2236 Page 1 1 SECTION 4 − INST ALLA TION 4-1. Specifications Rated Welding Amperes Input at Rated Load Output, 60 Hz, Three-Phase Model Rated W elding Output Amp Range DC Max OCV DC 220-230 V 440-460 V KV A KW 500 Amp 500 A @ 40 V olts DC, 60% Duty Cycle 50 − 525 77 98 4.5* 49 2.2* 38.9 1.8* 26 0.7* *While idling 4-2. Duty Cycle And Overheat[...]

  • Page 16

    OM-2236 Page 12 4-3. V olt-Ampere Curves V olt-ampere curves show mini- mum and maximum voltage and amperage output capabilities o f unit. Curves of other settings fall be- tween curves shown. 206 054 4-4. Selecting A Location 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit. If using lifting forks, extend forks beyond op[...]

  • Page 17

    OM-2236 Page 13 4-5. Dimensions And W eights Dimensions w/Running Gear And Lift Eye C Dimensions w/Running Gear And Lift Eye C D E Height 35-1/4 in (895 mm) E 4 Holes Width 28 in (71 1 mm) Depth 33-1/2 in (851 mm) A 27-1/2 in (699 mm) A B 3/4 in (19 mm) A C 21-1/8 in (537 mm) D 1-1/8 in (29 mm) E 7/16 in (1 1 mm) Dia W eight B 801 530 410 lb (186 k[...]

  • Page 18

    OM-2236 Page 14 4-7. Selecting And Preparing W eld Output Cables 10 ft (3 m) 1 T otal Cable Length In Weld Circuit = 20 ft (6 m) 10 ft (3 m) For Example, 2 4 3 2 T ools Needed: sb6.1 1 1/92 − S-0653 1 Weld Output Cable Determine t o t a l c a b l e length in weld circuit and maximum welding am- peres. See Section 4-8 to select proper cable size. [...]

  • Page 19

    OM-2236 Page 15 4-9. Connecting T o Weld Output T erminals Ref. 803 026-C T ools Nee d e d : 1 2 3/4 in Y T urn off power before con- necting to weld output terminals. 1 Positive (+) W eld Output T erminal 2 Negative (−) Weld Output T erminal 3 Cable Restraint Route weld cables through cable restraint. Fo r DC Electrode Positive (DCEP), connect w[...]

  • Page 20

    OM-2236 Page 16 4-1 1. Placing Jumper Links Y Disconnect a nd 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[...]

  • Page 21

    OM-2236 Page 17 4-12. Connecting Input Power 800 103-C / Ref. 801 1 16-A 3/8 in 3/8 in T ools Nee d e d : Y Installation must meet all National an d Local Codes − have only quali- fied persons make this installation. Y Disconnect and lockout/tagout in- put power before connecting input conductors from unit. Y Make input power connections to the w[...]

  • Page 22

    OM-2236 Page 18 SECTION 5 − OPERA TION 5-1. Controls 2 1 3 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 no t light when the power switch is turned on, replace the switch. NOTE: This unit has over-tempera- ture protection. If unit becomes [...]

  • Page 23

    OM-2236 Page 19 5-2. Electrode/Amperage Selector[...]

  • Page 24

    OM-2236 Page 20 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Clean and tighten weld terminals. Repair or replace cracked weld cable. 6 Months Blow out or vacuum inside. During heavy service, clean monthly Or 6-2. Fuse F1 Ref. ST-800 101-C Y Discon[...]

  • Page 25

    OM-2236 Page 21 6-3. T roubleshooting T able T rouble Remedy No weld output; unit completely inoperative. Place line disconnect switch in On position (see Section 4-12 ). 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-[...]

  • Page 26

    OM-2236 Page 22 Notes[...]

  • Page 27

    OM-2236 Page 23 SECTION 7 − ELECTRICAL DIAGRAM 205 900-C Figure 7-1. Circuit Diagram . For Primary Circuit Diagram Portion, refer to Circuit Diagram located inside wrapper of welding power source.[...]

  • Page 28

    OM-2236 Page 24 SECTION 8 − P ARTS LIST ST-803 137-D . Hardware is common and not available unless listed. 1 2 8 10 9 5 27 1 11 12 13 14 15 17 16 18 6 7 3 4 19 4 2 3 28 29 30 33 32 31 38 39 47 36 40 35 48 44 42 41 43 45 37 34 50 58 57 56 49 51 52 53 54 55 49 25 24 23 22 21 20 26 59 60 61 62 60 Figure 8-1. Main Assembly[...]

  • Page 29

    OM-2236 Page 25 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly Quanti ty 1 176254 LABEL,GENERAL PRECAUTIONARY WORDLESS,INTL 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 +179430 P ANEL,SIDE 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 30

    OM-2236 Page 26 Description Part No. Dia. Mkgs. Item No. 8-1. Main Assembly (continued) Quanti ty 53 205885 SP ACER,STL .500 ID X .625 OD X 1.267 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 024620 SPROCKET ,W/1/8 HOLE 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 31

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 3/04 Y our distributor also gives you ... Service Y ou 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 o[...]

  • Page 32

    PRINTED IN USA  2004 Miller Electric Mfg. Co. 1/04 Miller Elect ric Mfg. Co. An I l li noi s T ool W ork s Company 1635 W es t Spencer St reet Applet on, W I 5 4914 USA International He adquarters− USA USA Phone: 920-735-4505 Auto-A t t ended USA & C anada F A X: 920-735-4134 Int ernational F A X : 9 20-735-4125 European Headqua rte rs −[...]