Miller 900 860 Quick Start Manual - Page 7

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Miller 900 860 Quick Start Manual
NOTE
If
only
one
jumper
link
is
required
on
each of the
grouped
terminals,
it is recommended that the unused
jumper
links be
placed
across
the terminals which
are
to
be used. This will prevent
losing
the
jumper
links
which
are
not
required
for this connection.
G~D.
~Li ~L2 'L3
______
013 922
Figure
3-3.
Input Voltage Jumper
Link
Arrangement
3-3.
SECONDARY CONNECTIONS
The
Positive and
Negative secondary
terminals
are
located
behind the lower front
access
panel.
See
Figure
4-1 for
loca
tion of the terminals.
The
access
panel
which
covers
the
secondary
terminals
is
secured
by
two
fasteners. To open the
access
panel,
rotate
the fasteners counterclockwise
one
full
turn.
Likewise,
to
close the
panel,
rotate
the fasteners clockwise
one
full
turn.
A.
Welding
Cables
It is recommended that the
welding
cables be
kept
as
short
as
possible, placed
close
together,
and be of
adequate
current
carrying capacity.
The
resistance of the
welding
cables and
connections
cause
a
voltage drop
which
is
added
to
the volt.
age of the
arc.
Excessive cable resistance
may
result
in
over
loading
as
well
as
reducing
the maximum
current
output of
which the
welding
power
source
is
capable.
The proper opera
tion
of
any
arc
welding
power
source
is
to
a
great
extent
dependent
on
the
use
of
welthng
cables and connections that
are
in
good
condition
and of
adequate
size.
An
insulated
electrode holder
must
be
used
to ensure
the
operators
safety.
Use
Table 3-2
as
a
guide
for
selecting
the
correct
welding
cable size for the
anticipated
maximum weld
current
that will
be used.
Table 3-2
takes into
account
the total cable
length
for the weld circuit. This
means
the
length
of the
Electrode
cable that
connects
the wire
feeder
to
the
welding
power
source
and the Work
or
ground
cable between the
welding
power
source
and the work
piece.
For
example:
If the Elec
trode
cable
is
75 feet
long
and the
work
Or
ground
cable
is
25
feet
long,
select the size cable from
Table 3-2 that
is
recom
mended for 100 feet.
In
a
situation where
a
maximum weld
current
of
150
amperes is
anticipated,
No. 2
weld
cable
is
recommended
for both the
Electrode and Work cables.
WELDING
TOTA LLEN GTH OF CABLE
(COPPER
I
IN
WELD CIRCUIT
250
300
350
400
AMPERES
50
100
150
200
100
4
4
2
2
2
1
1/0
1/0
150
2
2
2
1
1/0
2/0
3/0
3/0
200
1
1
1
1/0
2/0
3/0
4/0
4/0
250
1/0
1/0
1/0
2/0
3/0
4/0
4/0
2-2/0
300
2/0
2/0
2/0
3/0
4/0
4/0
2-2/0
2.3/0
350
3/0
3/0
2/0
4/0
4/0
2-2/0
2-3/0
2-3/0
400
3/0
3/0
3/0
4/0
2-2/0
2-3/0
3.2/0
2-4/0
500
4/0
4/0
4/0
2-2/0
2-3/0
2.3/0
2-4/0
3-3/0
600
2.2/0
2-2/0
2-2/0
2-3/0
3-2/0
2-4/0
3.3/0
3.4/0
700
2-3/0
2.3/0
2.3/0
2-4/0
3-3/0
3-4/0
4-4/0
4-4/0
800
2.3/0
2-3/0
2-3/0
2.4/0
3-3/0
3-4/0
4.4/0
4-4/0
A002 623
NOTE:
A.
50 FEET OR
LESS.
8.
CABLE
SIZE
IS
BASED ON DIRECT CURRENT
(DCI,
100%
DUTY
CYCLE AND EITHER
A
4
VOLTS
OR LESS
DROP OR
A
CURRENT
DENSITY
OF NOT
OVER 300
CIRCULAR
MILS PER
AMP.
C.
WELD
CABLE
INSULATION
WITH
A
VOLTAGE
RATING
TO
WITHSTAND
THE OPEN-CIRCUIT
VOLT.
AGE
IOCVI
OF
THE
WELDING POWER SOURCE MUST
BE
USED. WHILE
MOST WELDING
POWER
SOURCES
HAVE
AN
OPEN-CIRCUIT
VOLTAGE OF
LESS
THAN
100
VOLTS.
SOME
WELDING
POWER
SOURCES OF
SPECIAL DESIGN
MAY
HAVE
HIGHER OPEN-CIRCUIT
VOLTAGE.
3-4.
115 VOLTS AC RECEPTACLES
(Figure
4-1)
Two
receptacles,
both labeled 115 VOLTS
AC,
are
provided
on
the
front
panel.
The
duplex
115 VOLTS AC
receptacle
is
intended
to
be used for
operating
accessory
equipment.
The
three-pole twistlock,
115 VOLTS AC
receptacle
is
intended
to
be used for
supplying operating
power
to
a
control/feeder.
To
secure
the
corresponding three-pole
plug
into this recep
tacle,
rotate
it
as
far
as
it will
turn
in
a
clockwise direction.
I
Both 115 VOLTS AC
Receptacles
and CONTACTOR
CONTROL
Circuitry
are
protected by
a
15
ampere
fuse
(F2)
which
is located
on
the front
panel.
If it
should
become
necessary
to
replace
the
fuse,
ensure
that
a
fuse of the
same
rating
is
used for
a
replace
ment.
A fuse of
a
larger rating
will
permit
overloading
of the 115 volts
circuitry
and
thereby
cause
damage
to
the
welding
power
source.
3-5.
CONTACTOR CONTROL CONNECTIONS
The
CONTACTOR CONTROL
Receptacle
located
on
the
front
panel,
is
a
two-pole, twistlock, motor-base,
male recep
tacle. The
corresponding
plug
for this
receptacle
is
supplied
with the
welding
power
source
as
standard
equipment.
The
function of the
CONTACTOR CONTROL
Receptacle
is
to
provide
a
connection
point
between the
remote
contactor
control
station
and
the
contactor
in
the
welding
power
source.
To
energize
the
contactor
from
a
remote
station,
the
remote
Station
must
be able
to
supply
115 volts
ac
60 Hertz
electrical
power
to
this
receptacle.
To
connect
the Remote Contactor Control device
to
the
CONTACTOR
CONTROL
Receptacle,
insert the
two-pole
plug
from
the Remote Contactor Control device
into the
CONTACTOR CONTROL
Receptacle
and
rotate
the
plug
as
far
as
it will
turn
in
a
clockwise direction. The
plug
will
now
be locked in the
receptacle
and
will
not
pull
out
under
stress.
Table 3-2.
Secondary
Cable Sizes
230 VOLTS
460 VOLTS
I
I
OM-238
Pa~
7