Table of Contents
Troubleshooting
Related Manuals for Miller Electric SRH-503
Summary of Contents for Miller Electric SRH-503
- Page 1 Visit our website at www.MillerWelds.com Arc Welding Power Source SRH-503 OM-2236 205 982G May 2004 Processes Stick (SMAW) Welding Air Carbon Arc (CAC-A) Cut- ting and Gouging Submerged (SAW) Welding Description...
- Page 2 ISO 9001:2000 Quality 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ............... . 1-2. - Page 4 Notes...
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Page 5: Section 1 − Safety Precautions - Read Before Using
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage Means Warning! Watch 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. 1-2. - Page 6 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
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. -
Page 8: Principal Safety Standards
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. -
Page 9: Section 2 − Consignes De Sécurité − À Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT 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 «... - Page 10 LES RAYONS DE L’ARC peuvent cau- ser des brûlures oculaires et cuta- nées. 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. D Porter un masque de soudage muni d’un filtre de la nuance adéquate pour se protéger le visage et les yeux pendant le soudage ou pour re- garder (voir les normes de sécurité...
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Page 11: Autres Symboles Relatifs À L'installation, Au Fonctionnement Et À L'entretien De L'appareil
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 surcharger l’installation électrique −... -
Page 12: Principales Normes De Sécurité
2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American Welding 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 Welding and Cut- ting of Containers and Piping, norme American Welding Society AWS F4.1, de l’American Welding Society, 550 N.W. -
Page 13: Section 3 − Definitions
SECTION 3 − DEFINITIONS 3-1. General Precautionary Label Warning! Watch Out! There are possible hazards as shown by the symbols. 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. -
Page 14: Input Connection Label
3-2. Input Connection Label 1/96 Í Í Í Í 3-3. Nameplate Safety Symbols 3-4. Do Not Lift OM-2236 Page 10 Í Í Í Í Í Í Í Í Í Í Í Í S-179 290 Warning! Watch Out! There are possible hazards as shown by the symbols. -
Page 15: Section 4 − Installation
SECTION 4 − INSTALLATION 4-1. Specifications Rated Welding Rated Welding Output Model 500 A @ 40 Volts DC, 500 Amp 60% Duty Cycle *While idling 4-2. Duty Cycle And Overheating 1000 60% Duty Cycle At 500 Amperes For 500 Ampere Models 6 Minutes Welding Overheating Amperes Input at Rated Load... -
Page 16: Volt-Ampere Curves
4-3. Volt-Ampere Curves 4-4. Selecting A Location Movement Location And Airflow 18 in (460 mm) OM-2236 Page 12 (460 mm) Volt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall be- tween curves shown. -
Page 17: Dimensions And Weights
4-5. Dimensions And Weights 4-6. Tipping 4 Holes 801 530 Dimensions w/Running Gear And Lift Eye 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) 27-1/2 in (699 mm) 3/4 in (19 mm) 21-1/8 in (537 mm) 1-1/8 in (29 mm) -
Page 18: Selecting And Preparing Weld Output Cables
4-7. Selecting And Preparing Weld Output Cables 10 ft (3 m) 10 ft (3 m) Tools Needed: 4-8. Weld Cable Sizes 100 ft (30 m) Or Less Welding 10 To 60% 60 Thru 100% Amperes Duty Cycle 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. -
Page 19: Connecting To Weld Output Terminals
4-9. Connecting To Weld Output Terminals Tools Needed: 3/4 in 4-10. Electrical Service Guide Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Rating In Amperes Time-Delay Normal Operating 3 Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil Reference: 1999 National Electrical Code (NEC) 1 Consult factory for circuit breaker applications. -
Page 20: Placing Jumper Links
4-11. Placing Jumper Links Do not overtighten jumper nuts. link 220−230 3/8, 1/2 in OM-2236 Page 16 440−460 Y Disconnect and lockout/tag- out input power before installing or moving jumper links. Check input voltage available at site. Jumper Link Label Check label −... -
Page 21: Connecting Input Power
4-12. Connecting Input Power L1 (U) L2 (V) L3 (W) Tools Needed: 3/8 in 3/8 in = GND/PE Earth Ground IMPORTANT Input Contactor GND/ PE Earth Ground Y Installation must meet all National and Local Codes − have only quali- fied persons make this installation. -
Page 22: Section 5 − Operation
SECTION 5 − OPERATION 5-1. Controls OM-2236 Page 18 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. -
Page 23: Electrode/Amperage Selector
5-2. Electrode/Amperage Selector OM-2236 Page 19... -
Page 24: Section 6 − Maintenance & Troubleshooting
SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. 6 Months Blow out or vacuum inside. During heavy service, clean monthly 6-2. Fuse F1 Tools Needed: 3/8 in OM-2236 Page 20 Repair or replace cracked... -
Page 25: Troubleshooting Table
6-3. Troubleshooting Table Trouble No weld output; unit completely Place line disconnect switch in On position (see Section 4-12). inoperative. 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). - Page 26 Notes OM-2236 Page 22...
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Page 27: Section 7 − Electrical Diagram
SECTION 7 − ELECTRICAL DIAGRAM For Primary Circuit Diagram Portion, refer to Circuit Diagram located inside wrapper of welding power source. 205 900-C Figure 7-1. Circuit Diagram OM-2236 Page 23... -
Page 28: Section 8 − Parts List
SECTION 8 − PARTS LIST Hardware is common and not available unless listed. ST-803 137-D Figure 8-1. Main Assembly OM-2236 Page 24... - Page 29 Item Dia. Part Mkgs....176254 ....+179430 ..
- Page 30 Item Dia. Part Mkgs....205885 ....024620 ..
- Page 31 Warranty Questions? Call LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after for your local the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.
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Page 32: Options And Accessories
For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2004 Miller Electric Mfg. Co. 1/04 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...