Miller | KG181431 | Owner Manual | Miller MAXTRON 450 380/415V CE User manual

Miller MAXTRON 450 380/415V CE User manual
Millerfi
July
Form:
1996
OM-167302C
L__Effe ctive With Serial No. KG181431
OWNERS
MANUAL
MaxtronTM 450
CCICV DC
Welding
Rated
Welding
Output
Power Source For GMAW,
Voltage
Range
In CV
Amperage
Range In
CC Mode
Mode
-
CE
GTAW, SMAW, FCAW, CAC-A, GMAW-P, GTAW-P, And SAW Welding
Maximum
Open-
i~
Circuit
Voltage DC
Rating
80 VDC
21
Amperes Input at
Output
50 Hz, Three-Phase
Rated Load
380 V
I
415 V
35
25
25
I
(0.7)
(0.5)*
(0.2)
KVA
I
KW
400 A ' 34 Volts
DC, 100% Duty
1238
V
5565
A
38
(08)
Cycle
*While
I
idling
cover_om 4/95
ST-BOO 763-A
'
1996 MILLER EIe~tric
Mfg.
Co.
PRINTED IN USA
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MILLERS
TRUE BLUEfi LIMITED WARRANTY
(Equipment
This limited warranty supersedes all
I
with
Effective January 1, 1995
serial number preface of KD
a
previous MILLER warranties
and is exclusive with
LIMITED WARRANTY
Subject to the terms snd conditions below, MILLER Electric
Mtg. Co., Appleton, Wisconsin, wsrrsnts to its original retail purchaser thst new
MILLER equipment sold sher the effective date ot this limited wsrrenty is tree ot de
tects in material snd workmanship st the time it is shipped by MILLER. THtS WAR
RANTY IS EXPRESSLY tN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
no
newer)
other guarantees
5.
6 Months
6.
go
or
warranties expressed
or
implied.
Bafteriea
Parts and Labor
Days
*
or
MtG Guns/TIG Torches
APT, ZIPCUT & PLAZCUT Model Plasma Curling Torches
IMPLtED, INCLUDtNG THE WARRANTIES OF MERCHANTABILITY AND FIT
NESS.
Remote Controls
*
wsrranty periods listed below, MILLER will repait or reptsce sny warparts or components thst tell due to such detects in material or workmanship.
MILLER tnust be notified in writing within thirty (30) days of such detect or failure, et
which time MtLLER will provide instructions on the warranty claim procedures to be
tollowed.
Accessory Kits
Within the
Replacement
Parts
rented
MILLERS
True Bluefi Limited
Items furnished
1.
Warranty
shall not
apply
to:
by MILLER, but manufactured by others, such
trade accessories. These items
are
covered
by
as
the manufacturers
engines
or
warranty, if
any.
MILLER shell honor warranty claims on werrented equipment listed below in the
event ot such e failure within the warranty time periods. All warranty time periods
Consumable components; such as contact tips, cusing nozzles, contaclors
relays or parts that tail due to normal wear.
2.
stert on the dete thet the
equipment wee delivered to the original retell purcheser, or
year after the equipment is sent to a North American distributor or eighteen
months after the equipment is sent to an International distributor.
and
one
that has been modified
by any party other than MILLER, or equip
improperly installed, improperly operated or misused
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.
Equipment
3.
ment that has been
5 Years Parts 3
1.
*
Original
*
tnverters
Years Labor
based upon
main power rectifiers
(input
and
output rectifiers only)
MILLER PRODUCTSARE INTENDED FOR PURCHASE AND USE BY COMMER
2.
Parts and Labor
3 Years
CIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EOUIPMENT.
Transformer/Rectitier Power Sources
*
Plasma Arc
Cuning
Power Sources
In the event of a warranty claim covered by this warranty, the exclusive remedies
shall be, at MILLERS option: (1) repair; or (2) replacement; or, where authorized in
writing by MILLER inappropriate cases, (3) the reasonable coat of repair or replace
ment at an authorized MILLER service station; or (4) payment of orcredit for the pur
Semi-Automatic and Automatic Wire Feeders
*
tnverter Power
Supplies
tntellitig
price (leas reasonable depreciation based upon actual use) upon return of the
at customers risk and espenae. MILLERS option of repair or replacement
will be FOB., Factory at Appleton, Wisconsin, or FOB. at a MILLER authorized ser
vice facility as determined by MILLER. Theretore no compensation or reimburse
chase
Robots
3.
goods
Parts and Labor
2 Years
Driven Welding Generators
(NOTE: Engines are warranted separately by
ment for
Engine
*
4.
Air
the
engine manutacturer.)
Parts and Labor
Motor Driven Guns
*
Process Controllers
*
Water Coolant
*
HF Units
*
Grids
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR
RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL
THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
IHPS Power Sources
Spot
Systems
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN
CLUDING ANY IMPUED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EOUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
Welders
*
Load Banks
*
SDX Transformers
Running Gear/Trailers
Cuffing Torches (escept APT, ZIPCUT
Tecumseh Engines
Deutz Engines (outside North America)
Plasma
*
coats of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVEHT SHALL MILLER BE
LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEOUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CON
TRACt TORT OR ANY OTHER LEGAL THEORY.
Compressors
1 Year
transportation
Some states in the U.S.A. do not allow limitations of how tong an implied warranty
lasts, or the esclusion of incidental, indirect, special or consequential damages, so
& PLAZCUT
the above limitation or exclusion may not apply to you. This warranty provides spe
cific legal rights, and other rights may be available, but may vary from state to state.
Models)
In
Canada, legislation in
some provinces provides for certain additional warranties
remedies other than as stated herein, and to the extent that they may not be
and
exclusions set out above may not apply. This Limited
limitations
the
waived,
Warranty provides specific legal rights, and other rights may be available, but may
Options
(NOTE: Field options are covered under True Bluefi for the remaining
warranty period of the product they are installed in, or for a minimum of
whichever is greater.)
one year
Field
or
vary from
province
to
province.
i-u
~Wt
I
WHO DO I CONTACT?
For
To file
help,
.
For
additional
information,
Technical Manuals
Engine
such
claim for loss
deliVering
For assistance in
.
Wiring Diagrams
contact the
as
(SerVice And Parts)
Manuals
Circuit And
a
or
damage during
Miller Electric
shipment,
contact your distributor
carrier
settling claims,
equipment
manufacturers Transportation
Department
filing
Mfg.
Co.
CALL:
~j~3jjj5~
414-735-4505
1211]
800-637-2348
or
contact your distributor and/or
FAX:
(in USA), or
(outside USA)
414-735-4136
Process Handbooks
Users
Guides
oi
Distr(butor Directories
.
WRITE:
Miller Electric
Mfg. Co.
P.O. BOX 1079
contact your distributor
Appleton,
Always provide Model
Name and Serial
or
Style
WI 54912 USA
Number
miller...wsrl 6/g5
Declaration of
Conformity For
EurOpean Community (CE) Products
Manufacturers
Name:
Miller Electric
Manufacturers
Address:
1635 W.
Declares that the
conforms to the
Co.
Spencer Street
Appleton, WI 54914 USA
M axtro flTM 450
product:
following
Mfg.
Directives and Standards:
Directives
Electromagnetic compatibility Directives: 89/336/EEC,
Low
Machinery
Voltage
92/31/EEC
Directive: 73/23/EEC
Directives: 89/392/EEC,
91/368/EEC, 93/C 133/04, 93/68/EEC
Standards
Electromagnetic compatibility (EMC)
Product standard for
EN50199:
Safety Requirements
Degrees
for Arc
of Protection
August
Welding Equipment part
provided by
Enclosures
Insulation coordination for
Part 1:
European
Contact:
Mr.
Luigi Vacchini, Managing
Milanese, Italy
Fax:
dec_coni 10/95
welding equipment:
1: EN 60974-1: 1989
(lP code):
IEC 529: 1989
equipment within low-voltage systems:
Principles, requirements and tests: lEG 664-1: 1992
MILLER Europe S.P.A.
Via Privata lseo
20098 San Giuliano
Telephone:
arc
1995
39(02)98290-1
39(02)98281-552
Director
SECTION 1
0M167 302C
-
SAFETY PRECAIJTIONS FOR ARC WELDING
7/96
safety_somi
4/95
Symbol Usage
1-1.
A
Warning! Watch Out! There are possible hazards with this
procedure! The possible hazards are shown in the adjoining symbols.
Means
~
Marks
a
special safety
~ Means NOTE; not
message.
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.
Arc
1-2.
Welding
Hazards
WARNING
a
The symbols shown below are used throughout this manuai 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 I:he more complete safety information found in the
Safety Standards listed in Section 1-4. Read and follow all Safety Standards.
persons should install, operate,
Only qualified
maintalin, and repair this unit.
During operation, keep everybody, especially children,
ELECTRIC SHOCK
can
away.
kill.
terminal in disconnect box
electrical parts can cause fatal
Touching
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.
5.
6.
when not in
cables
17.
Use
v
.
I
Keep
If
with
ear
plugs
or ear
muffs if noise level is
GASES
FUMES
AND
hazardous to your health.
these fumes and gases
health.
inside, ventilate the
welding fumes
area
and/or
be
arc
2.
is
required, ground it directly
clamp or work cable.
work
safety
work
Clamp
harness if
and
panels
or
working
covers
cable
with
worktable
as
or
replace
manual.
above floor level.
securely
in
place.
good metal-to-metal contact
near the weld as Dractical.
to
Wear
a
welding
helmet fitted with
a
proper shade of filter to
protect your face and eyes when welding orwatching (see ANSI
Z49.1 and Z87.1 listed in Safety Standards).
3.
4.
Wear
Use
and
approved safety glasses
with side shields.
protective screens or barriers to protect others from flash
glare; warn others not to watch the arc.
Wear
protective clothing made from durable, flame-resistant
(wool and leather) and foot protection.
a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained
watchpersonnearby.Weldingfumesandgasescandisplaceair
and lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
5.
Work in
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.
to
and gases.
use an
use
material
approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDS5) and the
manufacturers instruction for metals, consumables, coatings,
cleaners, and degreasers.
If ventilation is poor,
do not
ARC RAYS
and gases. Breathing
be hazardous to your
exhaust at the
Keep
workoiece
can
use
separate cable
a
your body.
only well-maintained equipment. Repair
damaged parts at once. Maintain unit according to
your head out of the fumes. Do not breathe the fumes,
remove
over
14. Use
high.
can
poorly spliced
13. Do not touch electrode it you are in contact with the work,
ground, or another electrode from a different machine.
5.
approved
or
cables.
Always verify
supply ground check and be sure that input
oower cord around wire is orooerlv connected to around
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Noise from some
use.
damaged, undersized,
a
Welding produces fumes
4.
worn,
all
I
3.
equipment
use
16.
NOISE
2.
Turn off all
10. Do not
15. Wear
damage hearing. Chipping,
processes
grinding, and welds cooling throw off pieces of
metal or slag.
1.
9.
Manual and national, state, and local codes.
can
~
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
Owners
ARC RAYS can burn eyes and skin;
NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes.
grounding
B.
grounding of the workpiece
the
a
double-check connections.
drape
parts.
attach proper
making input connections,
conductor first
12. If earth
~
1.
When
is connected to
outlet.
11. Do not
Do not touch live electrical
Wear
4.
7.
plug
that cord
dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating
mats or covers big enough to prevent any physical contact with
the work or ground.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according
to OSHA 29 CFR 191 0.147 (see Safety Standards).
Properly install and ground this equipment according to its
1.
2.
3.
or
properly grounded receptacle
live
7.
Do not weld
cadmium
on
coated metals, such as galvanized, lead, or
unless the coating is removed from the
plated steel,
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-167 302
Page
1
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CYLINDERS
1.
2.
3.
Protect
explode
can
if
4.
damaged.
high
a cylinder can explode.
pressure.
Since gas cylinders are normally part of the welding
process, be sure to treat them carefully.
5.
compressed gas cylinders from excessive heat,
shocks, slag, open flames, sparks, and arcs.
8.
Shielding
gas cylinders
If damaged,
contain gas under
6.
7.
9.
10. Read and follow instructions
in
use or
connected for
associated
equipment,
use.
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
Standards.
can
fire
cause
or
explosion.
objects
or
5.
Watch for fire, and
6.
Be
on
sparks, explosion, overheating,
can cause
fire. Check and be
sure
the
area
and others from
Protect
2.
Do not weld where
yourself
flying sparks
Remove all flammables within 35 ft
this is not
possible, tightly
strike flammable material.
(10.7 m) of the welding arc.
approved covers.
If
8.
9.
Do not
2.
Do not install unit
FALLING
near
when not in
tanks, drums,
pipes.
or
cut off
welding
wire at
use.
doing any welding.
MOVING PARTS
away from
1.
Keep
2.
Keep away
from
can cause
injury.
moving parts.
pinch points such
as
drive rolls.
or
DIRT
can
injure eyes.
1.
can
and
or
combustible
cause
safety glasses
Wear
with side shields
or
face
shield.
equipment
WELDING WIRE
lifting eye to lift unit only, NOT running gear,
gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
Use
1.
tip
as
FLYING PIECES OF METAL
EQUIPMENT
personal injury
damage.
welder to thaw frozen
from your person before
flammables.
serious
closed containers such
protective garments such as leather gIove~, heavy
shirt, cuffless trousers, high shoes, and a cap.
12. Remove any combustibles, such as a butane lighter or matches,
FIRE OR EXPLOSION can result from
unit
or
near
on,
over,
combustible surfaces.
or near
use
on
11. Wear oil-free
placing
Do not locate unit on, over,
surfaces.
partition
And Maintenance Hazards
Operation,
1.
or
the hidden side.
Do not weld
contact
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Additional Installation,
on
10. Remove stick electrode from holder
them with
cover
fire
keep a fire extinguisher nearby.
welding on a ceiling, floor, bulkhead,
pipes, unless they are properly prepared according to AWS F4. 1
(see Safety Standards).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
is safe before
flying sparks and hot metal.
can
that
7.
doing any welding.
1.
aware
can cause
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
Welding
1-3.
a
a
cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical
Install
WELDING
4.
drape
Never allow
mechanical
circuits.
3.
welding torch over a gas cylinder.
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.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is
Never
can
cause
puncture
wounds.
1.
Do not press gun
2.
Do not
trigger
until instructed to do
so.
point gun toward any part of the body, other
people, or any metal when threading welding wire.
unit.
HOT PARTS
can cause severe
1.
Do not touch hot parts bare handed.
2.
Allow
cooling period
before
working
HIGH-FREQUENCY
burns.
interfere with radio
on
gun
or
services,
1.
Have
equipment.
only qualified persons
equipment perform this
electronic
MOVING PARTS
can cause
injury.
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards closed
and securely in place.
1.
2.
2.
FIELDS
FROM
HIGH
affect
can
pacemaker
Pacemaker
arc
operations.
OM-167 302
Page
2
is
user
If notified
4.
Have
the
by the FCC about interference, stop
equipment at once.
the
installation
regularly
checked
and
maintained.
wearers
keep
away.
5.
Wearers should consult their doctor before
near
with
responsible for having a qualified
promptly correct any interference
problem resulting from the installation.
The
using
operation.
2:
familiar
installation.
electrician
3.
MAGNETIC
CURRENTS
can
and
computers,
communications
torch.
RADIATION
navigation, safety
welding, gouging,
or
going
spot welding
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
EQUIPMENT.
cause
1.
Allow
2.
Reduce current or reduce
starting to weld again.
duty cycle before
boards
duty cycle.
touchinq
can
or
or
in
capacitors
input power,
according
Maintenance
Section
and
to
before
any parts.
damage parts
II
parts.
static-proof bags and
ship PC boards.
BUILDUP OF SHIELDING GAS
health or kill.
Shut off
1.
~
boxes to store,
shielding
gas
supply
harm
can
when not in
use.
Principal Safety Standards
Safety
in
American
Welding and Cutting, ANSI Standard Z49.1, from
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
Cutting
Preparation
for
of Containers That Have Held Hazardous
Welding and
Substances,
American
Welding Society Standard AWS F4.i, 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.
1-5.
input
instructions
Use proper
1-4.
discharge
grounded wrist strap BEFORE handlinf
on
Turn Off inverter, disconnect
1.
STATIC ELECTRICITY
on circuit boards.
move,
SIGNIFICANT DC VOLTAGE exists after
removal of input power on inverters.
cooling period.
Follow rated
Put
OVERHEATED
Safe
Handling
of
Compressed Gases
in
Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis
Highway,
Suite 501,
Code for
Safety
in
Arlington, VA 22202.
Welding and Cutting, CSA
Standard Wi 17.2,
from Canadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
Safe Practices For
Occupation
And Educational
Eye
And Face
ANSI
Standard Z87.i, from American National
Standards Institute, 1430 Broadway, New York, NY 10018.
Protection,
Cutting
And
NFPA
Welding Processes,
National Fire Protection Association,
MA 02269.
Standard
51 B,
from
Batterymarch Park, Quincy,
EMF Information
Considerations About
To reduce
Electric And
procedures:
Welding And The Effects Of Low Frequency
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.
.
.
magnetic
fields in the
1.
Keep cables
2.
Arrange
3.
Do not coil
4.
Keep welding
practical.
power
source
5.
Connect work
clamp
to
close
cables to
or
workplace,
together by twisting
one
or
use
taping
the
following
them.
side and away from the operator.
drape cables around
the
body.
and cables
workpiece
as
as
far away
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-167 302
Page
3
SECTION 2- DEFINITIONS
2-1.
Manufacturers
Warning
Label Definitions
Warningt Watch
possible hazards
Outl There are
shown by the
as
symbols.
1
Electric shock from welding
electrode or wiring can kill.
1.1 Wear
dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet
or
damaged gloves.
1.2 Protect
yourself from electric
by insulating yourself
from work and ground.
shock
1.3 Disconnect
input plug
working
power before
machine.
or
on
2
Breathing welding fumes can
be hazardous to your health.
2.1
Keep your head out of the
fumes.
2.2 Use forced ventilation
exhaust to
2.3 Use
remove
ventilating fan
or
local
the fumes.
to remove
fumes.
3
Welding sparks can
explosion or fire.
3.1
Keep flammables away from
welding. Do not weld near
cause
flammables.
3.2
Welding sparks
can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
3.3 Do not weld
on drums
closed containers.
4
or
any
Arc rays can burn eyes and
injure skin.
4.1 Wear hat and
safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
5
Become trained and read the
instructions before working
on the machine or welding.
6
Do not
remove or
(cover) the
paint
over
label.
1/96
OM-167 302
Page
4
Warning! Watch Out! There
possible hazards as shown by
symbols.
are
Electric shock from
kill.
wiring
can
the
Disconnect input plug or power
before working on the machine.
Read the Owners
working
on
Manual before
this machine.
Consult
1
rating label for input
power requirements, and
check power available at the
job site they must match.
2
Read Owners Manual and
inside labels for connection
points and procedures.
3
jumper links as shown
inside label to match
voltage at job site.
Move
on
4
Having
loop of extra length,
grounding conductor
a
connect
first.
5
Connect line input conductors
as shown on inside label
double-check all connections,
jumper link positions, and
input voltage before applying
power.
1
2
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from
kill.
wiring
can
3
Disconnect
input plug
working
power before
machine.
4
or
on
Hazardous
on
voltage remains
input capacitors after
power is turned off.
5
Always
6
Check
wait 60 seconds after
power is turned off before
working on unit.
input capacitor
voltage, and be sure it is
0 before touching parts.
near
1/96
OM-167 302
Page
5
1
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2
When power is
applied failed
explode or cause
other parts to explode.
parts
/
/ /
a
/
3
can
Flying pieces
injury.
of parts
can
cause
4
Always
wear a
face shield
when
5
servicing unit.
Always wear long sleeves
and button your collar when
servicing unit.
1/96
1
2
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from
kill.
wiring
can
3
3
Disconnect input plug
power before working
or
on
machine.
4
Look at inside label, and
properly position jumper
input
links
to match available
voltage.
380V
415V
4
1/96
2-2.
Rating
Labels For CE Products
I
~OfIh
5*.
D
,
Un
EN 60974-1
1W
00
585.4
4W
X.
50%
80%
100%
12.
585
43
515
41
515A
80%
515
400
38
4W
100%
400
U2.
1=
80.
12V
.
=
A
Un
12.
~~tS
~>
fl5Df0O
00
X
H
Ui =415
(jMAX=4M I1EFF
35*.
1P21$
Ref. 5T-177 139
OM-167 302
Page
6
2-3.
Symbols
And Definitions
OM-167 302
Page
7
SECTION 3- INSTALLATION
3-1.
Selecting
A Location
1
Lifting Eye
2
Lifting Forks
Use
lifting eye
move
or
lifting
forks to
unit.
If
using lifting forks, extend forks
beyond opposite side of unit.
Movement
2
3
Plate Label
4
Rating
Label
Use
rating label to determine input
power needs. Label is on name
plate.
Line Disconnect Device
5
Locate unit
er
Location And Airflow
near correct
input pow
supply.
A Special installation may be
required where gasoline or
volatile liquids are present
NEC Article 511
Section 20.
18 in
see
(460 mm)
I
or
CEC
4
ST-800 763-A
3-2.
Dimensions And
Weights
Dimensions
(584 mm)
Height
23 in
Width
15-1/2 in
(394 mm)
Depth
26-1/8 in
(664 mm)
A
24-1/16 in
B
20-3/4 in
(527 mm)
C
12-3/8 in
(314 mm)
D
9/32 in
D
6 Holes
(611 mm)
(7 mm) Dia
Weight
Net: 165 lbs
Ship:
OM-167 302
Page
8
175 lbs
(75 kg)
(79 kg)
3-3.
Tipping
3-4.
Weld
Output
A
Terminals And
ARC WELDING
Selecting
can cause
Cable Sizes
Electromagnel:ic 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
100 ft
Weld Output
Terminals
~
Positive
(+)
Weld cable size
Negative
()
(AWG)
1060%
Welding
Amperes
OOQ
(30 m) Or
(Copper) Length
Less
In Weld Circuit Not
Exceeding
150ft
200 ft
250ft
300 ft
350ft
(45 m)
(60 m)
(70 m)
(90 m)
(105 m)
1
400 ft
(120 m)
60100%
Duty
Cycle
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
210
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
10
100%
Duty Cycle
.
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
600
4/0
2-2/0
2-3/0
2-4/0
3-4/0
3-4/0
4-4/0
4-4/0
is based on either
a
4 volts
or
less
drop
or a
current
density
of at least 300 circular mils per ampere.
S-0007-D
OM-167 302
Page 9
3-5.
Voltage Sensing
Terminal Connections
The
voltage sensing terminals pro
vide exact voltage measurement at
the welding arc.
(+) Voltage Sensing
Positive
1
Terminal
Negative () Voltage Sensing
2
Terminal
3
Receptacle
4
Proper Plug (Not Supplied)
5
18 Gauge
Supplied)
6
Nut
7
Lead Hole
For
Lead
Electrode
connect
(Not
Positive
remaining
end of
(DCEP),
negative
() terminal lead to work. Connect
remaining end of positive (+) termi
nal lead to weld cable conductor at
electrode holder end of weld cable.
For Electrode Negative (DCEN),
terminal lead connections.
reverse
Ref. ST-BOO 764 / Ref. ST-152 885-A
3-6.
Remote 14
Receptacle Information
REMOTE 14
24 VOLTS AC
G*
OUTPUT
Socket~
Socket Information
24 volts
B
Contact closure to A completes 24 volts
circuit.
C
Command reference; +10 volts dc in Cv, o to +10 volts dc in
CC.
D
Remote control circuit
E
0 to +10 volts dc
F
Current feedback; +1 volt dc per 100 amperes.
H
Voltage feedback;
(cONTACTOR)
ac.
Protected
REMOTE OUTPUT
CONTROL
A
ItI
AMPERAGE
VOLTAGE
115 VOLTS AC
f~
~-~
circuit breaker CB2.
A
by
ac
contactor control
.
input command signal from
+1 volt dc per 10
I
115 volts
J
Contact closure to I
circuit.
K
Chassis
G
Circuit
ac.
common.
Protected
by
arc
remote control.
volts.
circuit breaker CB1.
OW~UT
(cONTACTOR)
Ref. ST-800 764
completes
115 volts
ac
contactor control
common.
GND
The
remaining
OM-167 302
sockets
Page
10
are
not used.
common
for 24 and 115 volts
ac
circuits.
\ 7)
3-7.
Remote 17
Receptacle
Information
REMOTE 17
()~
OUTPUT
Socket Information
Socket*
D
Contactor on/off
dc contactor off.
A
+10 volts dc
(cONT~TOR)
output from
REMOTE OUTPUT
CONTROL
signal;
output
+13 to +24 volts dc contactor on, 0 volts
to remote
control; allows full control of MI
remote control.
B
0 to +10 volts dc
H
+24 volts
K
0 to +10 volts dc
L
24
C
CVICC select; +13 to +24 volts dc selects CV, 0 volts dc selects
input
command
signal
from remote control.
dc; fused at 1 ampere.
output to remote control set by panel AN con
trol; allows percent of panel AN control from remote control.
volts
dc; fused
at 1 ampere.
CC.
E/t~.
Cvicc
G
Dig/inductance control;
0 to +10 volts dc set
by panel Dig/
Inductance control.
A
~
~ ~
AMPERAGE
VOLTAGE
Ret. ST-Boo 764
GND
The
3-8.
remaining
sockets
are
115 Volt AC
feedback;
+1 volt dc per 100 amperes.
E
Current
M
Voltage feedback;
F
Circuit
common
for sockets A, B, D, E, K, and M.
P
Circuit
common
for sockets H and L.
S
Chassis
+1 volt dc per 10 arc volts.
common.
not used.
Receptacle
OM-167 302
Page
11
C
~N
~
--2
7
111::
Electrical Service Guide
3-9.
Input Voltage
Input Amperes
At Rated
Output (eff)
Max Recommended Standard Fuse Or Circuit Breaker
Mm
Input Conductor
Max Recommended
Mm
Grounding
Input Conductor Length
Page
Amperes
In Feet
(Meters)
12
38
35
50
45
8
8
10
(NEC).
Links And
415
219(67)
Conductor Size In AWGIKcm1I
Placing Jumper
OM-167 302
In
Size In AWGIKcmiI
Reference: 1993 National Electrical Code
3-10.
Rating
380
261
(79)
10
S-0092J
Connecting Input
Power
SECTION 4- OPERATION
4-1.
Controls
2
4
1/
5
6
-e
7
A
9
Ref. ST-165 852-B
8
1
Power Switch
2
Digital
3
AmperageNoltage Adjustment Control
Meters
Control adjusts voltage with process switch
in GMAW position, and adjusts amperage in
SMAW and GTAW positions.
Set control at 0 for normal welding amper
age. Turn clockwise to increase short-cir
cuit amperage.
4
Switch selects
panel or
amperage/voltage level.
6
Output (Contactor) Control Switch
Switch selects
output On/Off.
panel On or remote control of
Weld
7
Arc Force/Inductance Control Switch
is On.
Switch selects
tion for
GMAW
GTAW, GMAW-P, and CAC-A. Use
position for GMAW, and FCAW.
AmperageNoltage Control Switch
arc
8
short-circuit amperage at low arc voltage is
the same as normal welding amperage.
When set towards 100, short-circuit amper
age is increased at low arc voltage to assist
with arc starts as well as reduce sticking
while
output terminals are energized
when Output swil:ch is On and Power
A
Process Switch
Switch selects type of weld output. Use
SMAW position for SMAW. Use GTAW posi
5
remote control of
panel
or
remote control of
force/inductance.
Dig/Inductance
Control
Control adjusts dig with process switch in
SMAW position. When set towards 0 (zero),
welding.
Control adjusts inductance with process
switch in GMAW. Inductance determines
of the weld puddle. When set
the wetness
towards 100, wetness
(puddle fluidity)
increases.
This control is not functional with process
switch in GTAW.
Numbers around control
are
for reference
only.
9
High Temperature Shutdown Light
OM-167 302 Page 13
4-2.
Process Switch
Settings
Shielded Metal
Arc (SMAW)
Welding; Panel
Amperage Control
Tungsten Inert
Gas (GTAW)
Welding; Remote
Amperage Control
L~A
X~JA
g
g
~J~ii
switch in Remote
14/17
O~J~17
14
I ~
I ~
o
I ~
17
17
For panel control
of voltage, place
A/V switch in
Panel position.
panel control,
place A/V switch
in Panel position,
and Output
(Contactor) switch
in On position.
14 position, and
Output (Contactor)
g
o~ ~-o~
For
switch in Remote
Series Wire Feeder
c~ ~c-
17
For remote
Voltage Control
14
17
control, place AN
(GMAW)
Welding With 60M
O~J~~
14
c~
~
Gas Metal Arc
(GMAW)
Welding; Remote
g
~1~J~ii
14
Gas Metal Arc
position.
Ref. ST-165 852-B
4-3.
Duty Cycle
And
Overheating
Duty Cycle
is
percentage of 10
minutes that unit
load without
If
503
~
w
<
overheats, thermostat(s)
duty cycle
w
n~
303
weld at rated
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
,--
(.1)
unit
can
overheating.
A
_____
2~Q
before
welding.
Exceeding duty cycle
damage unit and void
can
war
ranty.
Ci
~
203
Example:
a
100%
Duty Cycle
=
-J
U
~
153
U)
1)
15
20
2530
40S)
W705)13)tO
0
Z DUTY CYCLE
Continuous Welding
Overheating
dutyl 4/95 / ST-175 981
OM-167 302
Page
14
SECTION 5- MAINTENANCE & TROUBLESHOOTING
5-1.
Routine Maintenance
OM-167 302 Page 15
5-2.
Measuring Input Capacitor Voltage
OM-167 302
Page
16
5-3.
Circuit Breakers And Fuses
4 Turn
Off welding power
source, disconnect input
power, and check voltage on
input capacitors according
Section
to
5-2
before
proceeding.
1
If
Circuit Breaker CB1
CB1
opens,
remote
devices
using 115 volts from Remote 14
receptacle stop. Manually reset
CB1.
2
Circuit Breaker CB2
If
CB2 opens, remote devices
using 24 volts from Remote 14
receptacle stop. Manually
reset
CB2.
4II~ r~i
LLo~
~L~JL?~~
M~ll~M
~LJ~
3
Circuit Breaker CB3
If CB3 opens, devices connected
to the 115 volt twistlock receptacle
stop. Manually reset CB3.
____
____
4
Fuse Fl
If Fl
opens, the welding power
shuts down.
source
5
Fuse F3
6
Fuse F4
If F3
or F4 opens, remote control
devices connected to Remote 17
receptacle RC1 may shut down.
See Parts List for fuse ratings. Use
proper tool when removing fuses.
Tools Needed:
cIII~zJ===~u
3/8 in
ST-800 768-A I Ret. ST-i 52 069-C / ST-I 50 173-C
OM-167 302
Page
17
4
5-4.
Troubleshooting
I__
Trouble
No weld
erative.
Remedy
output; unit completely mop-
Place line disconnect switch in On
Check fuse Fl
Check and
and
replace
replace
line
position (see Section 3-10).
if necessary
fuse(s),
(see Section 5-3).
if necessary,
or
Check for proper
input power connections (see Section 3-10).
Check for proper
jumper link position (see Section 3-10).
No weld output; Power switch on; fan
If
on.
remote control to Remote 14 cr Remote 17
using
remote
(see Section 3-10).
control, place Output (Contactor) switch in Remote 17/14 position, and connect
receptacle (see Sections 3-6
being used, place Output (Coritactor) switch in On position.
Check, repair,
or
replace
Have
Low weld
output with
no
control.
Check
Have
output and low open-circuit
Limited
voltage,
Factory
AmperageAoltage Control
of
weld
output.
Check incoming power for correct
circuit breaker (see Section 3-10).
jumper
link
voltage. Check and replace
tighten
Check for proper
line
fuse(s),
if necessary,
or
reset
position (see Section 3-10).
Use proper size and type of weld cable
Clean and
(see Section 4-3).
switch.
Check for proper input and output connections
improper
remote is not
Authorized Service Station/Service Distributor check control board PCi.
Check for proper
or
3-7). If
Authorized SeMce Station/Service Distributor check unit.
position
Factory
and
remcte control.
Unit overheated. Allow unit to cool with fan On
Erratic
reset circuit breaker
(see Section 3-10).
(see Section 3-4).
all weld connections.
input
and
output
connections
(see Section 3-10).
Replace electrode.
Remote device
completely
Check remote control connections
(see Sections
3-6 and
3-7).
inoperative.
Fan not
If remote device connected to Remote 14
(see Section 5-3)
receptacle,
reset circuit breaker CB1
If remote device connected tc Remote 17
ed (see Section 5-3).
receptacle,
check fuses F3 and/or F4 and
Check for and
operating.
Have
No 115 volts
ac
Factory
remove
anything blocking
fan movement.
Authorized Service Station/Service Distributor check fan motor.
Reset circuit breaker CB1
(see Section 5-3).
at Remote 14
Reset circuit breaker CB2
(see
at twistlock
Reset circuit breaker CB3
(see Section 5-3).
output
at Remote 14
receptacle.
No 24 volts
ac
output
Section
5-3).
receptacle.
No 115 volts
ac
output
receptacle.
OM-167 302
Page
18
CB2, and/or CB3
replace
if need
NOTES
OM-167 302
Page
19
SECTION 6- ELECTRICAL DIAGRAM
1E2
pcs
OCITAL PMU.
ITD~
8C50/PI.G50
7584812
~
J
42
.
R~I
0._I
~
-
E>-~8
>
14PFl
RECEPTACLE
Rc~-8:
24V. 181T.
~
PT9~P9~
<~31-5
~
c
>
>
57<~3lC31~c
~30-12
~~z~~c31-4
42
5
>
H
I
I
aI~
K
~
I~30-t1
42
>~>~
H,
I
A
K
17P~
RECEPTACLE
~
0~
I
F
~
Figure
OM-167 302
Page
20
6-1. Circuit
Diagram
For
Welding
Power Source
;~
1?
N N
N
N
N
N
N
~z
N
N
~\
r
~
U.
~
L~
I.~
A
~
AW ~
~t1
-l
ci) 9 -J ~0 ~0 0)
0
0) -~1 C.) 0
-u CD
I\)
Ph
N
\
\~ ~
N
~
N
N
N
N
~
P7
SECTION 7- PARTS LIST
0
c~J
c~J
0
~c~)
a)
LI~
0)
cj
o
C~)C~)
c~)
c~j
C~)
cJ
0
U)
c~)
cJ
(0
C.)
0
C.)
E
C.,
G)
a)
(I)
N-.
a)
U-
ST-BOO 7B9-B
Figure
OM-167 302
Page
22
7-1. Main
Assembly
(N
~
~,
7~N~
NY
(
S,,
…~
…
,
,,,
\
N
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure
C52-57, R17-19..
LABEL, warning general precautionary
LUG, univ w/scr 600V 2-14 wire .250 stud
2
RESISTOR/CAPACITOR
BLOCK, term 7C)A 3P
BLOCK, term 20A 3P
LINK, jumper term blk 20A
3
BRACKET, mtg term block
REACTOR, line
LIFT EYE, upright
LABEL, warning exploding parts can seriously injure
SCREW, .500-13 x 1 .000hexhd stl
1
1
.
.
.
179 190
...
145 743
...
179 970
147 386
165 857
.
.
...
...
...
...
...
166 074
...
ii
143 731
...
12
179 304
...
13
604 126
...
14
143732
...
144 929
..
.
088 058
...
135 291
...
+166 051
...
Fig
1
1
1
1
2
1
1
GASKET, lift eye
NUT, .500-13 stl elastic stop
RECEPTACLE, twlk grd 2P3W 15A 250V
PANEL, rear
1
1
1
1
1
TUBING, gI acryl 1.000-1.036 ID (order by ft)
143741
SPACER
TUBING, gI acryl .500-.524 ID (order by ft)
3ft
4
2ft
T2
166045
CHASSIS, mid lower
CHASSIS, mid upper
WASHER, shldr .203 ID nyl
TRANSFORMER, kVA 1.5 115-230/380/415-18/18-24
PLG11
166680
CONNECTOR & PINS
1
145477
STIFFENER, base
2
1
7-3
7-4
145053
...27
RC11
166679
CONNECTOR & PINS
...28
Zi
144050
...29
Z2
147901
STABILIZER, left
STABILIZER, right
BUS BAR, capacitor
BUS BAR, capacitor
CAPACITOR, elctlt 2700uf 35OVDC
CABLE TIE, 0-4.500 bundle
167742
166017
C8-1l
139151
605 538
35
36
166 551
INSULATOR, capacitor
166 550
BRACKET, mtg capacitor
EDGE TRIM, style 62-3/32 (order by ft)
148 001
...37..
Ti
166 099
Fig
7-2
40
179 310
41
+147 961
42
155 651
1
1
12
1
2ft
BASE
+165 859
39
+When
1
LIFT EYE
070 592
Fig
Fig
38
1
FAN MOTOR/MOUNTING BRACKET
7-5
605 603
...32
1
....
164812
038 861
RC3
2
1
...
TEl
15
CAPACITOR
....
TE2
Z3
1
.
601 219
10
COVER, top w/iinsulation (consisting of)
INSULATOR, top
PANEL, side RH w/insulator (consisting of)
INSULATOR, side RH
152 346
155 652
C50,51
Assembly
155653
+147 962
3
7-1. Main
Quantity
..
.
...
...
...
TRANSFORMEIR, HF
PANEL, front w/components
LABEL, warning general precautionary
PANEL, side LH w/insulator (consisting of)
INSULATOR, side LH
LABEL, warning electric shock can kill (on LH panel)
1
1
2
1
....
1
179 308
...
1
PLG21
168 165
...
PLG15
135 556
RC15
116045
ordering
a
...
...
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
CONNECTOR& PINS
component originally displaying
a
precautionary label,
1
1
1
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-167 302
Page
23
K\
~
\
N
N
N.
\~
5
8
9
10
11
12
13
14
35
34
33
19
27
34
33
24
25
28
27
29
30
28
31
ST-800 770-A
Figure
OM-167 302
Page
24
7-2.
Panel, Front w/Components
N
N
N
/
/~!
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure
146 684
Si
128 756
...
071 230
...
153 374
...
134 201
...
604 311
...
PC5
150 331
PLG5O
089 222
R3
030 856
...
R2
035 897
...
S2
088 409
S4
128 808
S3
011609
S5
011611
045 852
17
107 983
RC2
CB1
CB2
CB3
...22
C39
...23
R5
...24
R17
PC1O,RC1
...26
...27
28
C6,7
Neg,Pos
29
...
..
.
...
...
...
.
.
.
...
Panel, Front w/Components (Fig 7-1 Item 39)
INSULATOR, switch pwr
1
SWITCH, tgl 3PST 40A 600VAC
NUT, speed U type 10-32
2
1
BEZEL/FILTER, bik bezel/red filter 2.000 viewing
ENCLOSURE, PC card
STAND-OFF SUPPORT, PC card .312/.375
GROMMET, rbr .250 ID x .375mtg hole
CIRCUIT CARD, amp/volt meter
CONNECTOR, irect llskt plug
POTENTIOMETER, WW sltd sft 10/12W 1K ohm
POTENTIOMETER, C sltd sft 1/12W 1K ohm
SWITCH, tgl DPDT 15A 125VAC
SWITCH, tgl SPTT 15A 125VAC
SWITCH, tgl SPDT 15A 125VAC
SWITCH, tgl DPDT 15A 125V
LOCK, shaft pot .375-32 x .25Odia shaft
CLIP, component .687dia mtg adh back
BLANK, snap-in nyl .500mtg hole
2
1
4
1
1
1
1
1
1
1
1
1
1
1
1
CONNECTOR w/SOCKETS
089 807
CIRCUIT BREAKER, man reset 1 P 2.5A 250V
083 432
CIRCUIT BREAKER, man reset 1 P 1 OA 250V
083 431
CIRCUIT BREAKER, man reset 1 P 5A 250V
074 200
CAPACITOR, polye film .047uf 400VDC
028 271
RESISTOR, C .5W lOOK ohm
030 945
RESISTOR, C 2W 4.7K ohm
137542... CIRCUIT CARD, connector l7skt
119951
BLANK, snap-in nyl .437mtg hole
138115
CAPACITOR
129525
RECEPTACLE, twlk insul fem
117860
BLANK, snap-in nyl .l87mtg hole
143 976
165860
039 885
039 654
039 655
097 922
143 797
...38
...
148 297
135 299
25....
...
7-2.
Quantity
PC8
167 679
PLG3O,31
130 203
D17
175 815
PLG1O
158 719
...
1
...
1
...
1
...
1
...
1
...
1
...
1
1
4
2
2
4
PANEL,front
NAMEPLATE, (order by model and serial number)
CONNECTOR, circ protective cap
POST, bdg black
POST, bdg red
KNOB, pointer
SPACER, nyl .312 OD
1
1
2
1
1
2
x
.194 ID
CIRCUIT CARD, receptacle
CONNECTOR&SOCKETS
LED, yellow w/leads
CONNECTOR&SOCKETS
x
.437
Ig
4
bypass
1
2
1
1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-167 302
Page
25
N~
NN
N
N
N
N
/
~*
N
I)
C.)
a~
N)
(
/
/
C.)
(I,
-Il Ca C -I CD -4
0
0) -.4 C.) 0 I.) -u
(D
N) 0)
C)
Vt U) Ca,
a. I- 0
CD -I
0 0 -J -J
\~
N
~ ~N~\<.2
c–\
~
\~
~2
Item
No.
Dia.
Mkcis.
Part
No.
Description
Figure
010 014
153 403
157 425
166 068
166 069
C22-29,40-47
CM1,2
031 689
D1-16
149 209
PM1,2
TP1,2
006 334
157 497
157 566
072 253
143 722
142 592
135 661
...8
157 426
057 358
10
R13-16
139 812
C1-4
163 770
145 162
006 426
148 297
L1-4
144 325
7-3.
Chassis, Mid
Lower
(Fig
Quantity
7-1 Item
23)
CLAMP, stl CUSh .75Odia x .2O3mtg hole
BUSHING, snap-in nyl .750 ID x 1 .000mtg hole
BAFFLE, air
MODULE, pwr L.H (consisting of)
MODULE, pwr RH (consisting of)
CAPACITOR, cer disc .Oluf 1000VDC
MODULE, capacitor 2 polye met film .01 uf 1 600V
KIT, diode fast recovery
KIT, transistor IGBT module
THERMOSTAT, NC
STUD, connection single 10-32 x .500 x 1.250
HEAT SINK, pwr module
BAR, support heat sink
EDGE TRIM, style 3100-1/16 (order by if)
TRAY, mtg cmpts lower
BUSHING, snap-in nyl 1.000 ID x 1 .375mtg hole
RESISTOR, WW fxd 30W 5K ohm (460/575V)
CAPACITOR, polyp film .34uf 700VDC
STRIP, comb mrm .007 x 3.000 x 7.000
CLAMP, capacitor 2.000dia
NUT, 10-32 push-on stl
...CHOKE,DVDT
1
3
2
1
1
8
1
8
1
1
8
1
2
2ff
1
9
4
4
4
4
4
2
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-167 302
Page
27
\
N
N
N
/
N.
N
/
S
2
N
N:
11
23
20
19
ST-Boo 772-B
Figure
OM-1 67 302
Page
28
7-4.
Chassis, Mid Upper
N
N
N
N, N~
~:~N~Y\J>
~N~\
NN
/
-N
N
N
~
N
N
N
)
N
\
)
\
N
N)
\
N,
_
N
~
N
N
N-~
N
N
~
~
~
\NN:
~
~,
\\~N
N
1
<~_~
N
N
~tY
Item
No.
Part
No.
Dia.
Mkgs.
Description
Figure
1
HD1
156 313
PLG62
130 204
...
.
7
....
....
VCRM1
R20-22
Wi
1
1
PLG1 ,3-5,9
180 734
RESISTOR
1
....
148 439
+157549...
14
VCM1
16
17
CT1
PLG2
RC19
CONNECTOR &
152249... CONNECTOR&
131 054
CONNECTOR &
135635... CONNECTOR &
R1,19
136076...
153501
PLG7
PLG19
....
095847...
20
21
Fl
*162312...
143723...
22
23
SRi
141317...
148001
24
*Recommended
Spare
+When
a
ordering
1
1
1
1
5
1
CONNECTOR&SOCKETS
GROMMET, scr No. 8/10 panel hole .312sq
TRAY, mtg cmpts upper
142592... BAR, support heat sink
165313... MODULE, varistorkapacitor
179190... LABEL, warning electric shock can kill
020265... CABLE TIE, 0-1.750 bundle
157568... TRANSFORMER, current
083147...
13
18
1
153337...
12
....
2
CONTACTOR, def prp 40A 3P 24VAC
170626... BRACKET, mtg coritactor
057358... BUSHING, snap-in nyl 1.000 ID x 1 .375mtg hole
180872... CIRCUIT CARD, control
PCi
11
19
current 300A
CONNECTOR&SOCKETS
132889...
10
15
24)
2
*012 643
F3,4
5
.6
TRANSDUCER,
7-1 Item
HOLDER, fuse mintr
FUSE, mintr gi slo-blo 1 A
MODULE, capacitor/varistor/resistor
098376...
.
Chassis, Mid Upper (Fig
134058... STAND-OFF SUPPORT, PC card .lS6dia
154702... INSULATOR, fuse holder
...2
.
7-4.
Quantity
5
.500
high
8
1
2
1
2
1
1
SOCKETS
1
SOCKETS
1
SOCKETS, (part of CT1)
1
PINS
1
RESISTOR, WW fxd 30W 200 ohm
HOLDER, fuse crtg 30A 600V
FUSE, crtg 5A 600V time delay
HEAT SINK, rectifier
RECTIFIER, integ 11OA 1600V 3ph
EDGE TRIM, style 62-3/32 (order by ft)
2
1
1
1
1
itt
Parts.
component originally displaying
a
precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-167 302
Page
29
/~~
~
~
/
N
N <2
~NN)
1/
\\ \_
\\
I
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure
.1
7-5. Fan
Quantity
Motor/Mounting
Bracket
(Fig
7-1 Item
FM
153280
PLG18
131 054
RESISTOR, WW fxd 55W 25 ohm
SPACER, nylon .312 OD x .194 ID x .437 Ig
INLET, fan
EDGE TRIM, style 3100-1/16 (order by ft)
BUSHING, snap-in nyl .375 ID x .500mtg hole
BLADE, fan 7.600 in 5wg 24deg .312 bore CCW
BRACKET, fan
MOTOR, fan 230V 3000RPM .3l2dia shaft (consisting of)
CONNECTOR & SOCKETS, (part of FM)
RC18
135635
CONNECTOR & PINS
R9-12
...2
157297
143797
157429
135661
010546
153219
...6
143729
19)
4
4
1
2ft
1
1
1
1
1
1
3
I
2
I
,
I-
8
7
ST-150 168-D
Figure
OM-167 302
Page
30
7-5. Fan
Motor/Mounting
Bracket
N N
N
~~
N
.~
\,
N
N
,~,
N
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