Miller Electric MT-24F-1 2-1 Specifications

/1 Miller
November 1995
Form:
OM-2204F
Effective With Serial No. KGO1 7632
OWNERS
MANUAL
.1
XMTfi 300 CC/hG
CC/DC
Welding Power Source
For GTAW, GTAW.P, And SMAW
Amperes,
300
Uses
Welding
32 Volts DC At 60%
Single-Phase
Duty Cycle
Or Three-Phase
Input
Power
Protection For Control Circuit, 24 VAC, And
Overheating
AUTO.LINKTM Circuitry And Built-In High Frequency
14-Pin Remote Control
For
Options
Receptacle
And Accessories, See Rear Cover
Give this manual to the operator.
Read and follow these instructions and all
safety
blocks
Have
only
carefully.
and qualified persons
service this unit.
trained
install, operate,
or
For
Call your distributor if you do not understand
the directions.
cover
5/94
-
ST-146 123-A
'
1995 MILLER Electric
or:
help,
call your distributor
MILLER Electric Mfg. Co., RO. Box 1079,
WI 54912
414-734-9821
Appleton,
Mtg. Co.
PRINTED IN USA
1.
l
TRUE BLUETM LIMITED WARRANTY
MILLERS
Effective
(Equipment with
This limited warranty supersedes all
LIMITED WARRANTY
previous
a
January 1,1995
preface of KD
serial number
MILLER warranties and is exclusive with
Subject to the terms and conditions below, MILLER Electric
warrants to its original retail purchaser that new
6.
90
no
other
guarantees
warranties
expressed
or
implied.
Torches
MIG Guns/flG
MILLER equipment sold after the effective date of this limited warranty is free of de
fects in material and workmanship at the time it is shipped by MILLER. THIS WAR
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANT1ES, EXPRESS OR
IMPLJED, INCLUDING THE WARRAN11ES OF MERCHANTABILITY AND FIT
or
Parts and Labor
Days
Mfg. Co., Appleton, Wisconsin,
newer)
or
APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches
Remote Controls
*
Accessory Kits
Replacement Parts
NESS.
Within the warranty periods listed below, MILLER will repair or replace any war
ranted parts or components thaI fail due to such defects in material or workmanship.
MILLERS
MILLER must be notified in writing within thirty (30) days of such defect or failure, at
which time MILLER will provide instructions on the warranty claim procedures to be
followed.
1.
True
BIue~
Items furnished
Umited
Warranty
shall not
apply
to:
by MILLER, but manufaclured by others, such as engines or
are covered by the manufacturers warranty, if
trade accessories. These items
any.
MILLER shall honor warranty claims
on warranted equipment listed below in the
warranty time periods. All warranty time peflods
start on the date that the equipment was delivered tome original retail purchaser, or
one year after the equipment is sent to a North American distributor or eighteen
event of such a failure within the
2.
months after the
3.
equipment is
sent to an International distributor.
Consumable components; such as contact tips,
and relays or parts that fail due to normal wear.
Equipment
5 Years Parts 3
Original
*
2.
(input
and output rectifiers
only)
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER
CIALI1NDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
Parts and Labor
3 Years
Transforrner/Roctffier Power Sources
Plasma Arc
Cutting
Power Sources
by this warranty, the exclusive remedies
option: (1) repair, or (2) replacement; or, where authorized in
appropriate cases, (3) the reasonable coat of mpairor replace
ment at an authorized MILLER service station; or (4) payment of orcredit torthe pur
chase price (less reasonable depreciation based upon actual use) upon return of the
goods at customers risk and expense. MILLERS option of repair or replacement
will be FOB., Factoryat Appleton, Wisconsin, or FOB. at a MILLER authorized ser
vice facility as determined by MILLER. Therefore no compensation or reimburse
ment for transportation costs of any kind will be allowed.
In the event of a warranty claim covered
Semi-Automatic and Automatic Wire Feeders
Inverter Power
shall be, at MILLERS
writing by MILLER in
Supplies
Intellitigs
Robots
3.
2 Years
Parts and Labor
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the engine manufacturer.)
Air Compressors
1 YearPartsand
4.
*
by any party other than MILLER, or equip
improperly installed, improperly operated or misused
based upon industry standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has been used for operation
outside of the specifications for the equipment.
Years Labor
main power rectifiers
Inverters
contactora
that has been modified
ment that has been
1.
cutting nozzles,
TO ThE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE
UABLE FOR DIRECT, INDtRECT, SPECIAL INCIDENTALOR CONSEQUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT). WHETHER BASED ON CON
TRACT, TORT OR ANY OTHER LEGAL THEORY.
Labor
Motor Driven Guns
Process Controllers
IHPS Power Sources
Water Coolant
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPUED WAR
RANTY, GUARANTY OR REPRESENTATiON AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL
THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATiON,
Systems
HFUnits
Grids
OPERA11ON OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WiTH RESPECTTO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
Spot Welders
Load Banks
SDX Transformere
Running
Gear/Trailers
Cutting Torches (except APT, ZIPCUT
Tecumseh Engines
Deutz Engines (outside North America)
Plasma
*
Field
& PLAZCUT
Some states in the U.S.A. do not allow limitations of how long an implied warranty
lasts, or the exclusion of incidental, indirect, special or consequential damages, so
the above limitation or exclusion may not apply 10 you. This warranty provides ape
cific legal rights, and other rights may be available, but may vary from state to state.
Models)
Options
Field options are covered under True BIueTM for the remaining
wsrrsnty period of the product they are installed in, or for a minimum of
In
(NOTE:
one
5.
6 Months
year
whichever is
Canada, legislation in
greeter.)
1_________
provinces provides for certain
additional warranties
remedies other man
,~,,vary
Batteries
some
as stated herein, and to the extent that they may not be
waived, the limitations and exclusions set out above may not apply. This LImited
Warranty provides specific legal ngtrts, and other rights may be available, but may
or
from
province
to
province.
r.
RECEIVING-HANDLING
unpacking equipment, check carton for any damage that may have occurred during shipment. File any claims for loss or damage
delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment manufacturers
Transportation Department.
Before
with the
When
requesting information
following
nameplate.
Use the
or
about this
equipment, always provide
spaces to record Model
Designation and
Serial
or
Model
Style
Designation and
Serial
or
Style
Number.
Numberof your unit. The information is located
on
the
rating label
Model
__________
Serial
or
Style
No,
Date of Purchase
miller 6/95
ARC WELDING SAFETY PRECAUTIONS
WARNING
A~
ARC WELDING
can
be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to cerLain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
ELECTRIC SHOCK
can
terminal in disconnect box
kill.
live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electncally live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
1.
Do not touch live electrical parts.
2.
Wear
3.
4.
5.
dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating
mats or covers big enough to prevent any physical contact with
the work or ground.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according
to OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install and ground this equipment according to its
Owners
6.
Manual and national, state, and local codes.
Always verify the supply ground
power cord
check and be
sure
ground wire is properly connected
that input
to
~
7.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays that
can bum eyes and skin. Noise from some processes
can damage hearing. Chipping, grinding, and welds
cooling throw oft pieces of metal or slag.
approved
I
ear
plugs
or ear
muffs if noise level is
FUMES AND GASES
can
welding fumes
ventilation is poor,
Read the Material
manufacturers
area
11.
Do not
12.
If earth
with
and/or
exhaust at the
use an
Safety
and the
coatings,
a
safety
15.
Wear
a
16.
Keep
all
17.
Clamp
or
J~~~
Protect
2.
Wear
with
worktable
as
a
welding
4.
5.
a
proper shade of filter to
or watching (see ANSI
Safety Standards).
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained
watchperson nearby. Welding fumes and gases can displace
air
and lower the oxygen level causing injury
breathing air is safe.
Do not weld in locations
near
Do not weld
Never weld
compressed gas cylinders from excessive heat,
slag, open flames, sparks, and arcs.
8.
9.
spraying
react with vapors to
on
drape
a
a
can
give off
toxic fumes if welded.
welding torch over a gas cylinder.
welding electrode to touch any cylinder.
on a pressurized cylinder
explosion will result.
onlycorrectshielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is
Use
in use
10.
or
sure
plated steel,
6.
Install
death. Be
coated metals, such as galvanized, lead, or
unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
cadmium
7.
or
degreasing, cleaning,
operations. The heat and rays of the arc can
form highly toxic and irritating gases.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
welding
gas cylind:rs are
cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical
to
approved safety glasses with side shields.
Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
Never allow
~ ~ef~Iyfhe
place.
in
good metal-to-metal contact
near the weld as practical.
Wear
Never
damaged.
securely
helmet fitted with
Z49.1 and Z87.1 listed in
3.
5.
if
above floor level.
protect your face and eyes when welding
4.
explode
mechanical shocks,
circuits.
working
covers
cable
,
~
and
containing these elements
can
body.
ARC RAYS
cleaners, and degreasers.
CYLINDERS
harness if
panels
work
workpiece
7.
(MSDSs)
your
grounding of the workpiece is required, ground it directly
separate cable do not use work clamp or work cable.
Use only well-maintained equipment. Repair or replace
damaged parts at once. Maintain unit according to manual.
approved air-supplied respirator.
Data Sheets
over
poorly spliced
14.
arc to
instruction for metals, consumables,
drape cables
or
Do not touch electrode if you are in contact with the work,
ground, or another electrode from a different machine.
the
use
damaged, undersized,
13.
be hazardous to your
and gases.
grounding
not in use.
equipment when
Do not use worn,
cables.
head out of the fumes. Do not breathe the fumes.
inside, ventilate the
remove
attach proper
double-check connections.
Turn off all
6.
Keep your
a
9.
Welding produces fumes and gases. Breathing
can
making input connections,
10.
to your health.
these fumes and gases
health.
is connected to
plug
outlet.
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
high.
be hazardous
that cord
8.
5.
Use
When
conductor first
ground
ARC RAYS can burn eyes and skin;
NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes.
or
properly grounded receptacle
Touching
or
connected for use.
Read and follow instructions
on compressed gas cylinders,
associatedequipment,andCGApublicationP-1 listedinSafety
Standards.
srl.1.1 2/94
WELDING
fire
can cause
explosion.
or
Welding on closed containers, such as tanks, drums,
or pipes, can cause them to blow up. Sparks can fly
off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
bums.
Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating, or
fire. Check and be sure the area is safe before doing
any welding.
Be
6.
aware
that
fire
can cause
welding
ceiling, floor, bulkhead,
on a
or
partition
the hidden side.
on
closed containers such
tanks, drums,
7.
Do not weld
8.
pipes, unless they are properly prepared according to AWS
F4.1 (see Safety Standards).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long,
possibly unknown paths and causing electric shock and fire
on
as
or
hazards.
1.
2.
3.
4.
5.
Protect
yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
ENGINE EXHAUST GASES
Engines produce
ENGINE
can
kill.
can
fire
cause
or
explosion.
Engine
fuel is
1.
Stop engine
2.
Do not add fuel while
open flames.
highly
11.
Wear oil-free
heavy shirt,
smoking
or
MOVING PARTS
or
cut off
protective garments such
high shoes,
cuffless trousers,
as
welding
wire at
leather
gloves,
and
a
cap.
Remove any combustibles, such as a butane lighter
matches, from your person before doing any welding.
12.
or
j
be hazardous.
can
in open, well-ventilated areas.
equipment outside
1.
Use
2.
closed area, vent engine exhaust outside and
away from any building air intakes.
3.
Do not overfill tank
4.
Do not
If used in
a
allow
spill fuel. If fuel
for fuel to
room
spilled, clean
is
expand.
up before
starting
engine.
flammable.
and let it cool off before
pipes.
Remove stick electrode from holder
contact tip when not in use.
ENGINES
harmful exhaust gases.
FUEL
welder to thaw frozen
use
10.
WARNING
4~
A
Do not
9.
checking
or
adding fuel.
sparks or
if unit is near any
can cause
injury.
3.
only qualified people remove guards or
troubleshooting as necessary.
Have
covers
for
maintenance and
Moving parts, such as fans, rotors, and belts can
fingers and hands and catch loose clothing.
4.
cut
negative () battery
5.
1.
Keep all doors, panels,
securely in place.
2.
Stoo
ena~ne
before
covers,
installing
and
guards
closed and
connecting
Keep hands, hair,
loose
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin.
Reinstall
clothing,
and tools
disconnect
awayfrom moving
panels or guards and close doors
starting engine.
1.
2.
when
servicing
is
wear a face shield when working on a battery.
Stop engine before disconnecting or connecting battery
Always
cables.
3.
Do not allow tools to
4.
Do not
gases.
5.
Observe correct
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
1.
It is best to check coolant level when
to avoid scalding.
during servicing,
battery.
finished and before
unit.
Batteries contain acid and generate
cable from
parts.
6.
or
To prevent accidental starting
explosive
engine is cold
If the
use
cause
welder to
engine
is
sparks when working on
charge
polarity (+
warm
and
batteries
and
)
checking
on
or
jump
a
battery.
start vehicles.
batteries.
is needed, follow steps 2
and 3.
2.
3.
safety glasses and gloves and put a rag over cap.
Turn cap slightly and let pressure escape slowly before
Wear
completely removing
cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49. 1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA
dent of
29 CFR 1910, from Superinten
Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Ameri
can Welding Society Standard AWS F4.1 from American Welding So
ciety, 550 N.W. Le.Jeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Pro
Association, Batterymarch Park, Quincy, MA 02269.
tection
srl.1.1 2/94
Safe
Handling
of
Compressed
Gases in
Cylinders,
CGA
Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis High
way, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou
levard, Rexdale, Ontario, Canada M9W 1 R3.
SafePracticesForOccupationAndEducationalEyeAndFaceProtec
tion, ANSI
Standard Z87.1,
from
American
National
Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51 B, from National
Batterymarch Park, Quincy, MA 02269.
Fire Protection Association,
1
EMF INFORMATION
Considerations About
Magnetic Fields
NOTE ~
Welding
And The Effects Of Low
Frequency
Electric And
____________________
The
is a quotation from the General Conclusions Section
Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): .
there is now a very
large volume of scientific findings based on experiments at the
cellular level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible
risk or to offer clear science-based advice on strategies to minimize
or avoid potential risks.
following
of the U.S.
.
To
magnetic fields
reduce
the
in
workplace,
use
the
following
procedures:
Keep
1.
together by twisting
cables close
cables to
Arrange
3.
Do not coil
4.
Keep welding power
practical.
5.
Connect work clamp to
one
or
taping
side and away from the
2.
them.
operator.
.
or
drape cables
around the
source
body.
and cables as far away as
workpiece
as
close to the weld
as
possible.
AbOUt Pacemakers;
The
above
procedures
are
recommended for pacemaker
complete
information.
among
wearers.
those also normally
Consult your doctor for
modlO.1 4/93
TABLE OF CONTENTS
SECTION 1
-
SECTION 2
2-1.
2-2.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
SPECIFICATIONS
1
Volt-Ampere Curves
Duty Cycle
SECTION 3
3-1.
SAFETY INFORMATION
2
2
INSTALLATION
3
Process Connections
Typical
Selecting A Location And Moving Welding Power Source
Selecting And Preparing Weld Output Cables
Connecting To Weld Output Receptacles
Remote 14 Receptacle RC2 Information And Connections
Installing Gas Supply
Connecting Input Power
SECTION 4
OPERATION
SECTION 5
MAINTENANCE & TROUBLESHOOTING
5-1.
Routine Maintenance
Removing
5-3.
Overload Protection
5-4.
Changing AmperageNoltage
Troubleshooting
5-5.
4
5
6
6
7
8
9
5-2.
Case And
3
15
15
Measuring Input Capacitor Voltage
16
17
Meter Hold Function
18
18
SECTION 6- ELECTRICAL DIAGRAMS
20
SECTION 7- HIGH FREQUENCY
24
SECTION 8- TUNGSTEN ELECTRODE
26
8-1.
8-2.
Selecting Tungsten Electrode
Preparing Tungsten
SECTION 9
Figure
Figure
Figure
PARTS LIST
9-1. Main
Assembly (208-230/460V Model Illustrated)
Chassis, Mid (208-230/460V Model Illustrated)
9-3. Panel, Front w/Components
9-2.
26
27
28
28
30
33
OM.2204F- 11195
SECTION 1
SAFETY INFORMATION
-
modl.1 2/93
Read all
all
Obey
safety messages throughout
safety messages
Leam the
1
meaning
to avoid
this manual.
injury.
of WARNING and CAUTION.
2
1
Safety
Alert
2
Signal
Word
2
\
~r~!i!t~
AA CAUTION
3
ELECTRIC SHOC K
can
kill
L~
Do not touch live elect scat parts.
Disconnect
installing
or
input power
servicing.
serious
or
I
;1~II~eU
WARN ING
beforeJj_
4
means
injury
possible death
happen.
can
CAUTION
MOVING PARTS
Keep sway
Symbol
from
can
moving parts.
Keep all panels end
when operating.
I
means possible minor
injury or equipment damage can
happen.
I
3
Statement Of Hazard And
Result
4
Safety
injure.
covers
closed
I
/
5
Instructions To Avoid
Hazard
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
__!.
6
5
Hazard
6
Safety
Read
~
Turn Off switch when
using high frequency.
1-1.
Safety
blocks for each sym
NOTE
Special
ation
Figure
safety
bol shown.
7
NOTE
Symbol (If Available)
Banner
instructions for best oper
not related to
safety.
Information
SECTION 2- SPECIFICATIONS
Table 2-1.
Welding
Power Source
Specification
Type
Of
Welding
Description
Output
Constant CurrentiDirect Current
Processes
Gas
Tungsten Arc (GTAW), Gas Tungsten Arc
(SMAW)
Input Power Cord
12 ft
Overall Dimensions
Length:
Weight
Net: 84 lb (38 kg);
Output
(522 mm);
21-3/4 in
300
Ship:
Amperes, 32 Volts
(See Section 2-2)
Type Of Input
Input Amperes
At Rated
Output
-
Pulsed
(GTAW-P), Shielded
Width: 12 in
89 lb
(305 mm); Height:
17-3/8 in
With
Input
(441 mm)
DC At 60%
Duty Cycle
Single-Phase Input
Amperes, 29 Volts DC
(See Section 2-2)
225
At 60%
Duty Cycle
230, 460, Or 575 Volts AC; 50/60 Hz
230, 460, Or 575 Volts AC; 50/60 Hz
42 A At 230
50.8 A At 230 V, 29 A At 460 V, 23.6 A At 575 V
V, 21 A At 460 V, 16.4 A At 575 V
1.2 A At 230 V, 0.6 A At 460 V, 0.6 A At 575 V
1.1 A At 230
KVA/KW Used At Rated
16.1 kVA/1 1.3 kW
12.8 kVA/7.8 kW
Amperage Range
5-375 A
5-225 A
Max.
80 Volts DC
80 Volts DC
Open-Circuit Voltage
Welding
(40 kg)
Input Amperes While Idling
(Fan Not Running)
Output
Metal Arc
(3.7 m)
With Three-Phase
Rated Weld
(CC/DC)
V, 0.6 A At 460 V, 0.6 A At 575 V
OM-2204 Page 1
SECTION 3-INSTALLATION
4~
WARNING
HIGH-FREQUENCY RADIATION can interfere with radio
and communications equipment.
Have
only qualified person famitiar
with electronic
equipment perform this installation.
Read and follow entire Section 7 for proper location and installation
unit.
3-1.
Typical
navigation, safety services, computers,
requirements for high-frequency equipment before
swaml3.1 4/93
Process Connections
Work
+
GTAW
Pulse
Control
Scratch Start
Pulsed GTAW
Or
GTAW
+
+
Figure
3-1.
Typical
Process Connections
OM-2204
Page
3
3-2.
Selecting
A Location And
Moving Welding
Power Source
WARNING
£~
ELECTRIC SHOCK
can
kill.
FUMES can be hazardous; LACK OF
FRESH AIR AND PROPER VEN
TILATION can be harmful.
Do not touch live electncal parts.
Disconnect
input power conductors from de
line BEFORE moving welding
power
source.
Place unit
supply
FIRE OR EXPLOSION can result from
unit on, over, or near com
bustible surfaces.
welding
Do not breathe
energized supply
only
fumes.
where there is
a
good
fresh air
and proper ventilation.
placing
Do not locate unit on, over,
surfaces.
Do not install unit
near
or near
combustible
FALLING EQUIPMENT can cause
serious personal injury and equipment
damage.
flammables,
Lift unit at handles.
Have two persons of
unit.
BLOCKED AIRFLOW causes over
heating and possible damage to unit.
Move unit with hand cart
If
only factory-approved filter.
using
a
fork lift vehicle,
skid before
Warranty
is void if any
or
similar device of ade
quate capacity.
Do not block airflow.
Use
adequate physical strength lift
secure
unit
on a
proper
transporting.
unapproved filter is used.
swamll.1
1
Movement
Lifting
12/94
Handles
Use handles to lift unit.
Hand Cart
2
Use cart
unit.
or
3
Rating
Use
rating
similar device to
Label
label to determine
power needs.
4
input
Line Disconnect Device
Locate unit
er
move
near
correct
input pow
supply.
Location And Airflow
3 in
(78 mm)
6 in
(156 mm)
3
Special installation may be required
where gasoline or volatile liquids are
present
see
NEC Article 511
or
CEC
Section 20.
3 in
mm)
ssb9.15194 -ST-146 123-A/Ref. ST.151 556
Figure
OM-2204
Page
4
3-2. Location And Movement Of
Welding
Power Source
3-3.
Selecting
And
Preparing
Weld
Output Cables
Weld
1
Output
Cable
Determine total cable length In
weld circuit and maximum welding
amperes. Use Table 3-1 to select
proper cable size.
Use shortest cables
Do not
Terminal
2
possible.
damaged
use
cables.
Lug
Use
lugs of proper amperage
capacity and hole size for connect
ing to work clamp or electrode
holder.
3
Insulated Electrode I-folder
4
GTAW Torch
Install according to manufacturers
instructions.
For Example,
Total Cable
Length In Weld
Circuit
20 ft (6 m)
5
Work
Clamp
=
Install onto work cable.
Tools Needed:
~
6
-r
lOft
(3 m)
Dinse-Type Connector
Install onto weld cable
Figure 3-4.
as
sb62
3-3.
Figure
Selecting
And
Preparing
Output
Weld
-
S~O656
Cables
3~
2
shown in
5/94
1
Weld
2
Handle
3
Sleeve
Output
Cable
Slide handle onto cable;
strip cable
and install sleeve.
1 in
(26 mm)
5~
4~
4
Connector
5
Setscrew
Body
Insert cable with sleeve
connector
body, tighten
and slide handle
over
fully
into
setscrew,
connector.
If job
requires cable larger than 3/0
use 2 ft(610 mm) or shorter
piece of 3/0 AWG cable for Dinse
Type connector installation. Con
AWG,
nect other end of short cable to the
Tools Needed:
4/0
or
larger
weld cable.
ST.156 496
Figure
3-4.
Dinse-Type
Connector
Assembly
Table 3-1. Weld Cable Size*
Total Cable
100 ft
(30 m)
(Copper) Length
I
150 ft
Or Less
(45 m)
Welding
Amperes
10 To 60%
60 Thru 100%
Duty Cycle
Duty Cycle
In Weld Circuit Not
200 ft
I
(60_m)
250ft
I
(70_m)
10 Thru 100%
Exceeding
300ft
I
(90_m)
3~o~
400ft
(105_m)
(120_m)
Duty Cycle
100
4
4
4
3
2
1
1/0
1/0
150
3
3
2
1
1/0
2/0
3/0
3/0
200
3
2
1
1/0
2/0
3/0
4/0
4/0
250
2
1
1/0
210
3/0
4/0
2-2/0
2-2/0
2-3/0
300
1
1/0
210
3/0
4/0
2-2/0
2-3/0
350
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
400
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
500
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-3/0
WeId 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.
S-0007-D
OM-22O4 Page 5
3-4.
Connecting
To Weld
Output Receptacles
WARNING
4~
ELECTRIC SHOCK
can
kill; ARCING
burn skin
can
or
damage electrical equipment.
Do not touch live electrical parts.
Turn Off
Do not
Be
welding power source before making any weld output connections.
change position of welding cable connectors while welding.
sure connectors are secure
in
receptacles before welding.
swarnl2.2 2/93
1
Positive (+) Weld Output
2
Receptacle
Negative () Weld Output
Receptacle
3
Connector
DC
For
(DCEP),
Electrode
Positive
connect work cable con
negative ()
nector to
receptacle
and electrode holder cable
DC
For
(DCEN),
2
con
positive (+) receptacle.
nector to
Electrode
cable
reverse
Negative
connec
tions.
See
Figure
3-1 for
typical polarity
choices.
To
connect to receptacle, align
keyway, insert connector, and turn
clockwise until tight.
Ref. ST-i 55 091 / Ref. ST-i 53 625
Figure
3-5.
Remote 14
ReceptacJe
3-5.
Connecting
To Weld
Output Receptacles
RC2 Information And Connections
3
1
Remote 14 Receptacle RC2
(See Table 3-2)
2
Keyway
3
Plug
4
Threaded Collar
To
connect
keyway,
to
insert
receptacle, align
plug, and tighten
threaded collar.
9
sb7.1 5)94
Figure
ST-BOO 829 / Ref. S-0004-A / S-0750
3-6. Remote 14 Connections
Table 3-2. Remote 14 Socket Information
REMOTE
OUTPUT
(3~
(CONTACTOR)
A
The
Page
Socket Information
A
24 volts
B
Contact closure to A
C
+10 volts dc
D
Remote control circuit
common.
E
0 to +10 volts dc
command
K
Chassis
ac.
Protected
output
by fuse
F2.
completes
24 volts
ac
contactor control circuit.
to remote control.
AMPERAGE
remaining
OM-2204
Socket*
14
sockets
6
are
not used.
input
common.
signal
from remote control.
3-6.
Installing Gas Supply
4~
WARNING
CYLINDERS
can
explode
Keep cylinders away
from
if
BUILDUP OF SHIELDING GAS
health or kill.
damaged.
welding
and
other
electrical circuits.
Never touch
Shutoff
harm
when not in use.
~
cylinder with welding electrode.
Always secure cylinder to running gear, wall,
other stationary support.
shielding gas supply
can
or
wam4.1 9/Si
Obtain gas cylinder and chain to
running gear, wall, or other station
ary support so cylinder cannot fall
and break off valve.
1
Cap
2
Cylinder
Valve
Remove cap, stand to side of
valve, and open valve slightly. Gas
flow blows dust and dirt from valve.
Close valve.
3
Cylinder
4
Regulator/Flowmeter
Install
5
so
face is vertical.
Gas Hose Connection
Fitting has 5/8-18
threads. Obtain and
right-hand
install
gas
hose.
2
6
Flow
Adjust
Typical flow rate
feet per hour).
Make
is 15 cfh
(cubic
flow adjust is closed
opening cylinder to avoid
damage to the flowmeter.
sure
when
3
7
GaslnFitting
8
Gas Out
Fithng
The Gas In and Gas Out
have 5/8-18
Obtain
right
proper
fittings
hand threads.
size,
type,
and
length hose and make connections
as
follows:
Connect hose from
shielding gas
supply regulator/flowmeter to Gas
In fitting.
Connect shielding gas hose from
torch to Gas Out fitting.
Tools Needed:
~r 5/8, 1-1/8 in
ssb3.3
Figure
3-7.
5/94
Ref. ST-i 58 697-A/ Ref. S-0004-A / Ref. ST-i 53 625 / Ref. S-0621 -c
Typical Regulator/Flowmeter
Installation
OM-2204
Page
7
3-7.
Connecting Input
A~
1~
Power
WARNING
ELECTRIC SHOCK
HIGH-FREQUENCY RADIATION can
interfere with radio navigation, safety
services, computers, and communica
tions equipment.
Have only qualified person familiar with
equipment perform this installation.
welding power source, and disconnect
input power before inspecting or installing.
Have only qualified persons install unit.
electronic
Installation must meet National Electrical Code and
all other codes.
swam
Have
System
kill.
Tum Off
Read and follow entire Section 7 for proper location
and installation requirements for high-frequency
equipment before installing unit.
Three-Phase
can
Do not touch live electrical parts.
Single-Phase System
13.2 4/93
only qualified persons make
this installation.
1
Rating
Label
Use
single or three-phase, 50/60
input power which matches
one of the voltages shown. The
AUTO-LINK circuitry senses the
input voltage and automatically
links the unit for operation.
Hz,
ac
2
Line Disconnect Device Of
Proper Rating
3
Input Power Cord
4
Grounding
Conductor
Green Or Green With Yellow
Stripe(s)
Install
9
grounding
conductor and
input conductors from unit to deen
ergized line disconnect device.
Connect grounding conductorfirst,
input conductors.
then line
Be
sure
grounding conductor goes
ground.
to an earth
5
Black And White
Input Con
ductor
6
Insulation
7
Electrical
8
Red
Sleeving
Tape
Input Conductor
Red conductor not used in singlephase system. Insulate and isolate
conductor by sliding insulation
sleeving over end of lead, bending
lead back, and taping to power
cord.
9
Overcurrent Protection
Select
size
using
deenergized
line disconnect device (fused dis
connect switch shown).
type
and
Table 3-3. Install into
ssb2.3
Figure
OM-2204Page8
3-8.
11/93
Ref. ST-144 221 / Ref. ST-070 399-C / Ref. ST-146 123-A / S-0657 / Ref. S-0092-A
Input Power Connections
Table 3-3. Electrical Service Guide
Three-Phase
Input Voltage
Input Amperes
At Rated
230
460
575
230
460
575
42
21
16.4
50.8
29
23.6
60
30
25
80
40
35
Output
Max Recommended Standard Fuse Or Circuit
Breaker Rating In Amperes
Reference: 1993 National Electncal Code
(NEC).
S-0092J
SECTION 4
-
OPERATION
WARNING
AA
ELECTRIC SHOCK
Always
wear
Insulate
.
kill.
can
yourself
from work and
Wear
ground.
~_~-
panels
and
covers
FUMES AND GASES
to your health.
Keep your
securely
in
place.
be hazardous
can
head out of the fumes.
Ventilate area,
or use
breathing
(MSDSs)
Safety
manufacturers
instructions for material used.
can cause
Do not weld
near
fire
helmet with correct shade of filter.
body protection.
~
MOVING PARTS
can cause
injury.
Keep away from moving parts.
Keep all doors, panels,
securely in place.
covers, and
guards
closed
and
device.
Data Sheets
Read Material
WELDING
welding
Wear correct eye, ear, and
~
all
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
dry insulating gloves.
Do not touch live electrical parts.
Keep
Single-Phase
or
and
I
explosion.
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
Pacemaker
wearers
keep away.
flammable material.
Wearers should consult their doctor before
Watch for fire;
keep extinguisher nearby.
Do not locate unit
Do not weld
on
Allow work and
over
,~
near arc
welding, gouging,
or
going
spot welding opera-
tions.
combustible surfaces.
closed containers.
equipment to
cool before
See Safety Precautions at beginning of manual for ba
sic welding safety information.
swam6.1 10/91
handling,
10
9
8
2
7.
3
4
6
5
10
Optional AmperageNoltage
Meter And Switch
ST-146 125~A
Figure
4-1. Controls
OM-2204
Page
9
1
2
3
/
~
~
Wear the
following
1
Dry, Insulating
2
Safety
3
Welding
while
welding:
Gloves
Glasses With Side
Shields
Helmet With Correct
Shade Of Alter
(See ANSI
Z49.1)
s03.i 1/94
Figure
4-2.
Safety Equipment
Work
1
1
Tools Needed:
~=~==~
Clamp
Connect work clamp to a clean,
paint-free location on workpiece,
.
as
close to weld
area as
possible.
Use wire brush or sandpaper to
clean metal at weld joint area. Use
chipping hammer to remove slag
after
welding.
sM.1 2/93
Figure
4-3. Work
Clamp
1
Process Selector Switch
Use switch to select
type of weld
output. Use left position for SMAW
Welding. Use right position for
GTAW Welding with High Frequen
cy for arc starting, and center posi
tion for GTAW Welding without
High Frequency.
Switch position determines the op
eration of the Arc Force (Dig), Pre
flow, and Postf low controls (see
Figure 4-6 and Figure 4-9).
Ref. ST-i 53 625-A
Figure
4-4. Process Selector Switch
1
Amperage
Control
Use control to select weld amper
age. Amperage may be adjusted
while welding.
Figure
OM-2204
Page
10
4-5.
Amperage
Control
Arc Force Control
1
(Dig)
This control is used for SMAW
welding and only works when Pro
(see
posi
Selector
switch
is in the SMAW
cess
Figure 4-4)
tion.
Use control to
make vertical
help
or
start an
arc or
overhead welds.
Control increases amperage at low
arc
voltage (see Figure 2-1).
When set at 0, short-circuit amper
age is the same as normal welding
amperage.
When
set at 100, short-circuit
amperage increases to help arc
starting.
Select setting best suited for appli
cation. Numbers around control
are for reference only.
Set control at 0 for GTAW
Figure
AA
4-6. Arc Force Control
welding.
(Dig)
WARNING
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Do not touch weld output terminals when contactor is
Do not touch electrode and work
clamp
energized.
at the same time.
swaml.1 10191
1
Output (Contactor)
Switch
Use switch to select way ot control
ling output.
For
front
panel control,
position.
place
switch in On
For remote output control and to
preset amperage using optional
digital meter, place switch in Re
mote 14 position (see Section 3-5).
Weld output terminals are energized
when switch Is On and Power is On.
Figure
4-7.
Output (Contactor)
Switch
OM-2204 Page 11
Amperage Control Switch
1
Use switch to select way of control
ling amperage adjustment.
For front panel control,
switch in Panel position.
For remote control, place switch in
Remote 14 position (see Section
a
3-5).
PANEL
Remote control at Remote 14 is
percent of front panel
ting.
A
Example: Combinatien
Remote
2
Fingertip
control set
Control
3
Remote Hand Control
4
Remote Foot Control
See
example
below.
Amperage Control
175
Z143
place
200
0
PANEL
100~
A
75
~4~)
4
Unit
Mimimum
ION
(3~ OUTPUT (CONTACTOR)
5
Set Switches
A
Set Desired Maximum
~
Control
c:IiIIII~:~T
Setting
(200 A)
Adjust Remote Control
Amperage
ST-i 59 059/ S-0769 / S-0774
Figure
4-8.
Amperage
Control Switch
The scale around each control is
marked in seconds.
1
Preflow Time Control
Use control to adjust the time that
gas flows before the welding arc is
started.
2
Postf low Time Control
Use control to adjust the time that
gas flows after the welding arc
stops.
These controls are for GTAW weld
ing and only work when Process
Selector switch (see Figure 4-4) is
in one of the GTAW positions.
2
Figure
OM-2204
Page
12
4-9. Preflow/Postf low Time Controls
1
AmperageNoltage
Meter
Use meter to read amperage and
voltage output. The preset value is
displayed
when not welding. The
actual value is displayed while
welding and is held for 15 seconds
after welding stops (see Section
5-4).
See table for the values
for AN switch settings.
2
displayed
Meter Switch
Use switch to select amperage
or
voltage display.
Meter
AN Switch
Positions
Display
When Not
When
Welding
Welding
A
Preset
Amps
Actual
V
Preset
Amps
Actual Volts
Figure
4-10.
Amps
Amperage/Voltage
Meter And Switch
(Optional)
1
Power Switch
Use switch to turn unit and
light On and Off.
pilot
There is aS second time delay be
fore the unit is ready to weld.
Fan motor is
trolled and
is needed.
2
Figure
4-11. Power Switch And Pilot
Pilot
thermostatically con
only runs when cooling
Light
Light
OM-2204
Page
13
WARNING
£~
r~J
BUILDUP OF SHIELDING GAS
Shutoff
shielding gas supply
harm health
can
when not in
or
kill.
use.
waml.1 9/91
1
Shielding
2
Valve
3
Torch
4
Foot Control
Gas
Output
Open valve
welding.
Cylinder
Control
cylinder just before
on
Torch output control or foot control
turns weld output and gas flow on
OR
and off.
Close valve
ished
on
sb5.2
Figure
~S\)
))
)
Gas)) Weldin~)
Install&
Connect
)
4-12.
Equipment
Shielding
Insert
Tungsten
) ~
Into Torch
})
when f in
5/94
S-0621 -Cf S-0769
Gas
~\
~\
PutOn
Personal Safety
Select
Tungsten (See
Section 8)
cylinder
welding.
Equipment
))
Power))
Turn On
) Welding
Source
etControls~
Turn On
Shielding
Begin
ssb8.1
Figure
Install &
Connect
,
)
Equipment
)
}}
)
Figure
)
Sequence Of
Connec~ ~\
Install &
Pulser Control
Unit
Set Controls
4-14.
))
) Welding
Install &
Connect
4-13.
Equipment
Tungsten
~))
)) Control))
Select
Turn On
Gas
Sequence
))
Arc
Insert
Tunasten
) Tungsten (Se
Section8)
~,/)
i
Shielding
Select
Electrode
Gas
lntolbrch
Of Gas
Tungsten
Put On
Personal Safety
Equipment
Arc
I
)y
Begin
Put On
Personal Safety
Equipment
WeId~~
Welding
Set Controls
})
Welding (GTAW)
J
Turn On
Pulsing
12/92
))
Pulsed
(GTAW-P)
Insert
Electrode
Into Holder
Turn On
Source~
________________
Begin
ssb7.1 9/92
Figure
OM-2204
Page
14
4-15.
Sequence Of Shielded
Metal Arc
Welding (SMAW)
Replace
SECTION 5- MAINTENANCE & TROUBLESHOOTING
£~
WARNING
ELECTRIC
SHOCK
can
kill;
SIGNIFICANT DC VOLTAGE exists after
removal of input power.
Do not touch live electrical parts.
~
l~IPi~.~
MOVING PARTS
Keep away
from
can cause
Injury.
moving parts.
Turn Off
welding power source, disconnect input
power, wait 60 seconds, measure voltage on input
capacitors according to Section 5-2, and be sure
voltage is near zero before touching any parts.
~pI~
STATIC ELECTRICITY
circuit boards.
Put
on
boards
HOT PARTS
can cause severe
Allow
cooling
servicing.
period
before
burns.
maintaining
can
damage parts
on
grounded
or
wrist
strap BEFORE handling
parts.
Use proper
static-proof bags
and boxes.
or
Maintenance
persons.
to
be
performed only by qualified
swam8.3 2/94
Routine Maintenance
5-1.
3 Months
~
Turn Off all power before
Section
3 Months
~Replace
WARN~
See
-~
maintaining.
~j
Unreadable
Labels
Cracked
Parts
14/17-Pin Cord
Clean
~r
3-4
And
~iii!~~
Tighten
Weld
Connections
~
Gas Hose
-~
Torch Cable
6 Months
Blow Out
Or
Vacuum
Inside
During Heavy Service,
Clean Monthly
ST-148 123~A
Figure
5-1. Maintenance Schedule
OM-2204
Page
15
5-2.
Removing Case
And
Measuring Input Capacitor Voltage
~I_A~aI~~
~ Significant
DC
voltage can
remain
on
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
capacitors
is Off. Always check capacitors as shown to be
have discharged before working on unit.
Turn Off welding power source and
disconnect input power.
after unit
sure
1
they
Top Of Case
2
Handles
3
Outside Handle Screws
4
Side Bolts
To loosen top, remove two outside
handle screws from both handles
and all side bolts.
5
Bottom Of Case
6
Mounts
To loosen bottom,
remove
all side
bolts, carefully place unit on its side
3
the four mounts.
and
remove
7
Input Capacitors C12, C13
8
Input Capacitors C8,
Locate
9
on
C9
lower left side.
Voltmeter
Check
both
sets
of
input
capacitors.
Measure dc
voltage across posi
(+) and negative () terminals
until voltage drops to near 0 (zero)
tive
volts.
After task is
completed, reinstall
case.
9
Front Panel
(Controls Vary
According
To
7
Model)
Tools Needed:
5/32 in
~ 3/8,7/l6in
Ref. ST-I 52 11 4-E
Figure
OM-2204
Page
16
5-2.
Removing
Case And
Measuring Input Capacitor Voltage
5-3.
Overload Protection
I~L~W~4~
A.
Overheating
Figure
B.
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
5-3.
Overheating
Fuses
Turn Off welding power source,
disconnect input power, and check
voltage on input capacitors ac
cording to Section 5-2 before
proceeding.
1
Fuse F2
F2 protects the 24 volts ac winding
of control transformer T2. If F2
opens, remote control devices
connected to Remote 14 recep
tacle RC2 shut down.
Remove
5-2)
top
(see Section
replace fuse.
cover
to check and
See Parts List for fuse size. Use
proper tool when
2
removing fuse.
Fuse Holder
Tools Needed:
ST-146 126-F/Ref. ST-146 122-D
Figure
5-4. Overload Protection
OM-2204 Page 17
5-4.
Changing AmperageNoltage
Meter Hold Function
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
AmperageNoltage meter is
able to hold the displayed weld out
put value for 15 seconds after
welding stops. If the hold function
is not used, the displayed value
The
leaves when
This
welding stops.
procedure
allows the
function to be turned On
Turn Off
welding
or
hold
Off.
power source,
input power, and check
voltage on input capacitors ac
disconnect
Section
cording to
proceeding.
before
5-2
1
NV Meter Board PC5
2
DIP Switch S2
S2 is accessible from the left side
of the unit.
Front Panel
(Controls Vary
According To Model)
Tools Needed:
3
Toggle
1
4
Toggle
2
Set
toggles
Reinstall
in desired
position.
case.
Non-Conductive
ST-i 59050-B
Figure
5-5.
5-5.
Changing Amperage/Voltage
Meter Hold Function
Troubleshooting
WARNING
a
MOVING PARTS
ELECTRIC
SHOCK
kill.
can
SIGNIFICANT DC VOLTAGE exists after
removal of input power.
S
can cause
injury.
Keep away from moving parts.
Do not touch live electrical parts.
Turn Off
welding power source, disconnect input
power, wait 60 seconds, measure voltage on input
capacitors according to Section 5-2, and be sure
voltage is near zero before touching any parts.
STATIC ELECTRICITY
circuit boards.
Put
on
boards
HOT PARTS
Allow
can cause severe
cooling period
before
can
damage parts
on
burns.
grounded
or
wrist
strap BEFORE handling
parts.
Use proper
static-proof bags
and boxes.
servicing.
Troubleshooting
to be
performed only by qualified
persons.
swam9.3 2194
Table 5-1.
Welding
Trouble
No weld
output; unit completely mop-
i
-~
Be
sure
Power switch is On.
-~
Be
sure
line disconnect switch is On.
-~
Check line
breakers.
fuse(s)
Check for proper
Page
Section
Remedy
Figure
4-11
I
erative.
OM-2204
Trouble
18
and
input
replace
connections.
if
necessary.
Reset
circuit
3-7
3-7
-~
-~
3-7
Trouble
No weld output; fan motor FM
and
pilot light
Section
Remedy
running
on.
I
I
-~
Check position of Output
(Contactor)
switch.
-~
Thermostat TP1 open (overheating). Allow fan to run; thermostat
closes when unit has cooled.
Low weld output with
no
Check position of
control.
Amperage
4-7
5-3A
J
]_.
Control switch.
Factory Authorized Service Station/Service Distributor
Have
-~
Figure
-~
i.
Figure
4-8
-~
check control board PCi.
Limited
output and low open-circuit
~
-~
I
voltage.
Check
open
incoming
or
power for correct
voltage. Replace
line fuse if
-~
3-7
j
reset circuit breaker.
_____________
Check for proper
~fatic
or
improper weld output.
Tighten
all
input
and output connections.
-~
welding cable connections.
Check for proper size and type of cable.
Check for proper
input
Remote device completely inoperative.
-~
-~
3-3,3-4
-~
3-3
and output connections.
-~
Replace electrode.
receptacle RC2.
3-5
-~
Check fuse F2 and replace if necessary.
Fan motor FM does not
I---1
run.
Have
Factory
3-3, 3-4, 3-7
8-1,8-2
-~
Connect remote control to Remote 14
3-3, 3-4, 3-7
5-3D
Authorized Service Station/Service Distributor
check thermostats TP2 and/or TP3 and fan motor.
~
-~
I
____________
Wandering
arc; poor control ot arc di-
rection.
i.
-~
Reduce flow rate.
I
Select proper size tungsten.
Properly prepare tungsten.
Tungsten
electrode
remaining bright
oxidizing
and not
after conclusion
~.
-~
Shield weld
zone
from drafts.
--~
of
weld.
Increase
postflow time.
Check and tighten all gas
fittings.
Water in torch. Refer to torch Owners
replacement,
Lack of high frequency; difficulty
establishing an arc.
in
1-..
Be
sure
and
repair torch
torch cable is not
as
near
Manual for
part(s) requiring
any
grounded
metal.
Check work and torch cable for damaged insulation
nections, and repair as necessary.
No
high frequency.
or
bad
con
Check position of Process Selector switch.
Have
check
--~
necessary.
Factory Authorized Service Station/Service Distributor
high frequency board PC2.
-~
--~
Figure4-4
--
OM-2204 Page 19
SECTION 6- ELECTRICAL DIAGRAMS
12
U
I~7
R~7
~fP~G18
RC~2-4
RC31-3
~12-3
I~O-I2
~~r
>
CUT
~-<
~314
84
~. I~
< ~31-2
FC4
FL1~R
O/R~G3J
~3V~31
Q~O
42
< ~31-12
~4AwfG#S ~F
I~3O-11
I
I
Figure
OM-2204
Page
20
6-1. Circuit
Diagram
For 230/460 Volt Models
i~1Y
7
?
gp
ft~7
3
~11-e
ti
~
) _3>~-
~11-7
~11-1t
Pc3
~rt/Ptc1i
~/PLC13
~-2
)
9AAW/GAS
>0-~O
0
W
t7V
cTF/G~S
cN
RC11-~
I
~)
~
~-1
RC~1~
~1t~t
PGATNE
SD-178 777
OM-2204
Page
21
WI
LI
L2
ClO
L3
RC7
PLG7
12
PLOT
RC7
R
C~)
to
to
a
to
a
to
a
4
a
to
to
a
a
tO
a
RCA-a
PC2/PLO2
RC4/PLO4
RC6/PLOo
RCG-2
PCI
RC2
B>>
PtA
~C<c
A>~~fc
RC8/PLO8
fl
>
REF.
CON.
RCIO-4
PC30/PLO3Q
RC3 I /PL133 I
IC
>
c
>
QCI
E
)
~
IN
RC 10-2
E
42
cc RC3I-12
RCSO-I0
OUT
Rt28/PLO2B
42
CCRC3I-3
Rt4T
>>56
PC 12-3
~
CC
64
1<
z
a
a
RC3I-4
RC3O-B>>
Ct
a
?
to
tO
0
a
a
C)
C)
>
RNT.
CONTACTOR
a
0
0
o
to
to
a
UI
a
a
RCI2-9
RC3I-2
60
C RC3I-5
Figure
OM-2204
Page
22
a
a
RC3O-I I>>
B
PCI 0/PLO 10
PCI 2/PLO 12
PCI 8/PLO I B
PC3O-9>>
0
BOARD
F
6-2. Circuit
Diagram
For 460/575 Volt Models
PC7/
PLG7
PC2O/
U
Gd
~O
C4
Ca
ca
(.1
L
Gd
U
~
PLG2O
U
PCI 1-6
PC 11-7
PCI 1/PIGII
P~3
SMAW/GAS ~F
PCI9-2
RCI3/PL013
PC I 9/PLO 19
I
o
~c ~F/GAS £~4
i-c ~VGAS ~
PCI~-I
PC 18-6
PCI 8-3
PCI 8-8
PC 10-I
PC 12-10
PC 12-Il
J
SD-hO 4-40
OM-2204
Page
23
SECTION 7- HIGH FREQUENCY
mod6.1 5/94
WARNING
a
HIGH-FREQUENCY RADIATION can interfere with radio
and communications equipment.
Have
only qualified person
familiar with electronic
The user is
installation.
responsible
If notified
the FCC about interference, stop
by
Have the installation
for
regularly
Keep high-frequency
source
shown in
Figure
shielding
as
having
a
qualified
equipment perform
electrician
using
the
promptly
equipment
navigation, safety services, computers,
this installation.
correct any interference
problem resulting from
the
at once.
checked and maintained.
doors and
panels tightly shut, keep spark gaps
7-3 to minimize the
possibility
at correct
setting,
and
use
grounding
and
of interference.
1
Gas
2
High-Frequency Voltage
Used
to
Tungsten
help
arc
between torch and
or
stabilize the
Arc Torch
jump air gap
workpiece and/
arc.
3
Submerged Arc Welding
4
Flux
5
High-Frequency Voltage
Gun
Used to
Gas
Submerged Arc
Welding (SAW)
Tungsten Arc
Welding (GTAW)
Figure
7-1. Weldi ng Processes
help arc reach workpiece
through flux granules.
5-0693
Requiring High Frequency
1
Weld Zone
Sources Of Direct
High-Frequency Radiation
High-frequency
source
(welding
with built-in HF or
separate HF unit), weld cables,
torch, work clamp, workpiece, and
work table.
power
2
source
Sources Of Conduction Of
High Frequency
power cable, line disconnect
device, and input supply wiring.
Input
3
Sources Of Reradiation Of
High Frequency
Ungrounded metal objects, light
ing, wiring, water pipe and fixtures,
extemal phone and power lines.
S-0694
Figure
OM-2204
Page
24
7-2. Sources Of
High-Frequency
Radiation From Incorrect Installation
/
/
/
/
Nonmetal
\~uilding
Metal
Building
10
S-0695
1
High-Frequency
Built-In HF Or
Source
Separate
(Welder
Unit)
With
HF
Ground metal machine case, work output
terminal, line disconnect device, input
supply, and worktable.
2
Center Point Of
Welding
Zone
Midpoint between high-frequency
welding torch.
source
Welding
A circle 50 ft
directions.
4
Weld
(15 m) from
Output
6
Water
Bonding
Pipe And Fixtures
pipe every
External Power Or
7
Locate
high-frequency
(15 m) away from
Zone
center
point
in all
9
Electrically join (bond) all conduit sections
using copper straps or braided wire. Ground
conduit every 50 ft (15 m).
Ground water
and
3
Conduit Joint
5
8
Metal
Building
source
Panel
specifications.
Windows And
Doorways
(15 m).
Telephone Lines
power and
Consult the National Electrical Code for
10
50 ft
Grounding
Rod
at least 50 ft
Cover
all
windows
and
grounded copper screen
1/4 in (6.4 mm) mesh.
doorways
of not
more
with
than
phone lines.
Bonding
11
Overhead Door Track
Methods
Cables
Bolt
or
weld
copper
cables short and close toaether.
seams,
building panels together, install
straps or braided wire across
and ground frame
Figure
Ground the track.
7-3. Correct Installation
OM-2204
Page
25
SECTION 8- TUNGSTEN ELECTRODE
mod2.1 1)94
N OTE ~
For additional information, see your distributor for
Tungsten Arc Welding (GTAW) process.
Wear clean
8-1.
Selecting Tungsten
gloves
to
handbook
the Gas
on
prevent contamination of tungsten electrode.
Electrode
Table 8-1.
Tungsten
Size
Amperage Range
Electrode Diameter
a
DC
Electrode
Argon
Negative/Straight Polarity
-
Gas
DC
Argon Electrode
Positive/Reverse Polarity
Type
-
Polarity
Argon Using
High Frequency
AC
AC
Argon
Wave Using
Balanced
High Freq.
Pure
Tungsten
(Green Band)
.010
Uptol5
Uptol5
UptolO
.020
5-20
5-20
10-20
.040
15-80
10-60
20-30
1/16
70-150
10-20
50-100
30-80
3/32
125-225
15-30
100-160
60-130
1/8
225-360
25-40
150-210
100-180
5/32
360-450
40-55
200-275
160-240
3/16
450-720
55-80
250-350
190-300
1/4
720-950
80-1 25
325-450
250-400
Upto2O
Uptol5
15-35
5-20
2% Thorium
Alloyed
Tungsten (Red Band)
.010
Upto25
.020
15-40
*
.040
25-85
*
1/16
50-160
10-20
20-80
20-60
50-150
60-120
3/32
135-235
15-30
130-250
100-180
1/8
250-400
25-40
225-360
160-250
5/32
400-500
40-55
300-450
200-320
3/16
500-750
55-80
400-500
290-390
1/4
750-1000
80-125
600-800
340-525
Upto2O
Uptol5
Zirconium Alloyed
Tungsten (Brown Band)
.010
.020
15-35
5-20
.040
20-80
20-60
1/16
*
50-150
60-120
3/32
*
130-250
100-180
1/8
*
225-360
160-250
300-450
200-320
400-550
290-390
600-800
340-525
5/32
*
3/16
*
1/4
Typical argon shielding gas
Not
flow rates
are
15 to 35 cfh
(cubic
feet per
hour).
Recommended.
figures listed
manufacturers.
The
OM-2204
Page
26
are
intended
as a
guide
and
are a
composite of
recommendations from American
Welding Society (AWS)
and electrode
s-000s
8-2.
Preparing Tungsten
Tungsten
Balled End
Electrode
Ball end of tungsten before welding
by applying either an ac amperage
slightly higher than what Is recom
mended for a given electrode di
ameter (see Table 8-1), or a dc
1E:____
1 1/2 Times
Elect;ode Diameter
_______________________
______________________
1
2
electrode
positive amperage.
2
Ref. S-0161
Figure
a
~
8-1.
Preparing Tungsten
For AC Or DC Electrode Positive
(DCEP) Welding
CAUTION
FLYING SPARKS AND HOT METAL
can cause
injury
and start fires.
Shape tungsten electrode only on gnnder with properguards in a safe location wearing proper face, hand, and body protection.
Keep flammables away.
warn2.1 9/91
2
1
Tungsten
2
Tapered
Electrode
End
Grind end of tungsten on fine grit,
hard abrasive wheel before weld
ing. Do not use wheel for other jobs
or tungsten can become contami
nated causing lower weld quality.
2-1/2 Times
Electrode Diameter
Ref. S-0161
1
c1~
1
Stable Arc
2
Flat
2
Diameter of this flat determines
amperage capacity.
3
3
Grinding
Wheel
4
Straight
Ground
4
Ideal
Tungsten Preparation
Stable Arc
1
2
Ref. S-0182
1
Arc Wander
2
Point
3
Grinding
4
Radial Ground
Wheel
3
4
Wrong Tungsten Preparation
Figure
8-2.
Preparing Tungsten
Wandering Arc
For DC Electrode
Ref. S0162
Negative (DCEN) Welding
OM-2204
Page
27
SECTION 9- PARTS LIST
c~J
0)
LL
/
-~
U,
c~J
c1
c~)
1
c~,
CU
0
C.)
0)
a)
LI.
C.-
F
0
U)
0)
~
ST-146 121-F
Figure
OM-2204
Page
28
9-1. Main
Assembly (208-230/460V
Model
Illustrated)
Quantity
Item
No.
Dia.
Model
Part
No.
Mkgs.
Description
Figure
9-1. Main
208-230/460V
Assembly
CLAMP~ saddle
HANDLE, molded plastic
LABEL, caution falling equipment
4
126 415
126416...
138 442...
+141 350...
5
+141 574
1
...
2
3
6
7
2
2
2
2
2
2
CASE
1
1
CASE, bottom
1
1
1
1
1
1
1
1
1
1
C25
SR4
135289... CAPACITOR
149219... KIT, rectifier integ 35A
R17
136 191
CAP, protective
136185... RESISTOR
8
9
...
...
vinyl
.313 ID
x
can cause
.500
injury
Ig
ig 9-3... PANEL, front w/components
133405... NUT, speed 10-24 fIat type rectangular
108105... CLAMP, capacitor 2.500dia
136227... STRIP, mtg capacitor bracket
10
11
12
1
1
4
4
4
4
2
2
...
2
2
...
2
2
8
8
13
Li -4
133639
14
CHOKE, DVDT
145 245
15
INSULATOR, elctlt
155 642... SCREW, set .250-28 x 1.000 cup pt sch sti
16
17
Ci0,1i ....164812...CAPACITOR
143748... BUS BAR
18
19... C8,9,12,13 ..135 786... CAPACITOR, eIctlt4000uf25OVDC
19... C8,9,12,13... 140 981
CAPACITOR, elctIt2800uf300VDC
W1A
157 661
20
INTERLOCK, cntor lEG 2N0-2NC 1OA 4P
158567... LINK, jumper
Wi
21
157 660
CONTACTOR, lEG 25A 4P 2N0-2NC contacts
2
2
2
2
4
4
...
...
...
158 567... LINK, jumper
158 568
LINK, jumper large
131 054... CONNECTOR & SOCKETS, (consisting of)
113746.... CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & PINS, (consisting of)
135 635
114 656.... CONNECTOR, rect pin 24-l8ga Molex 39-00-0040
146 112
BLANK, snap-in nyl .2l8mtg hole
158 555
TRANSFORMER, current
CABLE TIE, 0-1.750 bundle
020 265
...
PLG21
....
RC21
...
1
3
1
1
1
1
1
2
2
1
1
2
2
2
...
22
23
...24
CT1
...
1
1
...
1
1
26
172012...TRANSFORMER,HF
139812... RESISTOR, WW fxd 30W 5K ohm
CHASSIS, mid
Fig 9-2
27
126 026...
25
Ti
R13-16
....
...
LABEL, warning electric shock
+161 438... CASE
28
SECTION, front/bottom/back (consisting of)
31
32
32
RC7
33
34
35
36
GS1
T3
40
41
C26
RiB
1
1
1
4
4
4
158559...CABLE,pwrl2ft
1
...
1
1
1
CABLE, port No. 104/c (orderbyft)
2
TRANSFORMER, control
162 166
TRANSFORMER, control
166 680... CONNECTOR & PINS, (consisting of)
113 633.... CONNECTOR, rect pin 20-l4ga Amp 350218-1
CONNECTOR & SOCKETS, (consisting of)
166679
114066.... CONNECTOR, rect skt 20-l4ga Amp 350536-1
140 894... BRACKE1 mtg stab
605 227... NUT, nyl hex jam .75ONPST
158 583
VALVE, 24VAC 2way custom port 1/8 orf
1
165 658
...
...
134 383
...
STARTER, pulser HF
NUT,speedUtypelo-32
ARC
BUS BAR
134421
138 115...CAPACITOR
031 613...
601 394...
CAPACITOR, elctlt bOut 15OVDC
RESISTOR, C 2W 10K ohm
2
1
...
...
1
12ff
141 437... STABILIZER
...
C7
1
1
4
136190...
38
1
NUT, .312-18 stl insert
NUT,1O-32 stl insert
148 329
LABEL, caution incorrect voltage will damage unit
148 330... LABEL, caution incorrect voltage will damage unit
134229... BUSHING, strain relief .640/.770 x 1 .47Omtg hole
152710
Z1 ,2
T2
T2
PLG7
1
4
....
...
30
1
4
161 135....
161 136
29
I 460/575V
1
1
12
12
1
1
12
12
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
OM-2204 Page 29
Quantity
Item
No.
Model
Part
No.
Dia.
Mkgs.
Description
Figure
9-1. Main
208-230/460V
Assembly (Continued)
49
RESISTOR, WW fxd 40W 500 ohm
ENCLOSURE, arc starter (consisting of)
137 198
NUT, insert 10-24
015 712
GROMMET, rbr .625 ID x .875mtg hole
141 690
GROMMET, scr No. 8/10 panel hole .281sq .197 high
134 386
INSULATOR, arc starter
151 248
KIT, circuit card arc starter
CONNECTOR & SOCKETS, (consisting of)
146 099
125748.... CONNECTOR, rectskt22-18gaJSTSVH-21T-1.1
CONNECTOR & SOCKETS, (consisting of)
165 884
125748.... CONNECTOR, rectskt22-18gaJSTSVH-21T-1.1
134 327... LABEL, warning general precautionary
133 948
FOOT, mtg
50
143915
134 198
162 960
R6
42
43
I 460/575V
1
1
...
1
1
2
2
...
....
44
...
46
.
1
4
1
1
1
1
...
PC2
PLG5
47
PLG14
...
1
1
..
4
4
1
1
..
3
3
...
....
48
...
2
2
4
4
4
4
...
PLG2O
....
115 093
...
...
MOUNT,sglstudl.5diaxl.000Ig.312-l8stud
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rectskt 24-l8ga Molex 39-00-0038
CONNECTOR & PINS, (consisting of)
131 059
114 656.... CONNECTOR, rect pin 24-l8ga Molex 39-00-0040
169 771
SCREW, shld sti hexhd 10-32 x .875
113746....
RC2O
..
1
1
6
6
1
1
6
6
8
8
...
51
+When
1
4
...
45
..
...
ordering
a
component originally displaying
a
precautionary label,
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
22
24
17
46
25
26
45
27
44
40
32
34
35
ST-146 122-E
Figure
OM-2204
Page
30
9-2. Chassis, Mid
(208-230/460V Model Illustrated)
Quantity
Item
No.
Dia.
Model
Part
No.
Mkgs.
Description
Figure
1
HD1
PLG62
156 313
....
2
3
PLG11,13
...
....
TRANSDUCER,
(Fig
9-1 Item
...
GROMMET,
No. 8/10
scr
1
panel
hole
....
CONNECTOR,
rect skt 24-1
.312sq
8ga Molex
.500
high
of)
39-00-0038
131 054... CONNECTOR & SOCKETS, (consisting of)
113 746
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
....
4
5
5
010 116...
PCi
PCi
PLG2
GROMME1~ rbr .375 ID
x
.SOOmtg
hole
171 902... CIRCUIT CARD, control
171 907... CIRCUIT CARD, control
131 054... CONNECTOR &
113746....
CONNECTOR,
115 094
PLG6
...
Molex 39-00-0038
CONNECTOR & SOCKETS,
....
PLG8,18,28
PLG1O
PLG12
...
....
7
a
9
PC6
PLG1
PLG22
9
R27,28
....
....
11
...
137 768
...
TRAY, mtg PC card
GROMMET, rbr .750 ID x .B75mtg hole
141 588... STAND-OFF, 8-32 x .500 lg
168 777... CIRCUIT CARD, driver
115 091
CONNECTOR & SOCKETS, (consisting of)
113746.... CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
131 054... CONNECTOR & SOCKETS, (consisting of)
113 746.... CONNECTOR, rect skt 24-1 8ga Molex 39-00-0038
136 076... RESISTOR, WW fxd 30W 200 ohm
072253... STUD, connection single 10-32 x .500 x 1.25Omtg
012 571
HOLDER, fuse mintr
*012 654... FUSE, mintr gI 2A
...
F2
SN1
14
C40-43
..
D9-12
.
.
152776...SUPPRESSOR
152 785... RECTIFIER, si diode LH (consisting
031 689.... CAPACITOR
149 209
KIT, diode fast recovery
of)
....
TP3
THERMOSTAT, NO
133290.... HEATSINK,rect
072 253.... STUD, connection single 10-32 x .500 x 1 .25Omtg
158 549... IGBT, LH (consisting of)
161 221
IGBT, LH (consisting of)
..157 451
CAPACITOR, polyemetfilm .Oluf 1600V
150 912
KIT, transistor IGBT module
150913.... KIT, transistor IGBT module
123 231
RESISTOR, WW fxd 50W 35 ohm
169402.... HEATSINK,IGBTLH
152 780... BAFFLE, air wind tunnel LH
000 527
BLANK, snap-in nyl .875mtg hole
146581
WINDTUNNEL, 6.500 in
133 295... CHAMBER, plenum 6.500 in
135661
EDGETRIM, style 3100-1/16 (orderbyft)
132 232
MOTOR, fan 220/230V 50/60Hz 3000RPM
131 054... CONNECTOR & SOCKETS, (consisting of)
113 746
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
086 323....
15
15
1
3
3
10
10
1
1
2
2
12
12
1
1
2
2
2
2
1
1
2
2
1
1
4
4
1
1
6
6
3
3
8
8
1
1
10
10
1
1
12
12
1
1
1
1
4
1
1
..
10
1
2
2
1
1
1
1
1
1
1
1
1
1
4
4
4
4
1
1
4
PM1
PM1
R9,i0
16
17
.
.
....
....
....
...
18
...
19
20
...
FM
PLG9
...
....
4
1
1
...
C14,15
21
162 096
...
10
12
...
....
6
1
1
1
24-l8ga
(consisting of)
113 746.... CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
115 093... CONNECTOR & SOCKETS, (consisting of)
113 746
CONNECTOR, rect skt 24-1 8ga Molex 39-00-0038
115 092
CONNECTOR & SOCKETS, (consisting of)
113 746.... CONNECTOR, rect skt 24-1 8ga Molex 39-00-0038
115 091
CONNECTOR & SOCKETS, (consisting of)
113746.... CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
130 203... CONNECTOR & SOCKETS, (consisting of)
113 746.... CONNECTOR, rect skt 24-1 8ga Molex 39-00-0038
PLG4
460/575V
1
SOCKETS, (consisting of)
rect skt
I
26)
current 300A
163784... CIRCUIT CARD, HF preflow/postf low
130203... CONNECTOR & SOCKETS, (consisting
113 746
PLG19
9-2. Chassis, Mid
130 204... CONNECTOR & SOCKETS, (consisting of)
114 066.... CONNECTOR, rect skt 20-l4ga Amp 350536-1
083 147
PC3
...
208-230/460V
2
2
1
2
2
1
1
1
1
2
2
1
1
1
1
2ft
2ft
1
1
1
1
2
2
OM-2204 Page 31
Quantity
Item
No.
Dia
Model
Part
No.
Mkgs
Description
Figure 9-2. Chassis,
(Continued)
RC9
135 635
...
Mid
CONNECTOR & PINS,
208-230/460V
(Fig
9-1 Item
26)
(consisting of)
CONNECTOR, rect pin 24-lBga Molex 39-00-0040
155426... KIT, fan blade (consisting of)
134209.... NUT, speed push-on type .250
136 076
RESISTOR, WW fxd 30W 200 ohm
052 964... RELAY, end 24VDC DPDT
114215... CAPACITOR, polye film 2.3uf 25OVAC
146 689
BAFFLE, air wind tunnel RH
158 815
IGBT, RH (consisting of)
114656....
22
23
24
R27
24
CR1
25
C50
I 460/575V
1
1
2
2
1
1
1
1
1
...
26
1
1
1
1
...
161 222... IGB1
27
C16,17
.
.
155053....
158816....
HEAT SINK, IGBTRH
1
169403....
HEATSINK,IGBTRH
....
PM2
150 913....
123 231
....
149 208....
006 334....
TP2
VR5
1
(consisting of)
2
150 912....
....
RH
CAPACITOR, polye met film .Oluf 1600V
KIT, transistor IGBT module
KIT, transistor IGBT module
RESISTOR, WW fxd 50W 35 ohm
KIT, diode pwr module
THERMOSTAT, NC
THERMOSTAT, NO
..157 451
PM2
All ,12
SRi
TP1
133 968
C44-47
.
D13-16
.
....
....
149 209
....
.
.
133290....
CAPACITOR
KIT, diode fast recovery
HEAT SINK, rect
STUD, connection single 10-32 x .500 x 1 .2SOmtg
601 835... NUT, brs hex 10-32
139 743... INSULATOR, heat sink lower
030 170
BUSHING, snap-in nyl .750 ID x 1 .000mtg hole
145 407... CONTACTOR, def prp 25A 2P 24VAC
145 407... CONTACTOR, def prp 25A 2P 24VAC
152 775... SNUBBER, poly met film .luf 600VDC
072 253....
29
30
...
31
W2
31
Wi
SN2
32
136190...
1
1
2
2
1
1
1
1
1
1
1
RECTIFIER, si diode RH (consisting of)
...
031 689
1
1
4
4
4
4
1
1
4
4
14
1
1
2
2
1
1
1
6
NUT,speedUtypelo-32
37
1
PANEL, center
TRIM, style 62-1/16 (order by ft)
2
153 178
LABEL, warning exploding parts
164 849
MODULE, varistor/capacitor4 400 joule 1620-198OVDC 1
2
126 026... LABEL, warning electric shock
145 053
WASHER, shldr nyl .298 OD x .203 ID x 1.000 x
38
099037... EDGE
39
010 493...
40
006 426...
33
+158 442
1
ift
2
...
VCM1
36
1
...
2
...
.O62shldr
133 405...
41
C1,2
..42
132844...
43
158557...
44
158 443...
158444...
46
134058
is
...
TRIM, style 62-1/16 (order by ft)
BUSHING, snap-in nyl. 625 ID x .875mtg hole
CLAMP, capacitor 2.000dia
NUT~ speed 10-24 fIat type rectangular
CAPACITOR, polyp film 2.luf 1000VDC
BUS BAR, interconnecting
INSULATOR, heat sink upper
STRIP, busrect
STAND-OFF SUPPORT, PC card .lS6dia
4
4
ift
ift
1
1
2
2
2
2
2
2
1
1
1
1
1
1
2
2
part of 042 517 Optional Meter Kit.
*Recommended
Spare
+When
a
ordenrig
Parts.
component originally displaying
a
precautionary label,
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-2204
6
...
099 037... EDGE
34
2
1
091 033... VARISTOR
28
PLG8
1
...
27
Page
32
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure
R2
...2
...8
073 562
R3
035 897
S5
134 849
S4
134 847
S3
134 848
PC5.... .157011
PLG5O
089 222
.134 058
.158 563
136 339
120 304
148 297
Si
PLG3....
128 756
131 054
113 746
RC3
135 635
114 656
11
146 684
R4,5
121 770
RC2
143 976
079 534
9-3. Panel, Front
w/Components (Fig
Quantity
9-1 Item
10)
POTENTIOMETER, C std slot l/T 2W 10K ohm
POTENTIOMETER, C std slot liT 2W 1K ohm
SWITCH, tgl DPDT 15A 125VAC
SWITCH, tgl SPDT 15A 125VAC
1
1
1
1
1
SWITCH, tgl DPDT 15A 125VAC
1
CIRCUITCARD, meter
1
CONNECTOR, rect llskt plug Amp 1-640440-1
STAND-OFF SUPPORT, PC card .l56dia
4
1
STRIP, protector PC card
1
COVER, opening meter (not used when unit has Meter Kit)
BLANK, snap-in nyl .25Omtg hole (not used when unit has Meter Kit). 1
2
NUT, speed U type 10-32
1
SWITCH, tgl 3PST 40A 600VAC
CONNECTOR & SOCKETS, (consisting of)
1
2
CONNECTOR, rect skt 24-1 8ga Molex 39-00-0038
CONNECTOR & PINS, (consisting of)
1
2
CONNECTOR, rect pin 24-l8ga Molex 39-00-0040
1
INSULATOR, switch power
POTENTIOMETER, C sltd sft l/T 1W lOOK ohm
CONNECTOR w/SOCKETS, (consisting of)
CONNECTOR, circ skt push-in 14-l8ga Amp 66358-6
2
1
14
ST-146 120-C
Figure
9-3. Panel, Front
w/Components
OM-2204
Page
33
Item
No.
Dia.
Part
No.
Mkgs.
Figure 9-3. Panel,
(Continued)
1
129525
RECEPTACLE, twlk insul fem (Dinse type) 50/70 series
CONNECTOR KIT, Dinse male 50 series (consisting of)
WRENCH, hex 5mm short
HOSE, SAE .187 ID x .41000 (order by ft)
FITTING, gas
CONNECTOR, circ protective cap Amphenol 9760-20
NAMEPLATE, (order by model and serial number)
KNOB, .l25dia shaft w/.125 setscrews
2
115440
PC4
166064
130 203
..
C6
...
042418
134746
18
134834
19
120854
20
039885
22
093551
PL1
157958
24
097924
...25
135299
097922
Part
of 042 517
10)
CAPACITOR
143922
14
23
9-1 Item
138115
079 739
Pos,Neg
w/Components (Fig
113746
134731
16
..17....
Front
CONNECTOR, circ 14 pin plug Amp 213571-2
CONNECTOR, circ pin push-in 14-l8ga Amp 21 3603-1
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2 (or)
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206070-3
STAND-OFF, 6-32 x .687 Ig
CIRCUIT CARD, receptacle bypass
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
134734
PLG3O,31
Quantity
Description
Optional
LIGHT,
KNOB,
LOCK,
KNOB,
md wht lens 28V
12
2
1
2ft
1
1
1
2
1
x
.25Odia shaft
pointer
Meter Kit.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-2204 Page 34
1
2
1
pointer
shaft knob .375-32
4
1
1
NOTES
OPTIONS AND ACCESSORIES
lNTELLITIG~ 4 PRECISION
Frequency: Adjust
TIG CONTROLLER
within
(#042 598)
high-frequency arc
starting, timed gas solenoid control
and metering, pulsing, sequencing,
sloping, on-screen voltage and
amperage metering, and two relay
contacts for fixturing. The control
provides four modes of operation:
second to 200
Automatic, Semiautomatic, Manual
wave
GTAW and SMAW. For detailed
information, refer to product
power
Literature Index No. AY/9.0.
the electrode
PC-300 PULSED GTAW
the
Provides
be
use
with
an
pulses-per-
Amphenol plug.
Pulse Width:
of on
Adjust
the amount
time. Maintains
stability. Adjusts
arc
from 1 to 5
milliseconds.
Peak Current Level: Set the
amperage that the pulse
form will allow (25% to
peak
source). Helps pinch
or
droplet.
second scale for both inverter and
non-inverter type power sources,
and a 10 to 300 pulses-per-second
scale for inverter power
sources
precision pulse
variety of wire
sizes, gases, materials, and joint
a
(7.6 m) connector
17-pin plug for direct
performance,
the XMT on 200
Control includes 8 ft.
(2.4 m)
when
using
or
panel controls
provide:
do not
208 pnma,y
run
voltage
this accessoty.
REMOTE CONTROLS
scale
RHC-14 HAND CONTROL
pulses-per-second scale)
Percent On Time Control
Remote/Panel Control
Amperage
Output Contactor
On/Off Control
(#129 339)
14-pin plug.
(#129 340)
(102 mm)
Includes 20
x
230
or
460 VAC
on
230
or
460 VAC
8 Pak Rack houses
66 in. (1.68 m) wide x
(1.04 m) deep x 72 in. (1.83
m) tall, and weighs 1700 lbs. (771
kg) when loaded with eight XMTs
(with no welding cables). The 4
Pak Rack measures 66 in. (1.68
m) wide x 41 in. (1.04 m) deep x
57 in. (1.45 m) tall, and weighs just
800 lbs. (363 kg) with four XMT
300 units.
(102 mm) x 4
3-1/4 in. (82 mm).
ft. (6 m) cord and
575 VAC
(#042 812)
The XMT Rack
Power On/Off
Receptacle (for
controls)
on
current and contactor control.
Dimensions: 4 in.
or
(#042 648)
Miniature hand control for remote
Pulser On/Off
Remote Control
rugged
460
measures
Foot current and contactor control.
Includes 20 ft. (6 m) cord and
10 to 300
The
operation
on
41 in.
Amperage Adjustment
Background Amperage
Adjustment
Pulses-Per-Second Adjustment
(0.5 to 20 pulses-per-second
or
operation
(#042 813)
and powers up to eight XMT 300
power sources. The rack
RFC-14 FOOT CONTROL
Peak
operation
8 Pak Rack
For
cord and 115 VAC
power cord. Front
For
4 Pak Rack
source.
Note: For best
only.
XMT RACK
For
connection to the front of the
power
14-pin Amphenol plug to a 14-pin
Amphenol socket.
lOft. (3 m)
(#122 972)
25 ft. (7.6 m)
(#122 973)
50 ft. (15.2 m) (#122 974)
75 ft. (22.8 m) (#122 975)
8 Pak Rack
Includes 25 ft.
a
REMOTE CONTROLS AND
wide
configurations.
cord and
(#151 086)14-pin plug
Rotary motion fingertip control
fastens to TIG torch using two
Velcro straps. Includes 28 ft. (8.5
m) control cord.
24 VAC WIRE FEEDERS
This control allows
welding with
RCC-14 REMOTE CONTACTOR
AND CURRENT CONTROL
EXTENSION CORDS FOR
off
source).
external
for momentary contact. Includes
20 ft. (6 m) cord and 14-pin
second.
Background Current Level: Set
background current level to
sustain the arc (3% to 25% of
high-frequency unit. The control
has two internally switchable
scales: a 0.5 to 20 pulses-per-
interconnecting
rate
maximum output of power
Can be used with power sources
that have built-in high frequency,
can
pulse
100% of maximum output of
(DC TIG) CONTROL
(#042 297)
it
the
range of 20 pulses-per-
a
in.
14-pin plug.
remote hand or foot
provides many
important features:
Two
115 VAC, 20 Amp GFCI
duplex receptacles for auxiliary
tools (8 Pak Racks only)
Provisions for paralleling power
TORCH-MOUNTED
REMOTE HAND
CONTROLS
connections
The MMP Manual MIG Pulser
RMLS-1 4
down to prevent theft
Captured secondary cable
Control allows manual control of
MMP MANUAL MUG PULSER
PENDANT CONTROL
(#042 727)
sources or common
Power
pulse wave form. This control
provides independent control of
(#129 337)
Momentary- and
cables
maintained-contact rocker switch
Center
the four
for contactor control. Push forward
the
pulse
parameters that affect the
process:
for maintained contact and back
sources can
work
be locked
hangers for work leads and weld
lifting eye
Rugged skids for dragging
pushing
or
OPTIONS AND ACCESSORIES
XMT ECONOMY CART
(#134 505)
lightweight.
Small and
convenient
controls.
Radiator, Watermate~,
Slanted for
front
panel
Storage compartment for
access to
gloves, helmet,
operator
or
CooImate~ coolant systems.
etc.
to read actual weld values
welding is stopped. Weld
setting is held for 15 seconds
before meter is automatically
after
UNIVERSAL CARRYING CART
AND CYLINDER RACK
are easy to read in
outdoor environment.
cleared. Meters
(#042 934)
Accommodates any XMT power
indoor
or
XMT WIRE FEEDER QUICK
source,
plus gas cylinder up to 56
(142.2 cm) high measuring 6 to
9 inches (15.2 to 22.8 cm) in
diameter. Also provides storage for
auxiliary items such as electrodes,
helmets, gloves, etc. Can also be
used with Econotig~, Maxstarfi
XMT INVERTER POWER
DISCONNECT
in.
SOURCES VIDEOTAPE
Series, Millermaticfi 130 and
MILLER EXPERT PROGRAM~
Millermaticfi 150 power
(#042 623)
Easy-to-use computerized
(#042 491)
Attaches S-21 E
feeder to XMT
or
S-22A wire
case.
XMT CYLINDER CART
(#042 537)
adjustable handles
Has
slanted for convenient
and is
access
to
power source front
Carries two 160 lb.
panel controls.
(72.6 kg) gas
cylinders, or one gas cylinder and
one coolant system for GTAW
(TIG) welding. Feeder mounted to
tray above power source. Can be
used with the Maxtron~, Miller Arc
Pak~
or
supplies.
XMl inverter power
Also accommodates
INTERNATIONALSTYLE
All XMT power
BACK-LIT LCD DIGITAL
(#042 518 Field)
presettability and real time
display of voltage and amperage.
Presetting welding current and
voltage helps to provide optimum
welding conditions. Meters feature
Allows
a
hold
function that allows
CONNECTOR KIT
mm
Accepts #1 or #2 AWG cable size.
Required if male plugs shipped
with power source must be
replaced, if additional plugs
needed.
size cable is to be used.
Kit includes
male
plug
one
International-style
which attaches to the
work and/or weld cables and
into the International
receptacles
on
plugs
style
the power
source.
sources.
source.
For detailed information,
reference Miller
Expert Program
Literature Index No. AV/6.0.
Note: The serial number of the power
source and diskette size (5-1/4 or 3-1/2
in.)
specified when ordering any
Expert Program diskette.
must be
INTERNATIONAL-STYLE CABLE
power source) on one end and
Cam-Lok receptacle (for weld
CONNECTORS
cable
Used to
adapt
and/or work cables.
Kit includes
one
connection)
on
a
other end.
extend weld
or
INTERNATIONALJTIG TORCH
male
International-style plug
CONNECTOR
and
one
International-style
receptacle.
(#042 419) 50 mm
Accepts #1 or #2 AWG size cable.
(#042 534) 70 mm
Accepts #1/0 or #2/0 AWG size
cable.
ADAPTER
(#042 465)
one-piece adapter which has an
International-style male plug (to
power source) on one end and a
female Tweco receptacle (for weld
cable connection) on other end.
INTERNATIONAL/CAM-LOK
direct connection of
torches with
a
or
air-cooled
one-piece cable
assembly.
Kit includes gas hose, gas hose
and International-style TIG
fitting,
Block.
(#135 492)
Amp, air-cooled torch
one-piece cable assembly.
with
(#135 493)
For 150
with
(#135 494)
Amp, air-cooled torch
one-piece cable assembly.
with
Amp, air-cooled torch
one-piece cable assembly.
For 200
(#135 495)
ADAPTER
(#042 466)
A one-piece adapter
International-style
Required for
water-cooled torches
For 80
A
(#042 533) 70 mm
Accepts #1/0 or #2/0 AWG cable
size. Required if #1/0 or #2/0 AWG
inverter power
Miller
INTERNATIONAL/TWECOfi
are
videotape
family of
the XMT
CONNECTORS (will accept DinseTM or other International connectors.)
in-line female
INTERNATIONAL-STYLE
describing
software program used to
diagnose and service the power
METERS
EXTENSION KIT FOR
sources are
equipped with Internationalstyle connectors for secondary
connections. (Power source is
shipped with two -50 mm male
International-style plugs for use
with #1 or #2 AWG size cable.)
(#042418)50
sources.
(#137 760)
An 8 minute VHS
Amp, water-cooled
one-piece cable
For 250/300
which has
male
plug (to
an
torch with
assembly.
9n4