Miller | KF969677 | Owner Manual | Miller DIMENSION 812 User manual

Miller DIMENSION 812 User manual
September 1995 Form: OM-278B
Effective With Serial No. KF969677
OWNER’S
MANUAL
Dimension™ 652 (60 Hz)
Dimension™ 812 (50 Hz)
CC/CV DC Welding Power Source For SMAW, GTAW, GMAW,
FCAW, SAW Welding, And CAC-A Cutting And Gouging
Model
650 Amp
Rated
Welding
Output
650 A @ 44
Volts DC,
100% Duty
Cycle
Amperage/
Voltage
Range DC
Maximum
Open
Open-Circuit
Circuit
Voltage DC
50 − 815 A In
CC Mode
72 In
CC Mode
10 − 65 V In
CV Mode
70 In
CV Mode
Amperes Input at Rated Load Output, 50 or 60
Hz, Three-Phase
230 V
380 V
400 V
440 V
460 V
575 V
KVA
KW
126
(3.8)*
78
(2.4)*
74
(2.2)*
67
(2.0)*
63
(1.9)*
50.4
(1.4)*
50
(1.52)*
34.8
(0.76)*
*While idling
cover_om 4/95 − ST-800 091
© 1995 MILLER Electric Mfg. Co.
PRINTED IN USA
MILLER’S TRUE BLUE™ LIMITED WARRANTY
Effective January 1, 1995
(Equipment with a serial number preface of “KD” or newer)
This limited warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions below, MILLER Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new
MILLER equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by MILLER. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, MILLER will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. 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.
MILLER shall honor warranty claims on warranted equipment listed below in the
event of such a failure within the warranty time periods. All warranty time periods
start on the date that the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American distributor or eighteen
months after the equipment is sent to an International distributor.
1.
5 Years Parts − 3 Years Labor
*
2.
*
4.
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Robots
2 Years — Parts and Labor
*
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the engine manufacturer.)
Air Compressors
1 Year — Parts and Labor
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Motor Driven Guns
Process Controllers
IHPS Power Sources
Water Coolant Systems
HF Units
Grids
Spot Welders
Load Banks
SDX Transformers
Running Gear/Trailers
Plasma Cutting Torches (except APT, ZIPCUT & PLAZCUT Models)
Tecumseh Engines
Deutz Engines (outside North America)
Field Options
™
(NOTE: Field options are covered under True Blue
for the remaining
warranty period of the product they are installed in, or for a minimum of
one year — whichever is greater.)
5.
6 Months — Batteries
6.
90 Days — Parts and Labor
*
*
Remote Controls
Accessory Kits
Replacement Parts
MILLER’S True Blue
™ Limited Warranty shall not apply to:
1.
Items furnished by MILLER, but manufactured by others, such as engines or
trade accessories. These items are covered by the manufacturer’s warranty, if
any.
2.
Consumable components; such as contact tips, cutting nozzles, contactors
and relays or parts that fail due to normal wear.
3.
Equipment that has been modified by any party other than MILLER, or equipment that has been 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.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
3 Years — Parts and Labor
*
*
*
*
3.
Original main power rectifiers
*
*
*
MIG Guns/TIG Torches
APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches
In the event of a warranty claim covered by this warranty, the exclusive remedies
shall be, at MILLER’S option: (1) repair; or (2) replacement; or, where authorized in
writing by MILLER in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized MILLER service station; or (4) payment of or credit for the
purchase price (less reasonable depreciation based upon actual use) upon return
of the goods at customer’s risk and expense. MILLER’S option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a MILLER authorized service facility as determined by MILLER. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE
LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED
WARRANTY, 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,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
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 to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain additional warranties
or remedies other than 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 rights, and other rights may be available, but may
vary from province to province.
WHO DO I CONTACT?
For help,
H contact your distributor
For additional information, such as
Technical Manuals (Service And Parts)
Engine Manuals
Circuit And Wiring Diagrams
Process Handbooks
User’s Guides
Distributor Directories
H contact your distributor
To file a claim for loss or damage during
shipment,
H contact the delivering carrier
Miller Electric Mfg. Co.
H CALL:
414-735-4505
For assistance in filing or settling claims,
H contact your distributor and/or equipment
manufacturer’s Transportation
Department
H FAX:
800-637-2348 (in USA), or
414-735-4136 (outside USA)
H WRITE:
Miller Electric Mfg. Co.
P.O. Box 1079
Appleton, WI 54912 USA
Always provide Model Name and Serial or Style Number
miller_war1 4/95
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS FOR ARC WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1.
1-2.
1-3.
1-4.
1-5.
1
Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Installation, Operation, And Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . . . .
Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
3
3
SECTION 2 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
2-1.
2-2.
2-3.
2-4.
2-5.
2-6.
2-7.
2-8.
Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote 14 Receptacle And Terminal Strip 1T Information . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115 Volts AC Duplex Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Placing Jumper Links And Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
5
5
6
7
7
8
SECTION 3 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1.
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2.
Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
10
SECTION 4 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
4-1.
4-2.
4-3.
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
11
11
SECTION 5 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
SECTION 6 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
OM-278B − 9/95
SECTION 1 − INSTALLATION
NOTE
See User’s Guide on unit for process connection information.
1-1. Selecting A Location
1
2
Lifting Eye
Lifting Forks
Use lifting eye or lifting forks to
move unit.
1
If using lifting forks, extend forks
beyond opposite side of unit.
Movement
3
OR
2
Rating Label (Under Access
Door)
Use rating label to determine input
power needs.
4
Line Disconnect Device
Locate unit near correct input power supply.
4
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
Location And Airflow
3
18 in
(460 mm)
18 in
(460 mm)
1-2. Dimensions And Weights
Dimensions
C
D
Height
27-1/4 in (692 mm)
Width
22-1/4 in (565 mm)
Depth
36 in (914 mm)
A
33 in (838 mm)
B
1-1/2 in (38 mm)
C
20 in (508 mm)
D
1-1/8 in (29 mm)
E
7/16 in (11 mm) Dia
E
4 Holes
A
Weight
B
Ref. ST-153 556-A
OM-278 Page 2
650 Amp
Net: 545 lbs (247 kg)
Ship: 561 lbs (254 kg)
1-3. Weld Output Terminals And Selecting Cable Sizes
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft (30 m) Or Less
Weld Output
Terminals
Positive (+)
High Inductance
Negative
(−)
Positive (+)
Low Inductance
See User’s Guide
for connections.
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
Welding
Amperes
10 − 60%
Duty
Cycle
60 − 100%
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
2/0
3/0
4/0
2-2/0
2-2/0
300
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
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
600
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
700
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
4-4/0
800
4/0
2-2/0
2-3/0
2-4/0
3-4/0
3-4/0
4-4/0
4-4/0
10 − 100% 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.
S-0007-D
1-4. Remote 14 Receptacle And Terminal Strip 1T Information
24 VOLTS AC
REMOTE OUTPUT CONTROL
115 VOLTS AC
GND
REMOTE POWER ON/OFF
REMOTE VOLTAGE SENSING
Socket
Terminal
Information
A
A
24 volts ac. Protected by circuit breaker CB2.
B
B
Contact closure to A completes 24 volts ac contactor control circuit.
C
C
Command reference; 0 to +10 volts dc.
D
D
Remote control circuit common.
E
E
0 to +10 volts dc input command signal from remote control.
F
*
Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.
H
*
Voltage feedback; 0 to +10 volts dc, 1 volt per 10 arc volts.
I
I
115 volts, 15 amperes, 60 Hz ac. Protected by circuit breaker CB1.
J
J
Contact closure to I completes 115 volts ac contactor control circuit.
K
K
Chassis common.
G
*
Circuit common for 24 and 115 volts ac circuits.
*
L
*
M
*
N
Voltage sensing signal from Negative (-) weld output terminal.
*
P
Voltage sensing signal from Positive (+) weld output terminal.
To remote On/Off switch.
switch
* Not Used
OM-278 Page 3
1-5. Connecting Remote Control
1
Remote 14 Receptacle RC8
Connect optional remote control to
RC8. If remote control plug does
not fit RC8, wire cord to terminal
strip 1T.
. Terminal connections are not
direct
replacements
for
sockets in Remote 14 receptacle (see Section 1-4).
OR
OR
Y Turn Off power before opening terminal strip cover.
2
3
4
Terminal Strip 1T
Remote Control Cord
Strain Relief (Customer
Supplied)
Secure cord in strain relief. Reinstall and secure access panel.
Close door.
1
A
B
K
J
I
H
C L N
M
D
G
E F
2
3
4
C
E
REMOTE
OUTPUT
CONTROL
D
I
J
A
B
115 VAC
24VAC
REMOTE
REMOTE
CONTACTOR CONTACTOR
N
P
REMOTE
VOLTAGE
SENSE
K
GND
M
L
REMOTE
POWER ON/OFF
S-162 895-B
Ref. ST-800 170 / Ref. S-0004-A / S-0750
OM-278 Page 4
1-6. 115 Volts AC Duplex Receptacle
Y Turn Off power before connecting to receptacle. Weld
output terminals are energized when Output switch is
On and Power is On.
1
115 V 15 A AC Receptacle
RC9
3
Power is shared between RC9 and
Remote 14 receptacle RC8 or
terminal strip 1T (see Section 1-5).
2
2
3
Circuit Breaker CB1
Circuit Breaker CB2
CB1 protects 115 volts ac portion of
RC8, 1T, and RC9 from overload.
CB2 protects 24 volts ac portion of
RC8 and 1T from overload.
1
Press button to reset breaker.
Ref. ST-800 166-A
1-7. Electrical Service Guide
60 Hz Models
50 Hz Models
Input Voltage
230
460
575
380
400
440
Input Amperes At Rated Output
126
63
51
78
74
67
Max Recommended Standard Fuse Or Circuit Breaker
Rating In Amperes
200
90
80
125
110
100
1
6
6
4
4
4
180 (55)
284 (87)
444 (135)
284 (86)
314 (96)
380 (116)
6
8
8
6
6
8
Min Input Conductor Size In AWG/Kcmil
Max Recommended Input Conductor Length In Feet
(Meters)
Min Grounding Conductor Size In AWG/Kcmil
Reference: 1993 National Electrical Code (NEC)
S-0092-J
OM-278 Page 5
1-8. Placing Jumper Links And Connecting Input Power
230 VOLTS
460 VOLTS
575 VOLTS
S-168 940
1
220 VOLTS
380 VOLTS
400 VOLTS
440 VOLTS
(FACTORY OPTION)
S-171 177-A
2
GND/PE
Earth
Ground
4
L1 (U)
L2 (V)
L3 (W)
3
IMPORTANT
6
3
Input Contactor
L1 (U)
5
L2 (V)
L3 (W)
GND/
PE
Tools Needed:
Connect GND/PE
Conductor First.
S-162 681
3/8 in
3/8 in
ST-800 103-A / Ref. ST-801 116
Check input voltage available at site.
4
1
Select type and size of overcurrent protection using Section 1-7.
Jumper Link Label
Check label − only one is on unit.
2
Jumper Links
Move jumper links to match input voltage.
3
Input And Grounding Conductors
Select size and length using Section 1-7.
OM-278 Page 6
5
6
Line Disconnect Device
Reed Switch
Grounding Conductor (Routed
Through Reed Switch)
If unit is equipped with optional ground current sensor, route grounding conductor
through reed switch two times before being
connected to ground terminal.
Close access door.
Y Special installation may be required
where gasoline or volatile liquids are
present − see NEC Article 511 or CEC
Section 20.
SECTION 2 − OPERATION
2-1. Controls
1
2
8
3
4
7
6
5
ST-162 500-A
1
Arc Force (Dig) Control
Control increases SMAW short-circuit amperage which allows the operator to use a
very short arc length without sticking the
electrode.
Set control at 0 for normal welding amperage. Turn clockwise to increase short-circuit
amperage.
2
3
4
5
6
Process Selector Switch
Amperage/Voltage Adjustment Control
Digital Meters
Power Switch With Indicator Light
High Temperature Shutdown Light
7
Remote Amperage/Voltage Control
Switch
8
Output Switch (Contactor)
Y Weld output terminals are energized
when Output switch is On and Power
is On.
OM-278 Page 7
2-2. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
Y Exceeding duty cycle can
damage unit and void warranty.
100% Duty Cycle
Continuous Welding
Overheating
A/V
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 / Ref. SA-168 918
SECTION 3 − MAINTENANCE & TROUBLESHOOTING
3-1. Routine Maintenance
Y Disconnect power before maintaining.
3 Months
Repair Or
Replace
Cracked
Weld
Cable
Replace
Unreadable
Labels
6 Months
OR
OM-278 Page 8
Blow Out Or Vacuum
Inside,
During Heavy Service,
Clean Monthly
Clean And
Tighten
Weld
Terminals
3-2. Fuse F1
Y Turn Off power before opening rear panel access door.
1
1
Fuse F1 (See parts List For
Rating)
Fuse F1 protects control transformer from overload. If F1 opens, weld
output and fan motor stops. Replace F1.
Tools Needed:
3/8 in
Ref. ST-800 101-C
3-3. Troubleshooting
Trouble
No weld output; unit completely inoperative.
Remedy
Place line disconnect switch in On position (see Section 1-8).
Check and replace line fuse(s), if necessary (see Section 1-8).
Check for proper input power connections (see Section 1-8).
Check for proper jumper link position (see Section 1-8).
No weld output; fan on.
If using remote control, place Output (Contactor) switch in Remote 14 position, and connect remote
control to either Remote 14 receptacle or terminal strip 1T (see Sections 1-4 and 1-5). If remote is not
being used, place Output (Contactor) switch in On position.
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 2-2).
Have Factory Authorized Service Agent check control board PC1.
Unit provides only maximum or minimum weld output.
Have Factory Authorized Service Agent check control board PC1 and hall device HD1.
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 1-3).
Clean and tighten all weld connections.
Check wire feeder installation according to its owner’s manual.
Check position of Process selector switch (see Section 2-1).
Have Factory Authorized Service Agent check control board PC1 and hall device HD1.
No 115 volts ac output at duplex receptacle, Remote 14 receptacle, or terminal strip 1T.
Reset circuit breaker CB1 (see Section 1-6).
No 24 volts ac output at Remote 14 receptacle or terminal strip 1T.
Reset circuit breaker CB2 (see Section 1-6).
Fan not operating. Note: the fan only
runs when cooling is necessary.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
Wandering arc; poor control of arc
direction.
Reduce gas flow rate.
Select proper size tungsten.
Properly prepare tungsten.
OM-278 Page 9
Trouble
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
Remedy
Shield weld zone from drafts.
Increase postflow time.
Check and tighten all gas fittings.
Properly prepare tungsten.
Check for water in torch, and repair torch if necessary. See torch Owner’s Manual.
OM-278 Page 10
SECTION 4 − SAFETY PRECAUTIONS FOR ARC WELDING
safety_som1 4/95
4-1. 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.
This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS,
and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to
avoid the hazards.
4-2. Arc Welding Hazards
WARNING
The symbols shown below are used throughout this manual to call attention to and identify possible
hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The
safety information given below is only a summary of the more complete safety information found in the
Safety Standards listed in Section 4-4. Read and follow all Safety Standards.
Only qualified persons should install, operate, maintain, and repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically 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 dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
4. 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).
5. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
6. Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal
ARC RAYS can burn eyes and skin;
NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes.
NOISE
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Noise from some
processes can damage hearing. Chipping, grinding,
and welds cooling throw off pieces of metal or slag.
7. When making input connections, attach proper grounding
conductor first − double-check connections.
8. Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
9. Turn off all equipment when not in use.
10. Do not use worn, damaged, undersized, or poorly spliced cables.
11. Do not drape cables over your body.
12. If earth grounding of the workpiece is required, ground it directly
with a separate cable − do not use work clamp or work cable.
13. Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
14. Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
15. Wear a safety harness if working above floor level.
16. Keep all panels and covers securely in place.
17. Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ARC RAYS
2. Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
3. Wear approved safety glasses with side shields.
4. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
5. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
1. Use approved ear plugs or ear muffs if noise level is high.
FUMES AND GASES can
hazardous to your health.
in disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
be
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings,
cleaners, and degreasers.
5. 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 or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, 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
containing these elements can give off toxic fumes if welded.
OM-278 Page 1
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flames, sparks, and arcs.
2. Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
WELDING
explosion.
can
cause
fire
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 burns. 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.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
4.
5.
6.
7.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
8. Turn face away from valve outlet when opening cylinder valve.
9. Keep protective cap in place over valve except when cylinder is in
use or connected for use.
10. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
8. 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 hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
11. Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
12. Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
4-3. Additional Installation, Operation, And Maintenance Hazards
FIRE OR EXPLOSION can result from
placing unit on, over, or near
combustible surfaces.
1. Do not locate unit on, over, or near combustible
surfaces.
2. Do not install unit near flammables.
FALLING EQUIPMENT can cause
serious personal injury and equipment
damage.
1. Use lifting eye to lift unit only, NOT running gear,
gas cylinders, or any other accessories.
2. Use equipment of adequate capacity to lift unit.
3. If using lift forks to move unit, be sure forks are long
enough to extend beyond opposite side of unit.
HOT PARTS can cause severe burns.
1. Do not touch hot parts bare handed.
2. Allow cooling period before working on gun or
torch.
MOVING PARTS can cause injury.
1. Keep away from moving parts such as fans.
2. Keep all doors, panels, covers, and guards closed
and securely in place.
MAGNETIC
CURRENTS
operation.
FIELDS FROM HIGH
can affect pacemaker
1. Pacemaker wearers keep away.
2. Wearers should consult their doctor before going
near arc welding, gouging, or spot welding
operations.
OM-278 Page 2
MOVING PARTS can cause injury.
1. Keep away from moving parts.
2. Keep away from pinch points such as drive rolls.
FLYING PIECES OF METAL or DIRT can
injure eyes.
1. Wear safety glasses with side shields or face
shield.
WELDING WIRE can cause puncture
wounds.
1. Do not press gun trigger until instructed to do so.
2. Do not point gun toward any part of the body, other
people, or any metal when threading welding wire.
HIGH-FREQUENCY RADIATION can
interfere with radio navigation, safety
services,
computers,
and
communications equipment.
1. Have only qualified persons familiar with electronic
equipment perform this installation.
2. The user is responsible for having a qualified
electrician promptly correct any interference
problem resulting from the installation.
3. If notified by the FCC about interference, stop using
the equipment at once.
4. Have the installation regularly checked and
maintained.
5. Keep high-frequency source doors and panels
tightly shut, keep spark gaps at correct setting, and
use grounding and shielding to minimize the
possibility of interference.
OVERUSE can cause OVERHEATED
EQUIPMENT.
SIGNIFICANT DC VOLTAGE exists after
removal of input power on inverters.
1. Allow cooling period.
2. Reduce current or reduce duty cycle before
starting to weld again.
3. Follow rated duty cycle.
1. Turn Off inverter, disconnect input power, and
discharge input capacitors according to
instructions in Maintenance Section before
touching any parts.
STATIC ELECTRICITY can
parts on circuit boards.
damage
1. Put on grounded wrist strap BEFORE handling
boards or parts.
2. Use proper static-proof bags and boxes to store,
move, or ship PC boards.
BUILDUP OF SHIELDING GAS can harm
health or kill.
1. Shut off shielding gas supply when not in use.
4-4. 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 29 CFR 1910, from
Superintendent of 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,
American Welding Society Standard AWS F4.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
4-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
The following is a quotation from the General Conclusions Section of
the U.S. 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.”
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around the body.
4. Keep welding power source and cables as far away as
practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
The above procedures are also recommended for pacemaker
wearers. Consult your doctor for complete information.
OM-278 Page 3
SECTION 5 − ELECTRICAL DIAGRAMS
For Primary Circuit Diagram Portion, refer to the Circuit Diagram
located inside the wrapper of the welding power source.
Figure 5-1. Circuit Diagram
OM-278 Page 4
SC-175 485
24
21
26
31
Fig 6-3
24
33
32
Fig 6-2
3
2
1
30
29
4
5
28
27
25
6
7
11
12
8
13
4
10
14
9
16
15
17 18
3
20
19
Fig 6-4
22
23
SECTION 6 − PARTS LIST
ST-800 703-A
Figure 6-1. Main Assembly (452 Model Illustrated)
OM-278 Page 5
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 6-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . . . . . +168 806
. . . 2 . . . . . . . . . . . . . . . . . . . 162 803
. . . 3 . . . . . . . . . . . . . . . . . . . 164 700
. . . 4 . . . . . . . . . . . . . . . . . . . 162 816
. . . 5 . . . . . . . . . . . . . . . . . . . 162 820
. . . 6 . . . . . . . . . . . . . . . . . . . 162 830
. . . . . . . . . . . . . . . . . . . . . . . . . 604 536
. . . 7 . . . . . . . . . . . . . . . . . . . 177 279
. . . 8 . . . . . . . . . . . . . . . . . . . 134 201
. . . 9 . . . . . . . . . . . . . . . . . . . 162 821
. . . 10 . . . . . . . HD1 . . . . . . 148 417
. . . . . . . . . . . . PLG14 . . . . . 130 204
. . . . . . . . . . . . . . . . . . . . . . . . . 114 066
. . . 11 . . . . . . . . . . . . . . . . . . . 164 717
. . . 12 . . . . . . . . Z1 . . . . . . . 163 220
. . . 13 . . . . . . C21-23 . . . . . 163 906
. . . 14 . . . . . . . . T2 . . . . . . . 159 042
. . . 14 . . . . . . . . T2 . . . . . . . 159 043
. . . 15 . . . . . . . TE1 . . . . . . 159 244
. . . 16 . . . . . . . . . . . . . . . . . . . 601 835
. . . 17 . . . . . . . . . . . . . . . . . . . 038 887
. . . . . . . . . . . . . . . . . . . . . . . . . 038 618
. . . . . . . . . . . . . . . . . . . . . . . . . 010 913
. . . . . . . . . . . . . . . . . . . . . . . . . 601 835
. . . 18 . . . . . . . . . . . . . . . . . . . 159 034
. . . 19 . . . . . . . . . . . . . . . . . . . . Fig 6-4
. . . 20 . . . . . . . . F1 . . . . . . *156 065
. . . 21 . . . . . . . . W . . . . . . . 160 794
. . . 22 . . . . . . . CR4 . . . . . ♦140 750
. . . 23 . . . . . . . . . . . . . . . . . . +168 805
. . . 24 . . . . . . . . . . . . . . . . . . . 134 464
. . . 25 . . . . . . . . . . . . . . . . . . . 163 359
. . . 26 . . . . . . . . T1 . . . . . . . 169 072
. . . 27 . . . . . . . . . . . . . . . . . . . 169 154
. . . 28 . . . . . . . . . . . . . . . . . . . 169 153
. . . 26 . . . . . . . . T1 . . . . . . . 172 356
. . . 27 . . . . . . . . . . . . . . . . . . . 172 358
. . . 28 . . . . . . . . . . . . . . . . . . . 172 357
. . . . . . . . . . . . TP1,2 . . . . . . 119 581
. . . . . . . . . . . . TP4,5 . . . . . . 168 891
. . . . . . . . . . . . . PLG6 . . . . . . 168 847
. . . . . . . . . . . . . . . . . . . . . . . . . 147 995
. . . . . . . . . . . . . RC6 . . . . . . 168 845
. . . . . . . . . . . . . . . . . . . . . . . . . 147 996
. . . . . . . . . . . . PLG13 . . . . . 169 242
. . . . . . . . . . . . . . . . . . . . . . . . . 009 419
. . . . . . . . . . . . . RC13 . . . . . . 169 241
. . . . . . . . . . . . . . . . . . . . . . . . . 009 418
. . . 29 . . . . . . . . . . . . . . . . . . . 144 468
. . . 30 . . . . . . . . . . . . . . . . . . . 605 538
. . . 31 . . . . . . . . . . . . . . . . . . . 161 294
. . . 32 . . . . . . . . . . . . . . . . . . . . Fig 6-2
. . . 33 . . . . . . . SR1 . . . . . . 175 072
. . . . . . . . . . . . . PLG7 . . . . . . 152 249
. . . . . . . . . . . . . . . . . . . . . . . . . 147 996
OM-278 Page 6
. . PANEL, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CHANNEL, upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAR, mtg lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, .312-18 x 1.750hexhd gr 5 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GASKET, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF SUPPORT, PC card .312/.375 . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg LEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSDUCER, current 1000A module . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 20-14ga . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUS BAR, stab jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, control 50VA 24V 230/460/575 (60Hz) . . . . . . .
. . TRANSFORMER, control 50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PRIMARY BOX, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINK, jumper term bd pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, flat .218 ID brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FUSE, crtg .5A 600V time delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTACTOR, def prp 75A 3P 24VAC . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, reed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . .
. . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, pwr main 230/460/575 (consisting of) . . . . . . . .
. . . . COIL, pri/sec 230/460/575 (center & RH) . . . . . . . . . . . . . . . . . . . .
. . . . COIL, pri/sec 230/460/575 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, pwr main 380/400/440 (consisting of)
. . . . COIL, pri/sec (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . COIL, pri/sec (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . THERMOSTAT, NC (Included w/T1) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . THERMOSTAT, NC (Included w/T1) . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect pin 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect pin 20-14ga . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 20-14ga . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STRIP, polyest gl lam .062 x 2.375 x 3.500 . . . . . . . . . . . . . . . . . . . .
. . CABLE TIE, 0-4.500 bundle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER, si diode (Fig 6-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect pin 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
4
2
1
2
1
4
1
1
1
3
1
1
3
1
1
1
24
24
8
24
24
1
1
1
1
1
1
2
1
1
2
1
2
1
2
2
1
12
1
12
1
9
1
9
4
4
2
1
1
1
15
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 6-1. Main Assembly (Continued)
. . . . . . . . . . . . . RC7 . . . . . . 168 846 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 147 995 . . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . . . 010 467 . . CONNECTOR, clamp cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦ Part of Option 042983 Ground Current Sensor.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 6-2. Panel, Front w/Components (Fig 6-1 Item 31)
... 1 ...................
. . . 2 . . . . . . . PC1 . . . . . .
... 2 ...................
. . . . . . . . . . . . . PLG1 . . . . . .
. . . . . . . . . . . . . PLG3 . . . . . .
.........................
. . . . . . . . . . . . . PLG4 . . . . . .
.........................
. . . . . . . . . . . . . PLG5 . . . . . .
.........................
159 863
163 875
174 594
158 720
169 240
147 995
148 439
147 995
152 249
147 995
. . ELECTRONICS BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD, control (60Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD, control (50Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (see Fig 6-3)
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
20
1
10
1
15
5
6
7
8
2
3
1
9 10 17
10 17
4
18
30
29
17
28
40
29
27
30
26
31
32
39
34
38
33
22
25
16 15 14 13 12
24
11
23
21
35
37
19
36
20
ST-800 705-B
Figure 6-2. Panel, Front w/Components
OM-278 Page 7
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 6-2. Panel, Front w/Components (Fig 6-1 Item 31)
(Continued)
. . . 3 . . . . . . . CR3 . . . . . . 006 393 . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . CR5 . . . . . ♦006 393 . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . CB1,2 . . . . . . 093 995 . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . .
. . . 6 . . . . . . . RC9 . . . . . . 604 176 . . RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . . . . . . . . . 163 855 . . CONNECTOR/CAPACITOR, w/leads (consisting of) . . . . . . . . . . . .
. . . . . . . . . . . . . RC8 . . . . . . 143 976 . . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . 079 534 . . . . . . CONNECTOR, circ skt push-in 14-18ga . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . C3 . . . . . . . 163 863 . . . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . C6 . . . . . . . 163 861 . . . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . C13 . . . . . . 163 858 . . . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . C14 . . . . . . 163 857 . . . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . . . . . . . . . 162 802 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . . . . . . . . . 161 303 . . SPRING, cprsn .600 OD x .072 wire x 1.500 lg . . . . . . . . . . . . . . . .
. . . 10 . . . . POS-CC,CV . . . 039 047 . . TERMINAL, pwr output red (consisting of) . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . NEG . . . . . . 039 046 . . TERMINAL, pwr output black (consisting of) . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . . . . . . . 601 976 . . . . SCREW, .500-13 x 1.500hexhd stl . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . . . . . . 039 049 . . . . TERMINAL BOARD, red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . . . . . . 039 045 . . . . TERMINAL BOARD, black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . . . . . . 601 880 . . . . NUT, .500-13 x .31 high stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . . . . . . 039 044 . . . . BUS BAR, term bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . . . . . . . 601 879 . . . . NUT, .500-13 x .44 high stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . C2,4,5 . . . . . 128 750 . . CAPACITOR, cer disc .1uf 500VDC . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . R4,5 . . . . . . 136 076 . . RESISTOR, WW fxd 30W 200 ohm . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . 1T . . . . . . . 159 040 . . BLOCK, term 20A 12P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . . . . . . 162 828 . . PANEL, mtg rcpt/terminal strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . . . . . . . 070 371 . . BLANK, snap-in nyl 1.093/1.125mtg hole . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . . . . . . . 174 937 . . PLATE, control lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . . . . . . . 162 891 . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . . . . . . . 160 530 . . COVER, stud output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . . . . . . . 160 935 . . CLIP, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . . . . . . 601 835 . . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . 010 913 . . WASHER, flat .218 ID brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . . . . . . . 038 887 . . STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . S1 . . . . . . . 011 610 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . S3,4 . . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . R1,2 . . . . . . 035 897 . . POTENTIOMETER, CP std slot 1/T 2W 1K ohm . . . . . . . . . . . . . . .
. . . 31 . . . . . . . PC2 . . . . . . 163 789 . . CIRCUIT CARD, digital meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . PLG10 . . . . . 153 501 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . 147 995 . . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . PLG11 . . . . . 148 439 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . 147 995 . . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . CR1 . . . . . . 134 163 . . RELAY, encl 24/120VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . CR2 . . . . . . 000 770 . . RELAY, encl 24VDC 3PDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . . . . . . . . . 165 316 . . STAND-OFF, 6-32 x .875 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . .
. . . 36 . . . . . . . . S2 . . . . . . . 159 039 . . SWITCH, rocker SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 37 . . . . . . . PL2 . . . . . . . 159 522 . . LED, yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 38 . . . . . . . . . . . . . . . . . . . 159 036 . . LENS, LED clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 39 . . . . . . . . . . . . . . . . . . . 097 924 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 40 . . . . . . . . . . . . . . . . . . . 097 922 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
♦Part of Option 042 983 Ground Current Sensor
+When 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.
OM-278 Page 8
1
1
2
1
1
1
14
1
1
1
1
1
3
2
1
1
1
1
1
1
1
3
2
1
1
1
1
1
1
3
2
1
1
1
2
1
1
1
6
1
10
1
1
4
1
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
SR1
175 072
. . . 1 . . . . C7-12 . . . .
... 2 ...............
... 3 ...............
... 4 ...............
. . . 5 . . . SCR1-6 . . .
... 6 ...............
... 7 ...............
. . . . . . . . . . PLG1 . . . .
.....................
. . . . . . . . . . . TP3 . . . . .
. . . . . . . . . . . TP6 . . . . .
048 420
176 168
166 667
160 962
161 668
160 961
161 302
158 720
147 995
168 895
168 894
Description
Quantity
Figure 6-3. Rectifier, Si Diode (Fig 6-1 Item 33)
. . CAPACITOR, cer disc .01uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAR, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, spring thyristor rectifier 5.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HEAT SINK, rectifier snowflake .800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . THYRISTOR, SCR 300A 300V hockey puck . . . . . . . . . . . . . . . . . . . . . . .
. . HEAT SINK, rectifier snowflake 1.600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, thyristor rectifier 5.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . THERMOSTAT, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . THERMOSTAT, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
6
2
3
6
6
3
3
1
12
1
1
3
1
4
5
3
6
5
6
2
1
ST-800 696-A
7
4
Figure 6-3. Rectifier, Si Diode SR1
7
8
10
9
ST-800 707-A
Figure 6-4. Panel, Rear w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 6-4. Panel, Rear w/Components (Fig 6-1 Item 19)
. . . 1 . . . . . . . . . . . . . . . 173 283
. . . 2 . . . . . . . . . . . . . . . 032 611
. . . 3 . . . . . . . . . . . . . . . 162 807
. . . 4 . . . . . . . . . . . . . . . 168 343
. . . 5 . . . . . . . . . . . . . . +162 818
. . . 6 . . . . . . . . . . . . . . . 168 384
. . . 7 . . . . . . . . . . . . . . . 602 177
. . . 8 . . . . . . . . . . . . . . . 124 274
. . . 9 . . . . . R3 . . . . . . 097 459
. . . 10 . . . . . FM . . . . . 116 190
. . . . . . . . . . . . . . . . . . . . . 010 467
..
..
..
..
..
..
..
..
..
..
..
CHAMBER, plenum 14 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLADE, fan 14 in 3wg 23deg .375 bore CCW . . . . . . . . . . . . . . . . . . . . . .
PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HINGE, door primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DOOR, access primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, set .250-20 x .250knrlpt sch stl . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, mtg fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, WW fxd 375W 20 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTOR, 1/12HP 230V 1550RPM 50/60Hz 1.5A . . . . . . . . . . . . . . . . . . .
CONNECTOR, clamp cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
1
1
2
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
OM-278 Page 9
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-278 Page 10
OPTIONS AND ACCESSORIES
A variety of optional controls and accessories allow you to tailor your Dimension welder to meet your specific
needs. All are specifically designed to be used with Dimension Series power sources, so you never have to worry
about compatibility.
REMOTE ON/OFF CONTROL
(#042 869)
Allows you to turn your Dimension
on or off from a distance of 20 ft
(6 m). This is especially useful if
your power source is located up in
a mezzanine. Connects to the
power source’s terminal strip.
POLARITY CONTROL
(#042 871)
This dual-function control is
designed for use with dual wire
feeders or any application where
electrical isolation and/or polarity
reversing of weld current is
required. Both functions can be
used at the same time.
CERTIFIED METERS
(#042 968 Factory)
These digital meters are certified
to an exact standard. Often
required for government work.
GROUND CURRENT SENSOR
(#042 983 Factory)
(#043 146 Field)
Disables power source if weld
current is present on primary
ground.
ENVIRONMENTAL
PROTECTION PACKAGE
(#043 049 Factory)
Internal machine components are
sprayed with a protective
polyurethane coating.
INTERNATIONAL CABLE
ADAPTER
(#168 077) Female 1 Qty.
Dinse brand insulated female
twistlock connector installs on
output stud, providing quick
disconnect of secondary weld
cables.
(#042 418) Male 1 Qty.
Cable mounted Dinse brand
insulated male twistlock connector
accepts #1 or #2 AWG cable sizes.
BALANCING/PARALLELING
CONTROL
(#042 810)
Allows you to parallel two
Dimensions in the constant voltage
mode while the control balances
the power source’s output
amperage throughout its operating
range. This control plugs directly
into the Dimension power supplies,
and is especially useful for
customers who need higher
amperages (for Submerged Arc).
STANDARD RUNNING GEAR
(#042 886)
The large 10-inch (254 mm) rear
wheels and 5-inch (127 mm) front
casters on this running gear
provide excellent mobility on the
shop floor, making it easier to
move the power source around
and over cables and cracks. Very
easy to install. Handles double as
weld cable holder.
ROUGH TERRAIN RUNNING
GEAR
(#043 043)
This two-wheel running gear
features pneumatic tires for extra
mobility. Handles double as a
cable holder.
CYLINDER RACK/LIFT
(#043 005)
Miller’s patent pending cylinder
rack features a lift which moves
the cylinders up onto the rack and
into position without manual
lifting! The rack accommodates
two cylinder bottles, and can be
attached directly to the running
gear.
STANDARD CYLINDER RACK
(#042 887)
Installs on standard running gear.
WELD CABLE HOLDER
(#043 055)
Attaches to front of power source,
allowing weld cables to be stored
near the control panel.
AIR FILTER KIT
(#042 939 Field)
Protect your Dimension from
dusty, dirty environments with this
reusable air filter that easily
attaches and detaches from the
front of the power source.
WATER COOLANT
SYSTEMS
For more information, see the
Miller Coolant Systems literature
sheet, Index No. AY/7.2.
WATERMATE 1A
(#042 495) 115 VAC
For use with water-cooled torches
rated up to 500 Amps. Vertical
design conveniently mounts to
Miller cylinder rack in place of one
cylinder.
COOLMATE 4
(#042 288)
For use with water-cooled torches
rated up to 600 Amps. Tough
molded polyethylene case with
carrying handle.
RADIATOR 1A
(#042 492) 115 VAC
RADIATOR 2A
(#042 493) 230 VAC
For use with water-cooled torches
rated up to 500 Amps.
GMAW/FCAW WELDING
S-22P12 WIRE FEEDER
(#125 616)
Compact, lightweight 24 VAC
constant speed semi-automatic
wire feeder provides portability and
access. Primarily designed for
gas-shielded wires.
Accommodates up to a 30 lb.
(13.6 kg), 12 in. (304 mm)
diameter spool. See literature,
Index No. M/7.0.
6/95
OPTIONS AND ACCESSORIES
S-22A WIRE FEEDER
(#115 396)
Lightweight, 24 VAC constant
speed semiautomatic wire feeder,
best suited for small diameter
wires. Accommodates up to a 60
lb. (27.2 kg) spool of welding wire
when using optional wire reel
assembly. See literature, Index No.
M/6.9.
60 SERIES WIRE FEEDERS
Heavy-duty, industrial, constant
speed 24 VAC semiautomatic wire
feeders in dual or single models,
with available digital meters. Ideal
for high duty cycle GMAW and
FCAW. Accommodates a wide
variety of wire sizes and types.
See literature, Index No. M/2.0.
SWINGARC ™ BOOM-MOUNTED
WIRE FEEDERS
Single and dual 24 VAC
semiautomatic wire feeders are
available with 12 ft. (3.7 m) and
16 ft. (4.9 m) booms. Ideal for long
reach and complete
maneuverability when working on
large weldments, or in
hard-to-reach areas. See literature,
Index No. M/13.0
HF-251D-1 HIGH-FREQUENCY
ARC STARTER/STABILIZER
(#042 388)
This portable 250 Amp, 60% duty
cycle unit adds high frequency to
the welding circuit to help start the
arc when using the GTAW (TIG)
process. Operates on 115 VAC
50/60/100 Hz. For more
information, see the literature
sheet, Index No. AY 5.1.
current and contactor control at
operator’s fingertips. Includes
28 ft. (8.5 m) cord and plug.
REMOTE CONTROLS AND
SWITCHES
RFC-14 FOOT CONTROL
(#129 339)
Heavy duty foot current and
contactor control. Includes 20 ft.
(6 m) cord and 14-pin plug.
RMLS-14
(#129 337)
Momentary- and maintainedcontact rocker switch for contactor
control. Push forward for
maintained contact and back for
momentary contact. Includes 20 ft.
(6 m) cord and 14-pin plug.
RCC-14 REMOTE CONTACTOR
AND CURRENT CONTROL
(#151 086)
Rotary motion fingertip control.
Fastens to TIG torch using two
Velcro strips. Allows complete
RHC-14 HAND CONTROL
(#129 340)
Miniature hand control for remote
current and contactor control.
Dimensions: 4 in. (102 mm) x 4 in.
(102 mm) x 3-1/4 in. (82 mm).
Includes 20 ft. (6 m) cord and
14-pin plug.
EXTENSION CABLES FOR
14-PIN PLUGS TO 14-PIN
SOCKETS
(#122 972) 10 ft. (3 m)
(#122 973) 25 ft. (7.6 m)
(#122 974) 50 ft. (15.2 m)
(#122 975) 75 ft. (22.8 m)
Extension cords make a direct
connection between the power
source and the accessory control.
No messy splicing or adapting
required.
6/95
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