Miller | KG054113 | Owner Manual | Miller GOLDSTAR 302 User manual

Miller GOLDSTAR 302 User manual
January 1996
Form: OM-222D
Effective With Serial No. KG054113
OWNER’S
MANUAL
Gold Star® 302, 452, 652 (60 HZ)
Gold Star® 402, 602, 852 (50/60 HZ -
)
CC/DC Welding Power Sources For SMAW, GTAW Welding, And CAC-A Cutting And Gouging
Maximum
Amperes Input at Rated Load Output, 50 or 60 Hz,
OpenThree-Phase
IP
Circuit
Rating
Voltage
200 V 230 V 380 V 400 V 440 V 460 V 575 V
DC
Rated
Welding
Output
Amp
Range
DC
300
Amp
300 A @
32 Volts
DC, 60%
Duty Cycle
15 − 395
72
(70)
21M
__
61
3.6*
35
1.1*
33
1.1*
31
1.0*
31
3.1*
450
Amp
450 A @
38 Volts
DC, 60%
Duty Cycle
20 − 590
72
(70)
21M
102
3.5*
89
3.1*
54
1.5*
51
1.4*
47
1.2*
650
Amp
650 A @
44 Volts
DC, 60%
Duty Cycle
50 − 850
72
(70)
21M
−−
124
5.2*
75
1.7*
71
1.6*
65
1.5*
Model
KVA
KW
25
1.5*
24.5
1.3*
13.8
0.67*
45
1.5*
36
1.2*
35.5
1.2*
23.3
0.51*
62
2.6*
50
2.1*
49.4
2.1*
36
0.58*
*While idling
( ) Indicates specification differences for CE models
cover_om 4/95 − ST-800 168-B
© 1996 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
Inverter Power Supplies
Intellitig
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
*
*
*
*
*
*
*
*
*
*
*
*
*
*
6.
6 Months — Batteries
90 Days — Parts and Labor
*
*
*
*
*
MIG Guns/TIG Torches
APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches
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
Inverters (input and output rectifiers only)
5.
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.)
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 6/95
Declaration of Conformity For
European Community (CE) Products
NOTE
This information is provided for units with CE certification (see rating label on unit.)
Miller Electric Mfg. Co.
Manufacturer’s Name:
1635 W. Spencer Street
Appleton, WI 54914 USA
Manufacturer’s Address:
Declares that the product:
Goldstar® 402, 602, And 852
conforms to the following Directives and Standards:
Directives
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Low Voltage Directive: 73/23/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Standards
Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990
Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1
(April 1995 − Draft revision)
Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989
Insulation coordination for equipment within low-voltage systems:
Part 1: Principles, requirements and tests: IEC 664-1: 1992
Electromagnetic compatibility (EMC) Product standard for arc welding equipment:
EN50199: August 1995
European Contact:
Telephone:
Fax:
dec_con1 10/95
Mr. Luigi Vacchini, Managing Director
MILLER Europe S.P.A.
Via Privata Iseo
20098 San Giuliano
Milanese, Italy
39(02)98290-1
39(02)98281-552
SECTION 1 − SAFETY PRECAUTIONS FOR ARC WELDING
OM-222D 1/96
safety_som1 4/95
1-1. 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.
1-2. 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 1-4. 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-222 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.
1-3. 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-222 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.
1-4. 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.
1-5. 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-222 Page 3
SECTION 2 − DEFINITIONS
2-1. Warning Label Definitions
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
1.1
1.2
1.3
2
1
1.1
2.1
1.3
1.2
2.2
2.3
3
2
2.1
2.2
3.1
2.3
3.2
3
3.1
3.2
3.3
3.3
4
4.1
4
4.1
+
+
+
5
6
5
+
Electric shock from welding
electrode or wiring can kill.
Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
Protect yourself from electric
shock by insulating yourself
from work and ground.
Disconnect input plug or
power before working on
machine.
Breathing welding fumes can
be hazardous to your health.
Keep your head out of the
fumes.
Use forced ventilation or local
exhaust to remove the fumes.
Use ventilating fan to remove
fumes.
Welding sparks can cause
explosion or fire.
Keep flammables away from
welding. Do not weld near
flammables.
Welding sparks can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
Do not weld on drums or any
closed containers.
Arc rays can burn eyes and
injure skin.
Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
Become trained and read the
instructions before working on
the machine or welding.
Do not remove or paint over
(cover) the label.
6
S-176 254-A
1/96
OM-222 Page 4
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
Electric shock from wiring can kill.
Disconnect input plug or power
before working on machine.
Read the Owner’s Manual before
working on this machine.
1
2
3
1
2
?
V
?
A
3
?
V
4
5
ÍÍÍ
ÍÍÍ
ÍÍÍ
ÍÍÍ
ÍÍÍ
5
3
Consult rating label for input
power requirements, and
check power available at the
job site − they must match.
Read Owner’s Manual and
inside labels for connection
points and procedures.
Move jumper links as shown
on inside label to match
voltage at job site.
Having a loop of extra length,
connect grounding conductor
first.
Connect line input conductors
as shown on inside label −
double-check all connections,
jumper link positions, and
input voltage before applying
power.
4
S-179 290
1/96
1
1
2
3
2
3
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from wiring and
exposed weld terminals can
kill.
Close door before turning on
unit.
S-179 563
1/96
1
1
1
2
3
4
5
2
3
4
5
6
6
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from welding
electrode or wiring can kill.
Sparks from arcing electrode
can cause explosion or fire −
disconnect cable for process
not in use.
Read Owner’s Manual for
connection procedures.
Electric shock from wiring can
kill.
Disconnect input power
before working on unit or
making terminal strip
connections.
Nameplate D-179 389
OM-222 Page 5
2-2. Manufacturer’s Rating Labels For CE Products
Match label to one on
unit. See Section 3-1.
S-174 342 / S-174 340 / S-174 341
OM-222 Page 6
2-3. Symbols And Definitions
NOTE
A
U0
I1
IP
Some symbols are found only on CE products.
Amperes
Amperage Control/
Panel
Gas Tungsten Arc
Welding (GTAW)
Shielded Metal Arc
Welding (SMAW)
Temperature
Do Not Switch
While Welding
Arc Force (DIG)
Percent
Output
Circuit Breaker
Remote
Protective Earth
(Ground)
Positive
Negative
Input
On
Off
Hertz
Direct Current
Conventional Load
Voltage
Line Connection
Duty Cycle
Three-Phase
Transformer
Rectifier
KVA
Work Connection
Rated No Load
Voltage (Average)
U1
Primary Voltage
Primary Current
I2
Rated Welding
Current
Degree Of
Protection
Three-Phase
Wire Feeder
Electrode
Connection
Hz
U2
X
S1
V
Volts
OM-222 Page 7
SECTION 3 − INSTALLATION
3-1. Selecting A Location
1
2
Lifting Eye
Lifting Forks
Use lifting eye or lifting forks to
move unit.
Movement
If using lifting forks, extend forks
beyond opposite side of unit.
1
3
Rating Label (Non CE Models
Only)
Use rating label to determine input
power needs. Label located under
front access door.
OR
2
4
Plate Label (CE Models Only)
Label located under front access
door.
Location And Airflow
5
6
Rating Label (CE Models
Only)
Use rating label to determine input
power needs. Label located on rear
access door (see Section 2-2).
3
6
Line Disconnect Device
Locate unit near correct input power supply.
18 in
(460 mm)
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
4
5
18 in
(460 mm)
3-2. Dimensions And Weights
Dimensions
C
D
E
4 Holes
A
Height
27-1/4 in (692 mm)
Width
22-1/4 in (565 mm)
Depth*
35-3/4 in (908 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
*300 Amp Model = 28-1/4 in (718 mm)
**300 Amp Model = 25-7/8 in (657 mm)
Weight
300 Amp
Net: 352 lb (160 kg)
Ship: 366 lb (166 kg)
450 Amp
Net: 404 lb (183 kg)
Ship: 418 lb (190 kg)
650 Amp
Net: 505 lb (299 kg)
Ship: 519 lb (235 kg)
B
Ref. ST-153 556-A
OM-222 Page 8
3-3. Tipping
Y Be careful when placing or
moving unit over uneven
surfaces.
3-4. 115 VAC Receptacle And Circuit Breakers
Y Turn Off power before
connecting to receptacle.
1
115 V 15 A AC Receptacle
RC9
Power is shared between RC9 and
Remote 14 receptacle RC8 or
terminal strip 1T (see Section 3-7).
2
3
Circuit Breaker CB1
Circuit Breaker CB2
CB1 protects 115 volts ac portion of
RC8, 1T, and RC9 from overload.
3
CB2 protects 24 volts ac portion of
RC8 and 1T from overload.
Press button to reset breaker.
2
1
Ref. ST-800 101-C
OM-222 Page 9
3-5. Weld Output Terminals And Selecting Cable Sizes
Y ARC WELDING can cause Electromagnetic Interference.
To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed
and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving
the welding machine, using shielded cables, using line filters, or shielding the work area.
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft (30 m) Or Less
Turn Off power before
connecting to weld
output terminals
Electrode
Work
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
3-6. 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
* Not Used
OM-222 Page 10
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
3-7. Connecting Remote Control
1
Remote 14 Receptacle RC8
Connect remote control to RC8. If
plug does not fit, wire cord to terminal strip 1T.
Y Turn Off power before
opening terminal strip cover.
2
3
4
OR
OR
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
D M
G
E F
2
3
4
C
E
REMOTE
OUTPUT
CONTROL
D
I
J
A
B
N
P
115 VAC
24VAC
REMOTE
REMOTE
REMOTE
VOLTAGE
CONTACTOR CONTACTOR
SENSE
K
GND
M
L
REMOTE
POWER ON/OFF
S-162 895-B
Ref. ST-800 898 / Ref. S-0004-A / S-0750
OM-222 Page 11
3-8. Electrical Service Guide
60 Hertz Models
300 Amp Model
450 Amp Model
650 Amp Model
Input Voltage
230
460
575
200
230
460
575
230
460
575
Input Amperes At Rated Output
61
31
25
102
89
45
36
124
62
50
Max Recommended Standard Fuse Or
Circuit Breaker Rating In Amperes
90
45
35
150
125
70
50
175
90
70
Min Input Conductor Size In AWG/Kcmil
8
10
12
4
4
8
10
3
8
8
114
(35)
308
(94)
296
(90)
118
(36)
156
(47)
276
(84)
290
(88)
125
(38)
182
(55)
284
(86)
8
10
12
6
6
8
10
6
8
8
Max Recommended Input Conductor
Length In Feet (Meters)
Min Grounding Conductor Size In AWG/
Kcmil
Reference: 1993 National Electrical Code (NEC)
50 Hertz Models
S-0092-J
300 Amp Model
450 Amp Model
650 Amp Model
Input Voltage
380
400
440
380
400
440
380
400
440
Input Amperes At Rated Output
35
33
31
54
51
47
75
71
65
Max Recommended Standard Fuse Or
Circuit Breaker Rating In Amperes
60
50
50
80
80
70
125
110
100
Min Input Conductor Size In AWG/Kcmil
10
10
10
8
8
8
6
6
6
210
(64)
233
(71)
282
(86)
188
(57)
209
(64)
253
(77)
189
(58)
210
(64)
254
(77)
10
10
10
8
8
8
6
6
8
Max Recommended Input Conductor
Length In Feet (Meters)
Min Grounding Conductor Size In AWG/
Kcmil
Reference: 1993 National Electrical Code (NEC)
OM-222 Page 12
S-0092-J
3-9. Placing Jumper Links And Connecting Input Power
200 VOLTS
230 VOLTS
460 VOLTS
Ref. S-174 976-A
230 VOLTS
1
460 VOLTS
575 VOLTS
Ref. S-174 973-A
220 VOLTS
380 VOLTS
400 VOLTS
440 VOLTS
(FACTORY OPTION)
Ref. S-174 975-A
2
Do not overtighten
jumper link nuts.
GND/PE
Earth
Ground
4
L1 (U)
L2 (V)
L3 (W)
Connect GND/PE
Conductor First.
6
3
IMPORTANT
3
Input Contactor
5
L1 (U)
L2 (V)
L3 (W)
Tools Needed:
3/8 in
3/8 in
GND/
PE
Connect GND/PE
Conductor First.
ST-800 103-A / Ref. ST-801 116
Check input voltage available at site.
3
1
See Section 3-8.
Jumper Link Label
Check label − only one is on unit.
2
Jumper Links
Move jumper links to match input voltage.
4
Input And Grounding Conductors
Line Disconnect Device
See Section 3-8.
5
Reed Switch (Ground Current Sensor)
(Optional)
6
Grounding Conductor
If unit is equipped with optional ground current sensor, route grounding conductor
through reed switch two times and connect
to ground terminal.
Close access door.
OM-222 Page 13
SECTION 4 − OPERATION
4-1. Controls
1
2
3
9
4
5
8
7
6
Ref. ST-800 101-C
1
Polarity Selector Switch (Optional On
50 Hz Models)
To change polarity on models not equipped
with a Polarity Selector switch, reverse work
and electrode cables at the weld output terminals (see Section 3-5).
Y Turn Off Power before reversing
cables.
2
Arc Force (Dig) Control
Control increases SMAW short-circuit
amperage which allows the operator to use
a very short arc length without sticking the
OM-222 Page 14
electrode.
8
Set control at 0 for normal welding
amperage. Turn clockwise to increase shortcircuit amperage.
For front panel control, place switch in Panel
position. For remote control, place switch in
Remote position, and connect remote device (see Section 3-7).
3
Hot Start Switch
Turn switch On for SMAW and Off for GTAW
welding.
4
5
6
7
Amperage Adjustment Control
Digital Meters (Optional)
Power Switch With Indicator Light
High Temperature Shutdown Light
9
Remote Amperage Control Switch
Output Switch (Contactor)
For front panel control of output, place switch
in Panel position. For remote control of output, place switch in Remote position, and
connect remote device (see Section 3-7).
Y Turn Off power before connecting remote device.
4-2. 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.
Example: 60% Duty Cycle =
6 Minutes Welding
Overheating
4 Minutes Resting
A
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 / SA-168 919
SECTION 5 − MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance
Y Disconnect power before maintaining.
3 Months
Repair Or
Replace
Cracked
Weld
Cable
Replace
Unreadable
Labels
Clean And
Tighten
Weld
Terminals
6 Months
OR
Blow Out Or Vacuum
Inside,
During Heavy Service,
Clean Monthly
OM-222 Page 15
5-2. Fuse F1
Y Turn Off power before opening rear 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
5-3. Troubleshooting
Trouble
No weld output; unit completely inoperative.
Remedy
Place line disconnect switch in On position (see Section 3-9).
Check fuse F1, and replace if necessary (see Section 5-2).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-9).
Check for proper input power connections (see Section 3-9).
Check for proper jumper link position (see Section 3-9).
No weld output; Power switch pilot light
on; fan on.
If using remote control, place Output (Contactor) switch in Remote 14 position, and connect remote
control (see Sections 3-6 and 3-7). If remote is not being used, place switch in On position.
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 4-2).
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 3-5).
Clean and tighten all weld connections.
Check position of Polarity selector switch (see Section 4-1).
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 3-4).
No 24 volts ac output at Remote 14 receptacle, or terminal strip 1T.
Reset circuit breaker CB2 (see Section 3-4).
Fan not operating. NOTE: fan only
runs when cooling is necessary.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
OM-222 Page 16
SECTION 6 − ELECTRICAL DIAGRAM
For Primary Circuit Diagram Portion, refer to the Circuit Diagram
located inside the wrapper of the welding power source.
SC-175 486
Figure 6-1. Circuit Diagram
OM-222 Page 17
24
22
14
16
26
Fig 7-2
Fig 7-3 & 4
24
33
32
31
3
2
1
30
29
4
28
27
5
25
6
7
8
12
11
13
4
10
9
15
17 18
3
20
19
Fig 7-5
21
23
SECTION 7 − PARTS LIST
ST-800 875-A
Figure 7-1. Main Assembly (452 Model Illustrated)
OM-222 Page 18
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Model
302 452 652
Figure 7-1. Main Assembly
. . . 1 . . . . . . . . . . . . +168 793
. . . 1 . . . . . . . . . . . . +179 432
. . . 2 . . . . . . . . . . . . . 162 806
. . . 2 . . . . . . . . . . . . . 179 431
. . . 3 . . . . . . . . . . . . . 164 699
. . . 3 . . . . . . . . . . . . . 164 700
. . . 4 . . . . . . . . . . . . . 162 816
. . . 5 . . . . . . . . . . . . . 162 820
. . . 6 . . . . . . . . . . . . . 162 830
. . . 7 . . . . . . . . . . . . . 177 279
. . . 8 . . . . . . . . . . . . . 604 536
. . . 9 . . . . . . . . . . . . . 134 201
. . . 10 . . . . . . . . . . . . . 162 821
. . . 11 . . . . HD1 . . . . 156 313
. . . 11 . . . . HD1 . . . . 148 417
. . . . . . . . . PLG14 . . 130 204
. . . . . . . . . . . . . . . . . . . 114 066
. . . 12 . . . . . Z1 . . . . 165 612
. . . 12 . . . . . Z1 . . . . 165 613
. . . 12 . . . . . Z1 . . . . 173 559
. . . . . . . . . . . . . . . . . . . 164 717
. . . 13 . . . C21-23 . . 163 906
. . . 13 . . . C21-23 . . 179 904
. . . 14 . . . . . T2 . . . . 159 042
. . . 14 . . . . . T2 . . . . 159 041
. . . 14 . . . . . T2 . . . . 159 043
. . . 15 . . . . TE1 . . . . 159 244
. . . 16 . . . . . . . . . . . . . 601 835
. . . 17 . . . . . . . . . . . . . 038 887
. . . . . . . . . . . . . . . . . . . 010 913
. . . . . . . . . . . . . . . . . . . 601 835
. . . . . . . . . . . . . . . . . . . 038 618
. . . 18 . . . . . . . . . . . . . 159 034
. . . 19 . . . . . . . . . . . . . . Fig 7-5
. . . 20 . . . . . F1 . . . *156 065
. . . 21 . . . . . W . . . . . 160 760
. . . 21 . . . . . W . . . . . 160 793
. . . 21 . . . . . W . . . . . 160 794
. . . 22 . . . . CR4 . . ♦140 750
. . . 23 . . . . . . . . . . . . +168 792
. . . 24 . . . . . . . . . . . . . 134 464
. . . 25 . . . . . . . . . . . . . 163 533
. . . 25 . . . . . . . . . . . . . 163 359
. . . 26 . . . . . T1 . . . . 172 207
. . . 27 . . . . . . . . . . . . . 172 209
. . . 28 . . . . . . . . . . . . . 172 208
. . . 26 . . . . . T1 . . . . 165 720
. . . 27 . . . . . . . . . . . . . 165 232
. . . 28 . . . . . . . . . . . . . 165 233
. . . 26 . . . . . T1 . . . . 172 213
. . . 27 . . . . . . . . . . . . . 172 215
. . . 28 . . . . . . . . . . . . . 172 214
. . . 26 . . . . . T1 . . . . 172 219
. . . 27 . . . . . . . . . . . . . 172 221
. . . 28 . . . . . . . . . . . . . 172 220
. . . 26 . . . . . T1 . . . . 172 403
. . . 27 . . . . . . . . . . . . . 172 404
. . . 28 . . . . . . . . . . . . . 172 405
. . PANEL, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . CHANNEL, upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4 . . . 4
. . BAR, mtg lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . GASKET, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . SCREW, .312-18 x 1.75 hexhd-pln gr 5 . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . STAND-OFF SUPPORT, PC card .312/.375 . . . . . . . . . . . . . . . 4 . . . 4 . . . 4
. . BRACKET, mtg LEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . TRANSDUCER, current 300A module . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . TRANSDUCER, current 1000A module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . CONNECTOR, rect skt 20-14ga . . . . . . . . . . . . . . . . . . . . . . . 3 . . . 3 . . . 3
. . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BUS BAR, stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CAPACITOR, 60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . 3 . . . 3
. . CAPACITOR, 50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . 3 . . . 3
. . TRANSFORMER, control 50VA 24V 230/460/575 (60Hz) . . . 1 . . . 1 . . . 1
. . TRANSFORMER, control 50VA 24V 200/230/460 (60Hz) . . . . . . . . . 1
. . TRANSFORMER, control 50VA 24V (50Hz) . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . PRIMARY BOX, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . . 24 . . 24
. . . . STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . 24 . . 24 . . 24
. . WASHER, flat .218 ID brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . . 24 . . 24
. . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . . 24 . . 24
. . LINK, jumper term bd pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . 8 . . . 8
. . HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . FUSE, crtg .5A 600V time delay . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . CONTACTOR, def prp 40A 3P 24VAC . . . . . . . . . . . . . . . . . . . . 1
. . CONTACTOR, def prp 60A 3P 24VAC . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONTACTOR, def prp 75A 3P 24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SWITCH, reed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . PANEL, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . TRANSFORMER, pwr main 230/460/575 (consisting of) . . . . 1
. . . . COIL, pri/sec 230/460/575 (center & RH) . . . . . . . . . . . . . . . . 2
. . . . COIL, pri/sec 230/460/575 (LH) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . TRANSFORMER, pwr main 200/230/460 (consisting of) . . . . . . . . . . 1
. . . . COIL, pri/sec 200/230/460 (center & RH) . . . . . . . . . . . . . . . . . . . . . . 2
. . . . COIL, pri/sec 200/230/460 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . TRANSFORMER, pwr main 230/460/575 (consisting of) . . . . . . . . . . 1
. . . . COIL, pri/sec 230/460/575 (center & RH) . . . . . . . . . . . . . . . . . . . . . . 2
. . . . COIL, pri/sec 230/460/575 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . TRANSFORMER, pwr main 230/460/575 (consisting of) . . . . . . . . . . . . . . . 1
. . . . COIL, pri/sec 230/460/575 (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . COIL, pri/sec 230/460/575 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . TRANSFORMER, pwr main 380/400/440 (consisting of) . . . . 1
. . . . COIL, pri/sec (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . COIL, pri/sec (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-222 Page 19
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Model
302 452 652
Figure 7-1. Main Assembly (Continued)
. . . 26 . . . . . T1 . . . . 172 408
. . . 27 . . . . . . . . . . . . . 172 410
. . . 28 . . . . . . . . . . . . . 172 409
. . . 26 . . . . . T1 . . . . 172 413
. . . 27 . . . . . . . . . . . . . 172 416
. . . 28 . . . . . . . . . . . . . 172 415
. . . . . . . . . TP1,2 . . . 119 581
. . . . . . . . . TP4,5 . . . 168 891
. . . . . . . . . PLG13 . . 169 242
. . . . . . . . . . . . . . . . . . . 009 419
. . . . . . . . . PLG6 . . . 168 847
. . . . . . . . . . . . . . . . . . . 147 995
. . . . . . . . . . RC6 . . . . 168 845
. . . . . . . . . . . . . . . . . . . 147 996
. . . 29 . . . . . . . . . . . . . 144 468
. . . 30 . . . . . . . . . . . . . 605 538
. . . 31 . . . . . . . . . . . . . 161 294
. . . 32 . . . . . . . . . . . . . . Fig 7-2
. . . 33 . . . . SR1 . . . . 175 070
. . . 33 . . . . SR1 . . . . 175 071
. . . 33 . . . . SR1 . . . . 175 072
. . . . . . . . . PLG7 . . . 152 249
. . . . . . . . . . . . . . . . . . . 147 996
. . . . . . . . . . RC7 . . . . 168 846
. . . . . . . . . . . . . . . . . . . 147 995
. . . . . . . . . . . . . . . . . . . 010 467
. . TRANSFORMER, pwr main 380/400/440 (consisting of) . . . . . . . . . . 1
. . . . COIL, pri/sec (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . COIL, pri/sec (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . TRANSFORMER, pwr main 380/400/440 (consisting of) . . . . . . . . . . . . . . . 1
. . . . COIL, pri/sec (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . COIL, pri/sec (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . THERMOSTAT, NC (Included w/T1) . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . THERMOSTAT, NC (Included w/T1) . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . CONNECTOR, rect pin 20-14ga . . . . . . . . . . . . . . . . . . . . . . . 9 . . . 9 . . . 9
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . 12 . . 12 . . 12
. . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . CONNECTOR, rect pin 22-18ga . . . . . . . . . . . . . . . . . . . . . . 12 . . 12 . . 12
. . STRIP, polyest gl lam .062 x 2.375 x 3.500 . . . . . . . . . . . . . . . . 3 . . . 3 . . . 4
. . CABLE TIE, 0-4.500 bundle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . 3 . . . 4
. . BRACKET, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . RECTIFIER, si diode (Fig 7-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RECTIFIER, SCR main (Fig 7-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RECTIFIER, SCR main (Fig 7-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . CONNECTOR, rect pin 22-18ga . . . . . . . . . . . . . . . . . . . . . . 15 . . 15 . . 15
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . 15 . . 15 . . 15
. . CONNECTOR, clamp cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
♦Part of Option 042 983 Ground Current Sensor
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-222 Page 20
Item
No.
Dia.
Mkgs.
Part
No.
Quantity
Model
302 452 652
Description
Figure 7-2. Panel, Front w/Components (Fig 7-1 Item 32)
. . . 1 . . . . . S5 . . ♦169 331
. . . 1 . . . . . S5 . . ♦169 332
. . . 2 . . . . PC1 . . . . 158 758
. . . 2 . . . . PC1 . . . . 165 904
. . . 2 . . . . PC1 . . . . 165 905
. . . 2 . . . . PC1 . . . . 175 035
. . . 2 . . . . PC1 . . . . 174 641
. . . 2 . . . . PC1 . . . . 174 642
. . . . . . . . . PLG1 . . . 158 720
. . . . . . . . . PLG3 . . . 169 240
. . . . . . . . . . . . . . . . . . . 147 995
. . . . . . . . . PLG5 . . . 152 249
. . . . . . . . . . . . . . . . . . . 147 995
. . . 3 . . . . CR3 . . . . 006 393
. . . 4 . . . . CR5 . ♦♦006 393
. . . 5 . . . CB1,2 . . . 093 995
. . . 6 . . . . RC9 . . . . 604 176
. . . 7 . . . . . . . . . . . . . 163 855
. . . . . . . . . . RC8 . . . . 143 976
. . . . . . . . . . . . . . . . . . . 079 534
. . . . . . . . . . . C3 . . . . 163 863
. . . . . . . . . . . C6 . . . . 163 861
. . . . . . . . . . C13 . . . . 163 858
. . . . . . . . . . C14 . . . . 163 857
. . . 8 . . . . . . . . . . . . . 162 802
. . SWITCH, mode polarity (single deck) . . . . . . . . . . . . . . . . . . . . . 1
. . SWITCH, mode polarity (double deck) . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . CIRCUIT CARD, control (60Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CIRCUIT CARD, control (60Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CIRCUIT CARD, control (60Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CIRCUIT CARD, control (50Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CIRCUIT CARD, control (50Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CIRCUIT CARD, control (50HZ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONNECTOR & SOCKETS, (see Fig 7-3 & 4)
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . 20 . . 20 . . 20
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . 15 . . 15 . . 15
. . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . 2 . . . 2 . . . 2
. . RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . CONNECTOR/CAPACITOR, w/leads (consisting of) . . . . . . . . 1 . . . 1 . . . 1
. . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . CONNECTOR, circ skt push-in 14-18ga . . . . . . . . . . . . . . 14 . . 14 . . 14
. . . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
5
1
6
8
7
2
3
4
9
16
17
18
30
16
38
29
30
28
26
27
31
24
19
23
37
36
35 34
33
14 13 12 11
15
25
32
10
20
22
21
ST-800 876-A
Figure 7-2. Panel, Front w/Components (452 Model Illustrated)
OM-222 Page 21
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Model
302 452 652
Figure 7-2. Panel, Front w/Components (Fig 7-1 Item 32)
(Continued)
. . . 9 . . . . POS . . . 039 047 . . TERMINAL, pwr output red (consisting of) . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 10 . . . . NEG . . . 039 046 . . TERMINAL, pwr output black (consisting of) . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 11 . . . . . . . . . . . . . 601 976 . . . . SCREW, .500-13 x 1.500hexhd stl . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 12 . . . . . . . . . . . . . 039 049 . . . . TERMINAL BOARD, red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 12 . . . . . . . . . . . . . 039 045 . . . . TERMINAL BOARD, black . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 13 . . . . . . . . . . . . . 601 880 . . . . NUT, .500-13 x .31 high stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 14 . . . . . . . . . . . . . 039 044 . . . . BUS BAR, term bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 15 . . . . . . . . . . . . . 601 879 . . . . NUT, .500-13 x .44 high stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 16 . . . . C4,5 . . . 128 750 . . CAPACITOR, cer disc .1uf 500VDC . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . . 17 . . . . . . . . . . . . . 161 303 . . SPRING, cprsn .600 OD x .072 wire x 1.500 lg . . . . . . . . . . . . 3 . . . 3 . . . 3
. . . 18 . . . . R4,5 . . . 136 076 . . RESISTOR, WW fxd 30W 200 ohm . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . . 19 . . . . . . . . . . . . . 174 939 . . PLATE, control lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . 1T . . . . 159 040 . . BLOCK, term 20A 12P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 21 . . . . . . . . . . . . . 162 828 . . PANEL, mtg rcpt/terminal strip . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 22 . . . . . . . . . . . . . 070 371 . . BLANK, snap-in nyl 1.093/1.125mtg hole . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 23 . . . . . . . . . . . . . 162 891 . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 24 . . . . . . . . . . . . +160 530 . . COVER, stud output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 25 . . . . . . . . . . . . . 160 935 . . CLIP, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . 3 . . . 3
. . . 26 . . . . . . . . . . . . . 601 835 . . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . . . . . . . . . . . . . . . . . . 010 913 . . WASHER, flat .218 ID x .460 OD x .031thk brs . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 27 . . . . . . . . . . . . . 159 863 . . ELECTRONICS BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 28 . . . . . . . . . . . . . 038 887 . . STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 29 . . . S1,3,4 . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . 3 . . . 3
. . . 30 . . . . R1,2 . . . 035 897 . . POTENTIOMETER, CP std slot 1/T 2W 1K ohm . . . . . . . . . . . 2 . . . 2 . . . 2
. . . 31 . . . . CR1 . . . . 134 163 . . RELAY, encl 24/120VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 32 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . 1 . . . 1 . . . 1
. . . 33 . . . . . S2 . . . . 159 039 . . SWITCH, rocker SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 34 . . . . PL2 . . . . 159 522 . . LED, yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 35 . . . . . . . . . . . . . 159 036 . . LENS, LED clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 36 . . . . . . . . . . . . . 097 924 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 37 . . . . . . . . . . . . . 097 922 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 38 . . . . . . . . . . . ♦148 956 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . . . . . . ♦♦♦042 967 . . DIGITAL METER KIT, (consisting of) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . ♦♦♦043 107 . . DIGITAL METER KIT, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . ♦♦♦043 108 . . DIGITAL METER KIT, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PC2 . . . . 158 791 . . . . CIRCUIT CARD, digital meter . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PC2 . . . . 163 788 . . . . CIRCUIT CARD, digital meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PC2 . . . . 163 789 . . . . CIRCUIT CARD, digital meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG4,11 . . 148 439 . . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . . . . . . . . . . . . . . . . . . 147 995 . . . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . 10 . . 10 . . 10
. . . . . . . . . PLG10 . . 153 501 . . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . . . . . . . . . . . 147 995 . . . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . 6 . . . 6 . . . 6
. . . . . . . . . . . . . . . . . . . 165 316 . . . . STAND-OFF, No. 6-32 x .875 lg . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4 . . . 4
♦Standard w/60 Hz/Optional w/50 Hz
♦♦Part of Option 042 983 Ground Current Sensor
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦♦♦Optional
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-222 Page 22
Item
No.
Dia.
Mkgs.
Part
No.
SR1
175 070
. . . 1 . . . . C7-12 . . . .
... 2 ...............
... 3 ...............
... 4 ...............
. . . 5 . . . . . TP3 . . . . .
. . . 6 . . . . . TP6 . . . . .
. . . 7 . . . SCR1-6 . . .
... 8 ...............
. . . . . . . . . . PLG1 . . . .
.....................
... 9 ...............
Description
Figure 7-3. Rectifier, Si Diode (302 Model) (Fig 7-1 Item 33)
048 420
177 316
177 317
175 258
604 515
168 898
161 668
028 516
158 720
147 995
166 667
. . CAPACITOR, cer disc .01uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HEAT SINK, rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HEAT SINK, rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, thyristor rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . THYRISTOR, SCR 300A 300V hockey puck . . . . . . . . . . . . . . . . . . . . . . .
. . PIN, spring CS .125 x .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, thyristor rectifier 4.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
3
2
3
1
1
6
3
1
12
3
4
3
1
Quantity
5
2
6
2
7
3
1
8
ST-800 697-B
9
Figure 7-3. Rectifier, Si Diode SR1 (302 Model)
4
5
6
7
ST-800 696-A
Figure 7-4. Rectifier, SCR Main SR1 (452 & 652 Model)
Item
No.
Dia.
Mkgs.
Part
No.
Figure 7-4. Rectifier, SCR Main (452 & 652 Model)
(Fig 7-1 Item 33)
SR1
. . . 1 . . . . C7-12 . . . .
... 2 ...............
... 3 ...............
... 4 ...............
. . . 5 . . . SCR1-6 . . .
. . . 5 . . . SCR1-6 . . .
... 6 ...............
... 7 ...............
. . . . . . . . . . PLG1 . . . .
.....................
. . . . . . . . . . . TP3 . . . . .
. . . . . . . . . . . TP6 . . . . .
Description
048 420
176 168
166 667
160 962
161 668
148 091
160 961
161 302
158 720
147 995
168 895
168 894
Quantity
175 071 175 072
. . CAPACITOR, cer disc .01uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . 6
. . BAR, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . CLAMP, spring thyristor rectifier 5.500 . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . 3
. . HEAT SINK, rectifier snowflake .800 . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . 6
. . THYRISTOR, SCR 300A 300V hockey puck . . . . . . . . . . . . . . . . . . 6
. . THYRISTOR, SCR 865A 300V hockey puck . . . . . . . . . . . . . . . . . . . . . . . . 6
. . HEAT SINK, rectifier snowflake 1.600 . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . 3
. . CLAMP, thyristor rectifier 5.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . 3
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . 12
. . THERMOSTAT, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . THERMOSTAT, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-222 Page 23
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-5. Panel, Rear w/Components (Fig 7-1 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1
1
1
2
1
1
2
1
1
1
1
4
5
6
2
1
7
8
10
9
ST-800 707-A
Figure 7-5. 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-222 Page 24
Notes
OPTIONS AND ACCESSORIES
A variety of optional controls and accessories allow you to tailor your Gold Star welder to meet your specific needs. All
are specifically designed to be used with Gold Star Series power sources, so you never have to worry about
compatibility.
REMOTE ON/OFF CONTROL
(#042 869)
Allows you to turn your Gold Star
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.
DIGITAL METERS
(#042 967 Field) Gold Star 302
(#043 107 Field) Gold Star 452
(#043 108 Field) Gold Star 652
Easy to install, front panel mount,
digital amp and volt meters.
STANDARD RUNNING GEAR
(#042 886)
The large 10 in. (254 mm) rear
wheels and 5 in. (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.
INTERNATIONAL CABLE ADAPTER
(#168 077) Female 1 Qty.
Dinse brand insulated female twist
lock connector installs on output
stud, providing quick disconnect of
secondary weld cables.
(#042 418) Male 1 Qty.
Cable mounted Dinse brand
insulated male twist lock connector
accepts #1 or #2 AWG cable sizes.
ENVIRONMENTAL
PROTECTION PACKAGE
(#043 049 Factory)
Internal machine components are
sprayed with a protective
polyurethane coating.
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 Field)
Attaches to front of power source,
allowing weld cables to be stored
near the control panel.
AIR FILTER KIT
(#042 939 Field)
Protect your Gold Star from dusty,
dirty environments with this
reusable air filter that easily
attaches and detaches from the
front of the power source.
GROUND CURRENT SENSOR
(#042 983 Factory)
(#043 146 Field)
Disables power source if weld
current is present on primary
ground.
WATER COOLANT
SYSTEMS
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.
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.
REMOTE CONTROLS
AND SWITCHES
(#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.
(#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.
1/95
OPTIONS AND ACCESSORIES
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
RFC-14 FOOT CONTROL
(#129 339)
Heavy duty foot current and
contactor control. Includes 20 ft. (6
m) cord and 14-pin plug.
This extension cord makes a direct
connection between the power
source and the accessory control.
No messy splicing or adapting
required.
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)
GMAW/FCAW WELDING
S-32S PORTABLE WIRE
FEEDER
(#088 816)
For .035 - 5/64 in. (0.6 - 2.0 mm)
flux-cored wire. See literature,
Index No. M/6.21.
SUPER S-32P SERIES
COMPACT, PORTABLE WIRE
FEEDER
(#159 928)
For .035 - 5/64 in. (0.6 - 2.0 mm)
flux-cored wire. See literature,
Index No. M/6.26.
1/95
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