Miller | KE634255 | Owner Manual | Miller DIMENSION 812 User manual

Miller DIMENSION 812 User manual
October 1994
Form: OM-278
Effective With Serial No. KE634255
OWNER’S
MANUAL
Dimension™ 652
CC/CV DC, 100% Duty Cycle Welding Power Source
For Multiple Welding Processes And CAC-A Cutting/Gouging
650 Amperes At 44 Volts DC
Uses Three-Phase Input Power (See Rating Label)
Overheating And Short Circuit Protection
14-Pin Remote Control Receptacle And Remote Control Terminal Strip
115 Volts AC 15 Amperes Auxiliary Power Receptacle
Read and follow these instructions and all
safety blocks carefully.
cover 5/94 − ST-800 091
Give this manual to the operator.
Have only trained and qualified persons
install, operate, or service this unit.
For help, call your distributor
Call your distributor if you do not understand
the directions.
or: MILLER Electric Mfg. Co., P.O. Box 1079,
Appleton, WI 54912
414-734-9821
© 1994 MILLER Electric Mfg. Co.
PRINTED IN USA
EMF INFORMATION
NOTE
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 among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.
mod10.1 4/93
TABLE OF CONTENTS
SECTION 1 − SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
SECTION 2 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1.
Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2.
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
2
3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting A Location And Moving Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115 Volts AC Duplex Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting And Preparing Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote 14 Receptacle Information And Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal Strip 1T Information And Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
4
5
5
6
7
8
9
10
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
5 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
18
19
21
SECTION 6 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
SECTION 7 − TUNGSTEN ELECTRODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1.
Selecting Tungsten Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2.
Preparing Tungsten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
26
27
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-1. Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-2. Panel, Front w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-3. Rectifier, Si Diode SR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-4. Panel, Rear w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
28
30
32
33
SECTION
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
SECTION
5-1.
5-2.
5-3.
OM-278 − 10/94
SECTION 1 − SAFETY INFORMATION
mod1.1 2/93
Read all safety messages throughout this manual.
Obey all safety messages to avoid injury.
Learn the meaning of WARNING and CAUTION.
1
2
2
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Disconnect input power before
MOVING PARTS can injure.
• Keep away from moving parts.
• Keep all panels and covers closed
4
installing or servicing.
when operating.
5
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
WARNING
6
Safety Alert Symbol
2
Signal Word
WARNING means possible death
or serious injury can happen.
CAUTION
3
1
CAUTION means possible minor
injury or equipment damage can
happen.
3
Statement Of Hazard And Result
4
Safety Instructions To Avoid
Hazard
5
Hazard Symbol (If Available)
6
Safety Banner
Read safety blocks for each symbol shown.
7
7
NOTE
Turn Off switch when using high frequency.
NOTE
Special instructions for best operation − not related to safety.
Figure 1-1. Safety Information
SECTION 2 − SPECIFICATIONS
Table 2-1. Welding Power Source
Specification
Description
Type Of Output
CC/CV DC (Constant Current/Constant Voltage Direct Current)
Rated Weld Output
NEMA Class I (100) − 650 Amperes, 44 Volts DC At 100% Duty Cycle (See Section 2-2)
Type Of Input Power
Three-Phase; 230, 460, Or 575 Volts AC; 60 Hz
Input Amperes At Rated Output
126 A At 230 V, 63 A At 460 V, 50.4 A At 575 V
Input Amperes While Idling
3.8 A At 230 V, 1.9 A At 460 V, 1.4 A At 575 V
KVA/KW Used At Rated Output
50 kVA/34.8 kW
KVA/KW Used While Idling
1.52 kVA/0.76 kW
Max. Open-Circuit Voltage
CC Mode: 72 Volts DC; CV Mode: 70 Volts DC
Welding Processes
Shielded Metal Arc (SMAW), Gas Tungsten Arc (GTAW), Gas Metal Arc (GMAW), Flux Cored Arc
(FCAW), And Submerged Arc Welding (SAW); Air Carbon Arc Cutting And Gouging (CAC-A)
Overall Dimensions
See Figure 3-3
Weight
Net: 545 lb (247 kg); Ship: 561 lb (254 kg)
OM-278 Page 1
2-1. Volt-Ampere Curves
The volt-ampere curves show the
minimum, mid, and maximum voltage and amperage output capabilities of the welding power source.
Curves of other settings fall between the curves shown.
A. CC Mode
B. CV Mode
ssb1.1* 10/91 − ST-168 916 / ST-168 917
Figure 2-1. Volt-Ampere Curves
2-2. Duty Cycle
CAUTION
WELDING LONGER THAN RATED DUTY CYCLE can damage unit and void warranty.
•
Do not weld at rated load longer than shown below.
warn7.1 8/93
Definition
Chart
0
10
Duty Cycle is percentage of 10
minutes that unit can weld at
rated load without overheating.
Minutes
100% Duty Cycle At 650 Amperes
Continuous Welding
sb1.1 8/93 − Ref. ST-168 918
Figure 2-2. Duty Cycle
OM-278 Page 2
SECTION 3 − INSTALLATION
3-1. Typical Process Connections
NOTE
See also operator booklet on unit for additional process connection information.
TYPICAL
POLARITY
14 Pin
GMAW
Welding
Power Source
Wire Feeder
14 Pin
Work
GMAW
Push-Pull
Feeder
Welding
Power Source
Work
SMAW
Welding
Power Source
Work
Remote
Control
14 Pin
Welding
Power Source
GTAW
HF Unit
Work
Figure 3-1. Typical Process Connections
OM-278 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 VENTILATION can be harmful.
Do not touch live electrical parts.
Disconnect input power conductors from deenergized supply line BEFORE moving welding power
source.
•
•
Do not breathe welding fumes.
Place unit only where there is a good fresh air supply
and proper ventilation.
FIRE OR EXPLOSION can result from
placing unit on, over, or near combustible surfaces.
FALLING EQUIPMENT can cause serious personal injury and equipment
damage.
Do not locate unit on, over, or near combustible surfaces.
Do not install unit near flammables.
Use lifting eye to lift unit only, NOT running gear, gas
cylinders, or any other accessories.
Use equipment of adequate capacity to lift the unit.
•
•
•
•
swarn11.1* 3/93
Movement
1
1
Lifting Eye
2
Lifting Forks
Use lifting eye or lifting forks to
move unit.
OR
If using lifting forks, extend forks
beyond opposite side of unit.
3
2
Location And Airflow
4
Rating Label (Under Access
Door)
Use rating label to determine input
power needs.
4
Line Disconnect Device
Locate unit near correct input power supply.
3
18 in
(460 mm)
18 in
(460 mm)
ssb9.1 12/93 − ST-800 402 / ST-800 091
Figure 3-2. Movement And Location Of Welding Power Source
NOTE
Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc.
H
A
B
C
F
G
D
E
Inches
Millimeters
A
27-1/4
692
B
22-1/4
565
C
36
914
D
33
838
E
1-1/2
38
F
20
508
G
1-1/8
29
H
7/16 Dia
4 Holes
11 Dia
4 Holes
Figure 3-3. Overall Dimensions And Base Mounting Hole Layout
OM-278 Page 4
Ref. ST-153 556-A
3-3. Installing Gas Supply
WARNING
CYLINDERS can explode if damaged.
•
•
•
BUILDUP OF SHIELDING GAS can harm
health or kill.
Keep cylinders away from welding and other
electrical circuits.
Never touch cylinder with welding electrode.
•
Shut off shielding gas supply when not in use.
Always secure cylinder to running gear, wall, or
other stationary support.
warn4.1 9/91
Obtain gas cylinder and chain to
running gear, wall, or other stationary support so cylinder cannot fall
and break off valve.
1
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.
2
3
3
Cylinder
4
Regulator/Flowmeter
Install so face is vertical.
5
1
6
OR
6
Argon Gas
2
5
4
3
7
Tools Needed:
5/8, 1-1/8 in
8
Gas Hose Connection
Fitting has 5/8-18 right-hand
threads. Obtain and install gas
hose.
Flow Adjust
Typical flow rate is 20 cfh (cubic feet
per hour). Check wire manufacturer’s recommended flow rate.
7
CO2 Adapter
8
O-Ring
Install adapter with O-ring between
regulator/flowmeter and
CO2
cylinder.
CO2 Gas
ssb3.1* 6/93 − ST-158 697-A
Figure 3-4. Typical Regulator/Flowmeter Installation
3-4. 115 Volts AC Duplex Receptacle
1
115 Volts AC Duplex Receptacle
This welding power source supplies up to 15 amperes of 115 volts
ac power.
1
Power output is shared between
this receptacle and the Remote 14
receptacle or terminal strip 1T (see
Sections 3-7 and 3-8).
Receptacle is protected from overload by circuit breaker CB1 (see
Section 5-2).
Close door.
Ref. ST-800 101-B
Figure 3-5. Connecting To 115 Volts AC Duplex Receptacle
OM-278 Page 5
3-5. Selecting And Preparing Weld Output Cables
1
Weld 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 possible.
3
4
Do not use damaged cables.
5
2
OR
OR
Use lugs of proper amperage
capacity and hole size for connecting to work clamp, wire feeder or
electrode holder, and weld output
terminals.
2
2
Terminal Lug
1
3
Wire Feeder
4
Insulated Electrode Holder
5
GTAW Torch
Install according to manufacturer’s
instructions.
6
Work Clamp
Install onto work cable.
10 ft (3 m)
6
For Example,
Total Cable
Length In Weld
Circuit = 20 ft (6 m)
10 ft (3 m)
Tools Needed:
sb6.5 11/92 − S-0752
Figure 3-6. Selecting And Preparing Weld Output Cables
Table 3-1. Weld Cable Size*
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft (30 m) Or Less
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 To 60%
Duty Cycle
60 Thru 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 Thru 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.
OM-278 Page 6
S-0007-D
3-6. Connecting To Weld Output Terminals
WARNING
ELECTRIC SHOCK can kill.
•
•
USING BOTH POSITIVE (+) WELD
OUTPUT TERMINALS AT SAME TIME
can cause serious electric shock and
arcing hazards.
Do not touch live electrical parts.
Turn Off welding power source, and disconnect
input power before making any weld output
connections.
•
•
•
Both positive (+) terminals are live at the same time.
Do not use both positive (+) weld output terminals at
the same time.
Remove any cable not being used. swarn12.1* 2/93
1
Positive (+) High Inductance
Weld Output Terminal
2
Positive (+) Low Inductance
Weld Output Terminal
While in the GMAW mode (see
Figure 4-4), use positive (+) weld
output terminal that provides the
best welding arc and weld puddle
properties for application.
When connected to Low terminal,
low inductance results in a stiff,
fast-responding arc, and small,
fast-freezing puddle.
1
When connected to High terminal,
high inductance results in a soft,
slower-responding, low spatter arc,
and more fluid weld puddle.
2
While in SMAW mode (see
Figure 4-4), use positive (+) High
Inductance weld output terminal.
3
3
NEGATIVE
Negative (−) Weld Output Terminal
For Electrode Positive (DCEP),
connect work cable to negative (−)
terminal and electrode holder or
wire feeder cable to proper positive
(+) terminal.
POSITIVE
Use ONLY one positive
(+) weld output terminal
at a time. Remove any
cable not being used.
For Electrode Negative (DCEN),
reverse cable connections.
Close door.
Welding Power Source
Welding Power Source
NEGATIVE
POSITIVE
POSITIVE
NEGATIVE
Wire
Feeder
Tools Needed:
Workpiece
Workpiece
GMAW or SAW Connections (DCEP) − For
FCAW Use Low Inductance Weld Output Terminal
3/4 in
SMAW Connections (DCEP)
Ref. ST-800 101-B / ST-162 508-A
Figure 3-7. Weld Output Connections
OM-278 Page 7
3-7. Remote 14 Receptacle Information And Connections
1
2
A
B
K
J
1
Remote 14 Receptacle RC8
(See Table 3-2)
2
Keyway
3
Plug
4
Threaded Collar
To connect to receptacle, align
keyway, insert plug, and tighten
threaded collar. Close door.
I
If remote control plug does not fit
receptacle, go to Figure 3-9 to wire
cord to terminal strip 1T.
H
C L N
D M
G
E F
4
3
OR
sb7.1* 12/93 − ST-800 693-A / Ref. S-0004-A / S-0750
Figure 3-8. Remote 14 Connections
Table 3-2. Remote 14 Socket Information
Socket*
*The remaining sockets are not used.
OM-278 Page 8
Socket Information
A
24 volts ac. Protected by circuit breaker CB2.
B
Contact closure to A completes 24 volts ac contactor control circuit.
I
115 volts ac. Protected by circuit breaker CB1.
J
Contact closure to I completes 115 volts ac contactor control circuit.
G
Circuit common for 24 and 115 volts ac circuits.
C
Command reference; CV: +10 volts dc or CC: 0 to +10 volts dc.
D
Remote control circuit common.
E
0 to +10 volts dc input command signal from remote control.
K
Chassis common.
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.
3-8. Terminal Strip 1T Information And Connections
WARNING
ELECTRIC SHOCK can kill; UNEXPECTED OUTPUT can cause serious injury.
•
•
•
Do not touch live electrical parts.
Turn Off welding power source, and disconnect input power before making any internal inspection or connections.
Do not connect to Remote 14 receptacle and terminal strip at the same time.
Output (Contactor) can be energized from either the receptacle or terminal strip. Use only one remote control method.
Turn Off welding power source.
In some cases, Terminal Strip 1T letter designators
do not match Remote 14 Receptacle RC8. Read
descriptions below before making connections.
1
Remote Control Cord
2
Terminal Strip Access Panel
Remove screws and tip access
panel forward.
3
Strain Relief (Customer
Supplied)
Install strain relief. Route leads
through strain relief.
1
E
D
REMOTE
OUTPUT
CONTROL
I
J
5
Terminal Strip Label
Secure cord in strain relief. Reinstall and secure access panel.
Close door.
4
C
Terminal Strip 1T
Connect leads to 1T using terminal
information below.
2
Turn Off power before
opening terminal strip
cover.
4
5
3
A
B
N
P
115 VAC
24VAC
REMOTE
REMOTE
VOLTAGE
REMOTE
CONTACTOR CONTACTOR SENSE
K
M
L
GND
REMOTE
POWER ON/OFF
S-162 895-B
Terminal Information:
Remote Contactor
A, B
Contact closure completes the 24 volts ac contactor control circuit. Protected by circuit breaker CB2.
Remote Amperage/Voltage Control
C
Command reference; CV: +10 volts dc or CC: 0 to +10 volts dc.
D
Control circuit common.
E
Input command signal (potentiometer wiper or 0-10 volts dc source); 0 to +10 volts dc.
115 Volts AC
I, J
Contact closure completes the 115 volts ac contactor control circuit. Protected by circuit breaker CB1.
Remote Power On/Off
K
L, M
GND (chassis common).
Remote power on/off connections.
Tools Needed:
Remote Voltage Sensing Signal
N
Voltage sensing signal from Negative (−) weld output terminal.
P
Voltage sensing signal from Positive (+) weld output terminal.
Ref. ST-800 170-C
Figure 3-9. Terminal Strip 1T Connections
OM-278 Page 9
3-9. Connecting Input Power
WARNING
ELECTRIC SHOCK can kill.
•
•
•
•
Do not touch live electrical parts.
Turn Off welding power source, and disconnect input power before inspecting or installing.
Have only qualified persons install unit.
Installation must meet National Electrical Code and all other codes.
swarn3.1 2/93
A. Positioning Jumper Links
Jumper links allow operation on different input voltages and are factory set for the highest input voltage.
Check input voltage available at
site.
Open rear panel access door to
check jumper links.
1
Input Voltage Label
Look at jumper links and compare
link position with unit label.
2
Input Voltage Jumper Links
Move links to match input voltage.
For example, use 230 volts position
when 230 volts input power is available.
Close rear panel access door or go
on to Figure 3-11.
1
2
230 VOLTS
460 VOLTS
575 VOLTS
S-168 940
Tools Needed:
3/8 in
3/8 in
ssb5.1* 2/92 − ST-800 104-A
Figure 3-10. Input Voltage Jumper Links Location
OM-278 Page 10
B. Connecting Input Power
Have only qualified persons make
this installation.
IMPORTANT
Open rear access door.
Three-Phase Input Power Connections
L1
Input
Contactor
W
L2
3
L3
Line Disconnect Device Of
Proper Rating
2
Input Conductors
3
Grounding Conductor
Select size and length using
Table 3-3. Conductor rating must
comply with national, state, and local electrical codes. Use lugs of
proper amperage capacity and correct hole size.
4
Strain Relief Connector
Insert conductors through strain
relief.
Green Or
Green With
Yellow Stripe(s)
GND/
PE
1
Cut All Conductors To Same Length, And Loop Back
Excess Grounding Conductor. Always Connect Input
Grounding Conductor To GND/PE Stud Near
Contactor On Base First.
S-162 681
5
Line Terminals
6
Welding Power Source
Ground Terminal
Connect grounding conductor to
ground terminal on base of unit first.
Then connect input conductors to
contactor.
7
Disconnect Device Ground
Terminal
Install and connect grounding
conductor and input conductors in
conduit or equivalent to deenergized line disconnect device.
Connect grounding conductor first,
then line input conductors.
Be sure grounding conductor goes
to an earth ground.
1
Close access door.
8
8
Overcurrent Protection
Select type and size using
Table 3-3. Install into deenergized
line disconnect device (fused disconnect switch shown).
4
7
2
5
3
Tools Needed:
6
3/8 in
3/8 in
ssb2.4* 1/94 − ST-800 103-A
Figure 3-11. Input Power Connections
OM-278 Page 11
Table 3-3. Electrical Service Requirements*
Input Voltage
230
460
575
Input Amperes At Rated Output
126
63
51
Recommended Standard Fuse Or Circuit Breaker
Rating In Amperes1
200
90
80
1
6
6
180 (55)
284 (87)
444 (135)
6
8
8
Input Conductor Size In AWG/Kcmil2
Max Input Conductor Length In Feet
Grounding Conductor Size In
(Meters)3
AWG/Kcmil4
*
These values are calculated from the 1993 edition of the National Electrical Code (NEC).
1 Recommended fuse or circuit breaker size is that closest to 150% of rated input amperage of the welding power source. Article 630-12(a) of NEC
allows fuse or circuit breaker sizing up to 200% of rated input amperage.
2 Input conductor size is for insulated copper wire with 75°C rating with not more than three single current-carrying conductors in a cable or raceway
(Table 310-16 of NEC).
3 Maximum length is to prevent more than a 3% voltage drop between service entrance and input terminals of the welding power source (Articles
210-19(a) and 215-2(b) of NEC).
4 The grounding conductor shall be colored or identified as specified in the NEC. Grounding conductor size for copper wire is not required to be larger
than input conductor (Article 250-95 of NEC).
S-0092-G
SECTION 4 − OPERATION
WARNING
ELECTRIC SHOCK can kill.
•
•
•
•
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Always wear dry insulating gloves.
Insulate yourself from work and ground.
Do not touch live electrical parts.
Keep all panels and covers securely in place.
•
•
MOVING PARTS can cause injury.
•
•
FUMES AND GASES can be hazardous
to your health.
•
•
•
Keep your head out of the fumes.
Ventilate area, or use breathing device.
Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.
•
•
Do not weld near flammable material.
Watch for fire; keep extinguisher nearby.
Do not locate unit over combustible surfaces.
Do not weld on closed containers.
Allow work and equipment to cool before handling.
1
2
3
4
5
Keep away from moving parts.
Keep all doors, panels, covers, and guards closed
and securely in place.
MAGNETIC FIELDS FROM HIGH CURRENTS can affect pacemaker operation.
WELDING can cause fire or explosion.
•
•
•
•
•
Wear welding helmet with correct shade of filter.
Wear correct eye, ear, and body protection.
Pacemaker wearers keep away.
Wearers should consult their doctor before going
near arc welding, gouging, or spot welding operations.
See Safety Precautions at beginning of manual for basic welding safety information.
swarn6.1 10/91
6
7
8
9
Figure 4-1. Controls
OM-278 Page 12
1
Output (Contactor) Switch
2
Arc Force (Dig) Control
3
Remote Amperage/Voltage
Control Switch
4
Process Selector Switch
5
Amperage/Voltage Adjustment
Control
6
Digital Voltmeter
7
Digital Ammeter
8
Power Switch/Pilot Light
9
High Temperature Shutdown
Light
Ref. ST-800 101-B
Wear the following while welding:
1
2
3
1
Dry, Insulating Gloves
2
Safety Glasses With Side
Shields
3
Welding Helmet With Correct
Shade Of Filter (See ANSI
Z49.1)
sb3.1 1/94
Figure 4-2. Safety Equipment
1
1
Work 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.
Tools Needed:
sb4.1 2/93
Figure 4-3. Work Clamp
1
1
Process Selector Switch
Use switch to select type of weld
output. Use SMAW (Hot Start On)
position for Shielded Metal Arc
Welding and Air Carbon Arc Cutting/Gouging processes. Use
GMAW position for Gas Metal Arc
and Flux Cored Arc Welding processes. Use SMAW (Hot Start Off)
position for Gas Tungsten Arc
Welding process.
Switch position determines operation of Amperage/Voltage Adjustment control (see Figure 4-5) and
Arc Force (Dig) control (see
Figure 4-6).
With switch in SMAW (Hot Start
On) position, unit automatically provides a starting amperage higher
than set value.
Ref. ST-162 500-A
Figure 4-4. Process Selector Switch
OM-278 Page 13
1
32
36
40
44
28
48
24
4
3
52
20
16
2
12
1
Amperage/Voltage Adjustment
Control
2
Volts Scale
3
Amps Scale
Use Process Selector switch (see
Figure 4-4) to select weld amperage or voltage. Use Volts scale for
GMAW and FCAW processes. Use
Amps scale for SMAW and GTAW
processes.
4
Remote Amperage/Voltage
Control Switch
Use switch to select way of controlling amperage and voltage adjustment.
56
60
For front panel control, place switch
in the Panel position.
V
For remote control, place switch in
Remote position. See Examples in
Figure 4-9 and Figure 4-10.
Figure 4-5. Amperage/Voltage Adjustment Control And Switch
1 Arc Force (Dig) Control
This control is used for SMAW,
SAW, or CAC-A, and only works
when Process Selector switch (see
Figure 4-4) is in the SMAW (Hot
Start On) position.
Control increases short-circuit amperage to help start an arc or make
vertical or overhead welds.
When set at 0, short-circuit amperage is the same as normal welding
amperage.
As setting increases, short-circuit
amperage increases to help arc
starting. See Figure 2-1.
Select setting best suited for application. Numbers around control are
for reference only.
Turn control to 0 (zero) for GTAW process.
1
Figure 4-6. Arc Force (Dig) Control
WARNING
ELECTRIC SHOCK can kill.
•
•
•
Do not touch live electrical parts.
Do not touch weld output terminals when contactor is energized.
Do not touch electrode and work clamp at the same time.
swarn7.1 10/91
1
Weld output terminals are
energized when switch is
On and Power is On.
1
Output (Contactor) Switch
Use switch to select way of controlling unit output.
For weld output, place switch in On
position.
For remote output control, connect
to Remote 14 receptacle or terminal
strip as instructed in Sections 3-7
and 3-8, and place switch in Remote position.
Figure 4-7. Output (Contactor) Switch
OM-278 Page 14
1
Digital Voltmeter
Voltmeter displays voltage (to 0.1
volt) at the weld output terminals,
but not necessarily the welding arc
due to cable resistance, poor connections, etc.
2
Digital Ammeter
Ammeter displays weld amperage
output of unit.
Both meters hold last weld value for
5 seconds after welding ends.
1
2
Figure 4-8. Voltmeter And Ammeter
EXAMPLE Of Combination Remote Amperage Control For GTAW Welding
1. Set Process
32
36
40
28
48
24
52
20
16
2. Set Switches
44
12
56
60
V
3. Set Desired Maximum Amperage For Application
Min (0 A DC)
Max (450 A DC)
4. Adjust Remote Control
Ref. ST-162 500-A
Figure 4-9. Remote Amperage Control Example
OM-278 Page 15
EXAMPLE Of Full Remote Voltage Control For GMAW Welding
1. Set Process
36
32
40
44
28
48
24
52
20
16
12
56
60
V
3. Front Panel Amperage/Voltage
Control Does Not Work
2. Set Switches
REMOTE VOLTAGE
4. Set Percentage On Remote
Voltage Control Of Wire Feeder
Min
(0 V)
Max
(60 V)
Ref. ST-162 500-A
Figure 4-10. Remote Voltage Control Example
1
1
2
Power Switch/Pilot Light
Use switch to turn unit on and off.
The switch lights when power is on.
2
High Temperature Shutdown
Light
Lights when unit internal temperature has reached maximum rated
temperature. Unit output shuts
down, but thermostatically controlled fan motor runs as long as
cooling is needed.
Figure 4-11. Power Switch/Pilot Light, And High Temp Light
OM-278 Page 16
WARNING
BUILDUP OF SHIELDING GAS can harm health or kill.
•
Shut off shielding gas supply when not in use.
warn1.1 9/91
2
1
5
1
Shielding Gas Cylinder
2
Valve
3
Gun Trigger
4
Foot Control
5
Finger Tip Control
Open valve on cylinder just before
welding.
4
Gun trigger, finger tip control, or foot
control turns weld output and gas
flow on and off.
Close valve on cylinder when finished welding.
3
sb5.2* 2/92 − S-0621-C
Figure 4-12. Shielding Gas
Install &
Connect
Equipment
Select
Electrode
Put On
Personal Safety
Equipment
Set Controls
Insert
Electrode
Into Holder
Turn On
Welding Power
Source
Begin Welding
ssb7.1 9/92
Figure 4-13. Sequence Of Shielded Metal Arc Welding (SMAW)
Install &
Connect
Equipment
Install & Prepare
Wire Feeding
System
Put On
Personal Safety
Equipment
Set Controls
Turn On
Shielding Gas
Turn On Feeder
And Welding
Power Source
Begin Welding
ssb6.1 9/92
Figure 4-14. Sequence Of Gas Metal Arc Welding (GMAW)
Install &
Connect
Equipment
Install & Prepare
Wire Feeding
System
Put On
Personal Safety
Equipment
Set Controls
Turn On Feeder
And Welding
Power Source
Begin Welding
ssb6.1* 9/92
Figure 4-15. Sequence Of Flux Cored Arc Welding (FCAW)
Install &
Connect
Equipment
Install & Prepare
Wire Feeding
System
Turn On
Flux System
Install & Prepare
Flux System
Put On
Personal Safety
Equipment
Set Controls
Turn On Feeder
And Welding
Power Source
Begin Welding
Figure 4-16. Submerged Arc Welding (SAW)
OM-278 Page 17
Install &
Connect
Equipment
Install & Connect
High-Frequency
Unit
Turn On
Shielding Gas
Select
Tungsten
(See Section 7)
Turn On
High-Frequency
Unit
Insert
Tungsten
Into Torch
Turn On
Welding Power
Source
Put On
Personal Safety
Equipment
Set Controls
Begin Welding
ssb8.1 12/92
Figure 4-17. Sequence Of Gas Tungsten Arc Welding (GTAW)
Install &
Connect
Equipment
Connect
Compressed Air
Supply
Turn On
Compressed Air
Supply
Select
Carbon Electrode
Turn On
Welding Power
Source
Put On
Personal Safety
Equipment
Insert Electrode
Into Torch
Set Controls
Begin
Cutting Or
Gouging
Figure 4-18. Air Carbon Arc Cutting And Gouging (CAC-A)
SECTION 5 − MAINTENANCE & TROUBLESHOOTING
WARNING
ELECTRIC SHOCK can kill.
•
•
Do not touch live electrical parts.
MOVING PARTS can cause injury.
•
Keep away from moving parts.
Turn Off welding power source, and disconnect
input power before inspecting, maintaining, or
servicing.
HOT PARTS can cause severe burns.
•
Allow cooling period before maintaining or servicing.
Maintenance to be performed only by qualified persons.
swarn8.1 2/93
5-1. Routine Maintenance
3 Months
Tape Or
Replace
Cracked
Weld
Cable
OR
Blow Out
Or
Vacuum
Inside
During Heavy Service,
Clean Monthly
Replace
Unreadable
Labels
Clean
And
Tighten
Weld
Terminals
ST-800 091
Figure 5-1. Maintenance Schedule
OM-278 Page 18
6 Months
Turn Off all power before maintaining.
5-2. Overload Protection
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
WARNING
A. Circuit Breakers CB1 And CB2
Turn Off welding power source.
Open lower access door.
1
1
2
Circuit Breaker CB1
CB1 protects the 115 volts ac portion of the Remote 14 receptacle or
terminal strip 1T and the 115 volts
ac duplex receptacle from overload.
2
Circuit Breaker CB2
CB2 protects the 24 volts ac portion
of Remote 14 receptacle or terminal
strip 1T from overload.
Should an overload occur, the appropriate circuit breaker opens and
stops output to the receptacle.
Press button to reset a breaker.
Close door.
Tools Needed:
Ref. ST-800 101-B / Ref. ST-162 507
Figure 5-2. Circuit Breakers CB1 And CB2
B. Overheating
0
15
minutes
When overheated, thermostat(s)
opens, output stops, and cooling
fan keeps running.
Let fan run until high
temperature shutdown
light turns off.
Start welding.
ssb10.1* 1/94 − ST-800 091
Figure 5-3. Overheating
OM-278 Page 19
C. Fuse F1
Turn Off welding power source.
1
Fuse F1 (See Parts List For
Rating)
Fuse F1 protects the control transformer from overload. If F1 opens,
weld output stops, and the fan
motor does not run. Replace F1.
Close door.
1
1
Turn
Pull Out And Replace Fuse
(Install Flat End Of Fuse Into Cover)
Turn
Tools Needed:
3/8 in
ST-800 104-A / ST-800 185-A
Figure 5-4. Fuse F1
D. Short Circuit Shutdown
When Process switch is in GMAW position and contact tip is shorted and sticks to workpiece, the unit output falls to a
safe operating level. To resume operation, release gun trigger, turn Off unit, and remove contact tip from workpiece.
Check contact tip and replace if damaged. Turn On unit to continue operation.
OM-278 Page 20
5-3. Troubleshooting
WARNING
ELECTRIC SHOCK can kill.
•
•
Do not touch live electrical parts.
MOVING PARTS can cause injury.
•
Keep away from moving parts.
Turn Off welding power source, and disconnect
input power before inspecting, maintaining, or
servicing.
HOT PARTS can cause severe burns.
•
Allow cooling period before servicing.
Troubleshooting to be performed only by qualified
persons.
swarn9.1 2/93
Table 5-1. Welding Trouble
Trouble
No weld output; unit completely inoperative.
No weld output; fan on.
Remedy
Section
Place line disconnect switch in On position.
3-9
Check and replace line fuse(s), if necessary.
3-9
Check for proper input power connections.
3-9
Check for proper jumper link position.
3-9
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. If remote is not being used,
place Output (Contactor) switch in On position.
3-7, 3-8,
Figure 4-7
Check, repair, or replace remote control.
−−
Unit overheated. Allow unit to cool with fan On.
5-2
Have Factory Authorized Service Station/Service Distributor
check control board PC1.
−−
Unit provides only maximum or minimum weld output.
Have Factory Authorized Service Station/Service Distributor
check control board PC1 and hall device HD1.
−−
Erratic or improper weld output.
Use proper size and type of weld cable.
3-5
Clean and tighten all weld connections.
−−
Check wire feeder installation according to its owner’s manual.
−−
Check position of Process selector switch.
Figure 4-4
Have Factory Authorized Service Station/Service Distributor
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.
5-2
No 24 volts ac output at Remote 14
receptacle or terminal strip 1T.
Reset circuit breaker CB2.
5-2
OM-278 Page 21
Trouble
Fan not operating.
Wandering arc; poor control of arc
direction.
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
OM-278 Page 22
Remedy
Section
Check for and remove anything blocking fan movement.
−−
Have Factory Authorized Service Station/Service Distributor
check fan motor.
−−
Reduce gas flow rate.
−−
Select proper size tungsten.
7-1
Properly prepare tungsten.
7-2
Shield weld zone from drafts.
−−
Increase postflow time.
−−
Check and tighten all gas fittings.
−−
Properly prepare tungsten.
7-2
Check for water in torch, and repair torch if necessary. See
torch Owner’s Manual.
−−
For Primary Circuit Diagram Portion, refer to the Circuit Diagram
located inside the wrapper of the welding power source.
SECTION 6 − ELECTRICAL DIAGRAMS
Figure 6-1. Circuit Diagram For Welding Power Source
SC-158 979-D
OM-278 Page 23
Figure 6-2. Wiring Diagram For Welding Power Source
OM-278 Page 24
SD-166 008-C
OM-278 Page 25
SECTION 7 − TUNGSTEN ELECTRODE
mod2.1 1/94
NOTE
For additional information, see your distributor for a handbook on the Gas
Tungsten Arc Welding (GTAW) process.
Wear clean gloves to prevent contamination of tungsten electrode.
7-1. Selecting Tungsten Electrode
Table 7-1. Tungsten Size
Amperage Range - Gas Type♦ - Polarity
Electrode Diameter
DC − Argon − Electrode
Negative/Straight Polarity
DC − Argon − Electrode
Positive/Reverse Polarity
AC − Argon − Using
High Frequency
AC − Argon − Balanced
Wave Using High Freq.
Up to 15
*
Up to 15
Up to 10
.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
Pure Tungsten
(Green Band)
.010”
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
80-125
325-450
250-400
.010”
Up to 25
*
Up to 20
Up to 15
.020”
15-40
*
15-35
5-20
2% Thorium Alloyed
Tungsten (Red Band)
.040”
25-85
*
20-80
20-60
1/16”
50-160
10-20
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
.010”
*
*
Up to 20
Up to 15
.020”
*
*
15-35
5-20
.040”
*
*
20-80
20-60
1/16”
*
*
50-150
60-120
3/32”
*
*
130-250
100-180
Zirconium Alloyed Tungsten (Brown Band)
1/8”
*
*
225-360
160-250
5/32”
*
*
300-450
200-320
3/16”
*
*
400-550
290-390
1/4”
*
*
600-800
340-525
♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).
*Not Recommended.
The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode
manufacturers.
S-0009
OM-278 Page 26
7-2. Preparing Tungsten
1
1
Tungsten Electrode
2
Balled End
Ball end of tungsten before welding
by applying either an ac amperage
slightly higher than what is recommended for a given electrode diameter (see Table 7-1), or a dc electrode positive amperage.
1-1/2 Times
Electrode Diameter
2
Ref. S-0161
Figure 7-1. 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 grinder with proper guards in a safe location wearing proper face, hand, and body protection.
Keep flammables away.
warn2.1 9/91
1
2
1
Tungsten Electrode
2
Tapered End
Grind end of tungsten on fine grit,
hard abrasive wheel before welding. Do not use wheel for other jobs
or tungsten can become contaminated causing lower weld quality.
2-1/2 Times
Electrode Diameter
Ref. S-0161
1
2
3
1
Stable Arc
2
Flat
Diameter of this flat determines
amperage capacity.
3
Grinding Wheel
4
Straight Ground
4
Ideal Tungsten Preparation − Stable Arc
1
2
Ref. S-0162
1
Arc Wander
2
Point
3
Grinding Wheel
4
Radial Ground
3
4
Wrong Tungsten Preparation − Wandering Arc
Ref. S-0162
Figure 7-2. Preparing Tungsten For DC Electrode Negative (DCEN) Welding
OM-278 Page 27
OM-278 Page 28
23
Fig 8-3
32
31
Fig 8-2
30
3
2
1
29
28
4
Figure 8-1. Main Assembly
25
27
26
5
24
6
7
11
12
13
8
4
14
10
9
16
15
17 18
3
20
19
23
22
21
Fig 8-4
SECTION 8 − PARTS LIST
ST-800 703
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . . . . . +168 806
. . . 2 . . . . . . . . . . . . . . . . . . . 162 803
. . . 3 . . . . . . . . . . . . . . . . . . . 164 700
. . . 4 . . . . . . . . . . . . . . . . . . . 162 816
. . . 5 . . . . . . . . . . . . . . . . . . . 162 820
. . . 6 . . . . . . . . . . . . . . . . . . . 162 830
. . . . . . . . . . . . . . . . . . . . . . . . . 604 536
. . . 7 . . . . . . . . . . . . . . . . . . . 160 928
. . . 8 . . . . . . . . . . . . . . . . . . . 134 201
. . . 9 . . . . . . . . . . . . . . . . . . . 162 821
. . . 10 . . . . . . . HD1 . . . . . . 153 518
. . . . . . . . . . . . PLG14 . . . . . 130 204
. . . . . . . . . . . . . . . . . . . . . . . . . 114 066
. . . 11 . . . . . . . . . . . . . . . . . . . 148 056
. . . 12 . . . . . . . . Z1 . . . . . . . 163 220
. . . 13 . . . . . . C21-23 . . . . . 163 906
. . . 14 . . . . . . . . T2 . . . . . . . 159 042
. . . 15 . . . . . . . TE1 . . . . . . 159 244
. . . 16 . . . . . . . . . . . . . . . . . . . 601 835
. . . 17 . . . . . . . . . . . . . . . . . . . 038 887
. . . . . . . . . . . . . . . . . . . . . . . . . 038 618
. . . . . . . . . . . . . . . . . . . . . . . . . 010 913
. . . . . . . . . . . . . . . . . . . . . . . . . 601 835
. . . 18 . . . . . . . . . . . . . . . . . . . 159 034
. . . 19 . . . . . . . . . . . . . . . . . . . . Fig 8-4
. . . 20 . . . . . . . . F1 . . . . . . *156 065
. . . 21 . . . . . . . . W . . . . . . . 160 794
. . . 22 . . . . . . . . . . . . . . . . . . +168 805
. . . 23 . . . . . . . . . . . . . . . . . . . 134 464
. . . 24 . . . . . . . . . . . . . . . . . . . 163 359
. . . 25 . . . . . . . . T1 . . . . . . . 169 072
. . . 26 . . . . . . . . . . . . . . . . . . . 169 154
. . . 27 . . . . . . . . . . . . . . . . . . . 169 153
. . . . . . . . . . . . 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
. . . 28 . . . . . . . . . . . . . . . . . . . 144 468
. . . 29 . . . . . . . . . . . . . . . . . . . 605 538
. . . 30 . . . . . . . . . . . . . . . . . . . 161 294
. . . 31 . . . . . . . . . . . . . . . . . . . . Fig 8-2
. . . 32 . . . . . . . SR1 . . . . . . 168 893
. . . . . . . . . . . . . PLG7 . . . . . . 152 249
. . . . . . . . . . . . . . . . . . . . . . . . . 147 996
. . . . . . . . . . . . . RC7 . . . . . . 168 846
. . . . . . . . . . . . . . . . . . . . . . . . . 147 995
. . . . . . . . . . . . . . . . . . . . . . . . . 010 467
. . 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 . . . . . . . . . . . . . .
. . 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 . . . . . . . . . . . . . . . . . . . . . . . .
. . 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 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 8-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect pin 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR, clamp cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
4
2
1
2
1
4
1
1
1
3
1
1
3
1
1
24
24
8
24
24
1
1
1
1
1
2
1
1
2
1
2
2
1
12
1
12
1
9
1
9
4
4
2
1
1
1
15
1
15
1
+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.
OM-278 Page 29
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-2. Panel, Front w/Components (Fig 8-1 Item 31)
... 1 ...................
. . . 2 . . . . . . . PC1 . . . . . .
. . . . . . . . . . . . . PLG1 . . . . . .
. . . . . . . . . . . . . PLG3 . . . . . .
.........................
. . . . . . . . . . . . . PLG4 . . . . . .
.........................
. . . . . . . . . . . . . PLG5 . . . . . .
.........................
. . . 3 . . . . . . . CR3 . . . . . .
159 863
163 875
158 720
169 240
147 995
148 439
147 995
152 249
147 995
006 393
. . ELECTRONICS BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (see Fig 8-3)
. . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
20
1
10
1
15
1
4
5
6
7
2
3
1
8 9 16
9
16
17
30
29
16
28
41
29
27
30
26
31
32
40
34
39
33
21
25
22
15 14 13 12 11
24
10
23
35
20
36
38
19
ST-800 705
37
Figure 8-2. Panel, Front w/Components
OM-278 Page 30
18
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-2. Panel, Front w/Components (Fig 8-1 Item 31)
(Continued)
. . . 4 . . . . . . CB1,2 . . . . . . 093 995 . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . .
. . . 5 . . . . . . . RC9 . . . . . . 604 176 . . RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . . . . . . . . . 162 802 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . . . . . . . . . 161 303 . . SPRING, cprsn .600 OD x .072 wire x 1.500 lg . . . . . . . . . . . . . . . .
. . . 9 . . . . POS-CC,CV . . . 039 047 . . TERMINAL, pwr output red (consisting of) . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . NEG . . . . . . 039 046 . . TERMINAL, pwr output black (consisting of) . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . . . . . . . 601 976 . . . . SCREW, .500-13 x 1.500hexhd stl . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . . . . . . . 039 049 . . . . TERMINAL BOARD, red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . . . . . . . 039 045 . . . . TERMINAL BOARD, black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . . . . . . 601 880 . . . . NUT, .500-13 x .31 high stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . . . . . . 039 044 . . . . BUS BAR, term bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . . . . . . 601 879 . . . . NUT, .500-13 x .44 high stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . C2,4,5 . . . . . 128 750 . . CAPACITOR, cer disc .1uf 500VDC . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . R4,5 . . . . . . 136 076 . . RESISTOR, WW fxd 30W 200 ohm . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . 1T . . . . . . . 159 040 . . BLOCK, term 20A 12P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . . . . . . 162 828 . . PANEL, mtg rcpt/terminal strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . . . . . . 070 371 . . BLANK, snap-in nyl 1.093/1.125mtg hole . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . . . . . . +162 508 . . PLATE, control lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . . . . . . . 162 893 . . LABEL, warning disconnect pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 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 . . . . . . . . . . . . . . . . . . . 159 035 . . CLIP, retainer lens .312dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . .
. . . 37 . . . . . . . . S2 . . . . . . . 159 039 . . SWITCH, rocker SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 38 . . . . . . . PL2 . . . . . . . 159 522 . . LED, yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 39 . . . . . . . . . . . . . . . . . . . 159 036 . . LENS, LED clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 40 . . . . . . . . . . . . . . . . . . . 097 924 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 41 . . . . . . . . . . . . . . . . . . . 097 922 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
1
3
2
1
1
1
2
1
1
1
6
1
10
1
1
4
1
1
1
1
1
1
1
+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 31
Item
No.
Dia.
Mkgs.
Part
No.
SR1
168 893
. . . 1 . . . . C7-12 . . . .
... 2 ...............
... 3 ...............
... 4 ...............
... 5 ...............
. . . 6 . . . SCR1-6 . . .
... 7 ...............
. . . . . . . . . . PLG1 . . . .
.....................
. . . . . . . . . . . TP3 . . . . .
. . . . . . . . . . . TP6 . . . . .
151 880
164 634
161 089
082 694
160 962
148 091
160 961
158 720
147 995
168 895
168 894
Description
Quantity
Figure 8-3. Rectifier, Si Diode (Fig 8-1 Item 32)
. . CAPACITOR, cer disc .01uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUS BAR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAR, clamp rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, thyristor rectifier 5.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HEAT SINK, rectifier snowflake .800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . THYRISTOR, SCR 865A 300V hockey puck . . . . . . . . . . . . . . . . . . . . . . .
. . HEAT SINK, rectifier snowflake 1.600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . THERMOSTAT, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . THERMOSTAT, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
2
2
3
6
6
3
1
12
1
1
4
3
1
2
5
6
7
4
ST-800 696
Figure 8-3. Rectifier, Si Diode SR1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-278 Page 32
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-4. Panel, Rear w/Components (Fig 8-1 Item 19)
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
. . . . . . . . . . . . . . . 124 275
. . . . . . . . . . . . . . . 032 611
. . . . . . . . . . . . . . . 162 807
. . . . . . . . . . . . . . . 168 343
. . . . . . . . . . . . . . +162 818
. . . . . . . . . . . . . . . 168 384
. . . . . . . . . . . . . . . 602 177
. . . . . R3 . . . . . . 097 459
. . . . . FM . . . . . 116 190
..
..
..
..
..
..
..
..
..
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 . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, WW fxd 375W 20 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTOR, 1/12HP 230V 1550RPM 50/60Hz 1.5A . . . . . . . . . . . . . . . . . . .
3
1
1
1
2
1
1
2
1
1
4
5
6
2
1
7
9
8
ST-800 707
Figure 8-4. Panel, Rear w/Components
+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 33
OPTIONS AND ACCESSORIES
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.
PROCESS SELECTOR AND
ISOLATION CONTROL
(#042 872)
If you have multiple accessories
connected to your power source,
such as a wire feeder and a spool
gun, this control allows you to
electrically isolate them so that
only one accessory at a time is
“hot”. In addition, it transfers
control circuitry between the two
accessories. A 14-pin Amphenol
plug that connects to the power
source, and two 14-pin receptacles
accommodate accessories.
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.
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.
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. For more information, see
the Miller Coolant Systems
literature sheet, Index No. AY/7.2.
COOLMATE 4
(#042 288)
For use with water-cooled torches
rated up to 600 Amps. Tough
molded polyethylene case with
carrying handle. For more
information, see the Miller Coolant
Systems literature sheet, Index
No. AY/7.2.
RADIATOR 1A
(#042 492) 115 VAC
RADIATOR 2A
(#042 493) 230 VAC
For use with water-cooled torches
rated up to 500 Amps. For more
information, see the Miller Coolant
Systems literature sheet, Index
No. AY/7.2.
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.
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.
7/94
OPTIONS AND ACCESSORIES
REMOTE CONTROLS AND
SWITCHES
RMLS-14
(#129 337)
Momentary- and
maintained-contact 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
current and contactor control at
operator’s fingertips. Includes 28
ft. (8.5 m) cord and plug.
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.
RFC-14 FOOT CONTROL
(#129 339)
Heavy duty foot current and
contactor control. 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)
This extension cord makes a direct
connection between the power
source and the accessory control.
No messy splicing or adapting
required.
7/94
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