Junction Box for Welding System
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OM-241 101A 2008−11 Processes Multiprocess Welding Description Junction Box For Welding System Junction Box Includes System Connection Information File: MIG (GMAW) Visit our website at www.MillerWelds.com From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They Working as hard as you do − every power source from will help you protect yourself against potential hazards on the worksite. Miller is backed by the most We’ve made installation and operation quick hassle-free warranty in the business. and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The Miller is the first welding parts list will then help you to decide the equipment manufacturer in exact part you may need to fix the problem. the U.S.A. to be registered to the ISO 9001:2000 Quality Warranty and service information for your 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 specification 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 4/05 TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING. 1 1-1. Symbol Usage . 1 1-2. Arc Welding Hazards . 1 1-3. Additional Symbols For Installation, Operation, And Maintenance. 3 1-4. California Proposition 65 Warnings. 4 1-5. Principal Safety Standards . 4 1-6. EMF Information . 4 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION. 5 2-1. Symboles utilisés . 5 2-2. Dangers relatifs au soudage à l’arc. 5 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance. 7 2-4. Proposition californienne 65 Avertissements. 8 2-5. Principales normes de sécurité. 9 2-6. Information EMF . 9 SECTION 3 − DEFINITIONS . 11 3-1. Symbols And Definitions . 11 SECTION 4 − SPECIFICATIONS . 11 4-1. Welding System Description . 11 4-2. Junction Box Description . 11 4-3. Welding System Specifications. 12 4-4. Junction Box Specifications . 12 SECTION 5 − INSTALLATION . 13 5-1. Typical Equipment Location − Wire Feeder Mounted On Boom. 13 5-2. Typical Equipment Location − Wire Feeder Mounted On Post. 13 5-3. Mounting Junction Box . 14 5-4. Junction Box Components . 15 5-5. Connecting Weld Cables To Junction Box. 16 5-6. Connecting Remote Control Cables. 17 5-7. Remote 16 Receptacle RC3 Information. 18 5-8. Remote 14 Receptacle RC4 Information. 19 5-9. Connecting AC Power Cable. 20 5-10. Connecting Compressed Air To Junction Box. 21 5-11. Connecting Welding Gas To Junction Box. 22 SECTION 6 − OPERATION . 23 6-1. Junction Box Components . 23 SECTION 7 − MAINTENANCE AND TROUBLESHOOTING. 24 7-1. Routine Maintenance . 24 SECTION 8 − ELECTRICAL DIAGRAM. 25 SECTION 9 − PARTS LIST . 26 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007−04 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if . Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible This group of symbols means Warning! Watch Out! ELECTRIC hazards are shown in the adjoining symbols or ex- SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym- plained in the text. bols and related instructions below for necessary actions to avoid the NOTICE − Indicates statements not related to personal injury. hazards. 1-2. Arc Welding Hazards D Always verify the supply ground − check and be sure that input The symbols shown below are used throughout this manual power cord ground wire is properly connected to ground terminal in to call attention to and identify possible hazards. When you disconnect box or that cord plug is connected to a properly see the symbol, watch out, and follow the related instructions grounded receptacle outlet. to avoid the hazard. The safety information given below is D only a summary of the more complete safety information When making input connections, attach proper grounding conduc- found in the Safety Standards listed in Section 1-5. Read and tor first − double-check connections. follow all Safety Standards. D Keep cords dry, free of oil and grease, and protected from hot metal and sparks. Only qualified persons should install, operate, maintain, and D Frequently inspect input power cord for damage or bare wiring − repair this unit. replace cord immediately if damaged − bare wiring can kill. D Turn off all equipment when not in use. During operation, keep everybody, especially children, away. D Do not use worn, damaged, undersized, or poorly spliced cables. D Do not drape cables over your body. ELECTRIC SHOCK can kill. D If earth grounding of the workpiece is required, ground it directly with a separate cable. Touching live electrical parts can cause fatal shocks D Do not touch electrode if you are in contact with the work, ground, or severe burns. The electrode and work circuit is or another electrode from a different machine. electrically live whenever the output is on. The input D power circuit and machine internal circuits are also Do not touch electrode holders connected to two welding ma- live when power is on. In semiautomatic or automatic wire welding, the chines at the same time since double open-circuit voltage will be wire, wire reel, drive roll housing, and all metal parts touching the present. welding wire are electrically live. Incorrectly installed or improperly D Use only well-maintained equipment. Repair or replace damaged grounded equipment is a hazard. parts at once. Maintain unit according to manual. D Do not touch live electrical parts. D Wear a safety harness if working above floor level. D Wear dry, hole-free insulating gloves and body protection. D Keep all panels and covers securely in place. D Insulate yourself from work and ground using dry insulating mats D or covers big enough to prevent any physical contact with the work Clamp work cable with good metal-to-metal contact to workpiece or ground. or worktable as near the weld as practical. D D Do not use AC output in damp areas, if movement is confined, or if Insulate work clamp when not connected to workpiece to prevent there is a danger of falling. contact with any metal object. D Use AC output ONLY if required for the welding process. D Do not connect more than one electrode or work cable to any D If AC output is required, use remote output control if present on single weld output terminal. unit. SIGNIFICANT DC VOLTAGE exists in inverter-type D Additional safety precautions are required when any of the follow- ing electrically hazardous conditions are present: in damp welding power sources after removal of input locations or while wearing wet clothing; on metal structures such power. as floors, gratings, or scaffolds; when in cramped positions such D Turn Off inverter, disconnect input power, and discharge input as sitting, kneeling, or lying; or when there is a high risk of unavoid- capacitors according to instructions in Maintenance Section able or accidental contact with the workpiece or ground. For these before touching any parts. conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- HOT PARTS can cause severe burns. age. In most situations, use of a DC, constant voltage wire welder D is recommended. And, do not work alone! Do not touch hot parts bare handed. D D Disconnect input power or stop engine before installing or Allow cooling period before working on gun or servicing this equipment. Lockout/tagout input power according to torch. OSHA 29 CFR 1910.147 (see Safety Standards). D To handle hot parts, use proper tools and/or D Properly install and ground this equipment according to its wear heavy, insulated welding gloves and Owner’s Manual and national, state, and local codes. clothing to prevent burns..