Miller | KD414913 | Owner Manual | Miller XMT 300 CC/TIG User manual

Miller XMT 300 CC/TIG User manual
77 iMjIIerfi
April
Form:
1993
OM-2204C
Effective With Serial No. KD41 4913
OWNERS
MANUAL
XMTfi 300 CC/TIG
CC/DC Welding Power Source
For GTAW, GTAW.P, And SMAW
300
Amperes,
Uses
Welding
32 Volts DC At 60%
Single-Phase
Duty Cycle
Or Three-Phase Input Power
Protection For Control Circuit, 24 VAC, And
U
safety
blocks
14-Pin Remote Control
Receptacle
Overheating
High Frequency
Have
only
trained
or
and
qualified
the directions.
ST.146 123-A
Give this manual to the operator.
U
For
persons
service this unit.
Callyourdistributorifyoudonotunderstand
U
U
carefully.
install, operate,
8/92
And Built-In
Read and follow these instructions and all
U
cover
AUTO-LINKTM Circuitry
IIlfl
or:
help,
call your distributor
MILLER ELECTRIC
Mfg. Co.,
1079, Appleton, WI 54912
P.O. Box
414-734-9821
PRINTED IN USA
:1~R
~~:
TRUE BLUETM LIMITED WARRANTY
MILLERS
(Equipment
with
Effective January 1, 1992
serial number preface of KC
This limited warrsnty supersedes all previous MILLER warranties end is esctusive with
LIMITED WARRANTY
Subject
no
to the terms and conditions below. MILLER Electric
Mfg. Co., Appleton. Wisconsin, warrants
equipment sold after the effective
MILLER
tects in material and
to its
retail purchaser that
original
other
guarantees
Accessory
new
*
warranty is tree ot de
shipped by MILLER. THIS WAR
newer)
or
warranties
esprassed
or
implied.
Kits
Replacement Parts
date of this limited
at the time it is
workmanship
or
a
MILLERS
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES. EXPRESS OR
True
Bluene
Limited
Warranty
shall not
apply
to:
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT
Items furnished by MILLER. but manufactured by others, such as engines or
trade accessoriea These items are covered by the manufacturers warranty, iI
r.
NESS.
any.
Within the warranty periods listed below. MILLER will repair or replace any war
ranted parts or components that tail due to such detects in material or workmanship.
Consumable components: such
2
in writing within thirty (30) days of such detect or failure, at
provide instructions on the warranty claim procedures to be
MILLER must be notified
which time MILLER will
and
as contact
tips, cutting nozzles,
contactors
relays.
followed.
that has been modified by any party other than MfLLER, or equip
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
Equipment
3.
ment that
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
and
are as
outside of the
5 Years Parts 3
In the event of a
Plasma Arc
Cutting
(3) the reasonable cost of repair or replace
(4) payment of or credit for the pur
chase price (less reasonable depreciation based upon actual use) upon return of the
risk
and
MILLERS
customers
at
option of repair or replacement
espense
goods
will be FOB.. Factory at Appleton. Wisconsin. or F.O B. ala MILLER authorized ser
vice facility as determined by MILLER. Therefore no compensation or reimburse
ment for transportation costs of any kind will be allowed.
Parts and Labor
Engine Driven Welding Generators
(NOTE Engines are warranted separately by
1
Year
the
inappropriate
cases.
engine manufacturer.)
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 CON
Parts and Labor
Motor Driven Guns
Process Controllers
Water Coolant
MILLER
ment at an authorized MILLER service station, or
Robots
2 Years
warranty claim covered by this warranty, the eaclusive remedies
option: (1) repair: or (2) replacement: or, where authorized in
shall be, at MILLERS
writing by
Power Sources
Semi-Automatic and Automatic Wire Feeders
4.
equipment.
INTENDED FOR PURCHASE AND USE BY COMMER
CIAIJINDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EOUIPMENT.
Transformer/Rectifier Power Sources
*
for the
Parts and Labor
3 Years
3.
specifications
MILLER PRODUCTS ARE
Years Labor
main power rectifiers
Original
2
original retail purchaser,
follows.
TRACT, TORT OR ANY OTHER LEGAL THEORY
Systems
HF Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR
RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE. AND ANY
Grids
REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL
THEORY WHICH. BUT FOR THIS PROVISION. MIGHT ARISE BY IMPLICATION.
Spot Welders
Load Banks
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER tS EXCLUDED AND DISCLAIMED BY MILLER.
SDX Transformers
Running Gear/Trailers
Field Options
Field options are covered under True BluenM for the remaining
warranty period 01 the product they are installed in. or for a minimum of
(NOTE
one
5.
6 Months
6.
go
year
Days
whichever
is
Some slates in the U.S-A. do nol allow limitations of how long an implied warranty
lasts, or the esciusion of incidental, indirect. special or consequential damages. so
greater.)
the above limitation or eaclusion may not apply to you. This warranty provides spe
cific legal rights, and other rights may be available, but may vary from slate to slate.
Baneries
In Canada,
Parts and Labor
legislation
in some
provinces provides for certain additional warranties
remedies other than as staled herein, and to the ealehl that they may not be
waived. the limitations and eecluaions sal out above may not apply. This Limited
or
MIG Guns/TIG Torches
Plasma
Cutting
Torches
Warranty provides specific legal rights. and other rights may be available. bul may
very Irom province to province.
Remote Controls
*
:i~U
RECEIVING-HANDLING
unpacking equipment, Check carton for any damage that may have occurred during shipment. File any claims for loss or damage
delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment manufacturers
Transportation Department.
BefDrB
with the
When
requesting
Use the
or
following
information about this
equipment, always provide Model Designation
spaces to record Model
Designation
and Serial
or
Style
and Serial
or
Style
Number.
Number of your unit. The information is located
on
the
rating
label
nameplate.
Model
_________
Serial
or
Style
No.
Date of Purohase
miller 5/93
ARC WELDING SAFETY PRECAUTiONS
WARNING
a
ARC WELDING
be hazardous.
can
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL INSTALLATION, OPERATION,
QUALIFIED PEOPLE.
ELECTRIC SHOCK
can
MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
kill.
5.
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.
2.
3.
Owners
6.
Disconnect input power
this equipment.
or
stop engine before installing
or
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
~
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can damage
equipment according
making input connections,
Turn off all equipment when not in
Do not
to its
attach
grounding
proper
use
worn,
use.
damaged, undersized,
or
poorly spliced
cables.
9.
Do not wrap cables around your body.
10.
Ground the workpiece to
11.
Do not touch electrode if in contact with the work
12.
only well-maintained equipment.
damaged parts at once.
13.
Wear
a
14.
Keep
all
good electrical (earth) ground.
a
Use
safety
harness if
panels and
working
covers
ground.
or
Repair
replace
or
above floor level.
securely
in
place.
ARC RAYS
2.
Wear
3.
eyes when welding or watching.
Wear approved safety glasses. Side shields recommended.
4.
hearing.
this
8.
Wear
servicing
ground
7.
mats or covers.
4.
When
install and
Manual and national, state, and local codes.
conductor first.
Do not touch live electrical parts.
dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating
Properly
a welding helmet fitted with a proper shade of filter (see
ANSI Z49. I listed in Safety Standards) to protect your face and
Use
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
material (wool and leather) and foot protection.
and
NOISE
5.
1.
Use
approved
ear
plugs
or ear
muffs if noise level is
FUMES AND GASES
high.
be hazardous
can
5.
to your health.
Welding produces fumes and gases. Breathing these
fumes and gases
be hazardous to your health.
can
a.~.
6.
Keep your head
If inside, ventilate the area and/or use exhaust at the arc to
remove
welding
If ventilation is poor,
use an
4.
Read the Material
Safety
manufacturers
form
7.
fumes and gases.
3.
plated steel,
area
unless the
Watch for fire, and keep
Be
yourself
and others from
1.
Protect
2.
Do not weld where
3.
Remove all flammables within 35 ft
flying sparks
this is not
flying sparks
can
cause fire
welding
on
a
7.
Do not weld
Connect work cable to the work
on
or
partition
the hidden side.
closed containers such
as
as
tanks
close to the
or
drums.
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.
can
11.
Wear oil-free
1.
or
cut off
welding
wire at
protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Wear
approved face shield
or
safety goggles. Side
shields
recommended.
injury,
Chipping and grinding cause flying
cool, they can throw off slag.
or
is removed from the
extinguisher nearby.
ceiling, floor, bulkhead,
8.
openings to adjacent areas.
can
galvanized, lead,
fire
on a
Remove stick electrode from holder
contact tip when not in use.
FLYING SPARKS AND HOT METAL
cause
that
10.
small cracks and
as
coating
(10.7 m) of the welding arc. If
them with approved covers,
possible, tightly cover
Be alert that welding sparks and hot materials from welding
easily go through
aware
can
and hot metal.
strike flammable material.
spraying
is well ventilated, and if necessary, while
5.
or
or
react with vapors to
irritating gases.
6.
fire
degreasing, cleaning,
coated metals, such
explosion.
can cause
near
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
fire.
I
on
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode or welding wire
to metal objects can cause sparks, overheating, or
WELDING
>j
toxic and
weld area, the
(MSDS5) and the
coatings,
instruction for metals, consumables,
and cleaners,
4.
highly
Do not weld
cadmium
approved air-supplied respirator.
Data Sheets
Do not weld in locations
operations. The heat and rays of the arc can
out of the fumes. Do not breathe the fumes.
1.
2.
a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
Work in
metal. As welds
2.
Wear proper
body protection
to
protect skin.
en
9192
CYLINDERS
explode
can
if
damaged.
Keep cylinders away from any welding
3.
or
other electrical
circuits.
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.
a welding electrode to touch any cylinder.
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 allow
4.
5.
Use
6.
Protect
1.
mechanical shocks, and
2.
heat,
7.
upright position by chaining
equipment cylinder rack to
8.
compressed gas cylinders
from
excessive
in
arcs.
cylinders in
them to a stationary support
prevent falling or tipping.
Install and secure
an
or
connected for
use or
use.
Read and follow instructions
associated
compressed gas cylinders.
publication P-i listed in Safety
on
and CGA
equipment,
Standards.
-
____________________
WARNING
a
ENGINE EXHAUST GASES
Engines produce harmful
FUEL
ENGINE
ENGINES
can
kill.
can
fire
cause
or
be hazardous.
outside in open, well-ventilated
1.
Use
2.
If used in
closed area, vent engine exhaust outside and
away from any building air intakes.
1.
Stopenginebeforecheckingoraddingfuel.
Do not add fuel while smoking or if unit is near
exhaust gases.
2.
explosion.
can
equipment
areas.
a
any
sparks
or
open flames.
3.
Engine
fuel
is
highly
flammable,
engine to cool before fueling. If possible, check and add
engine before beginning job.
allow room for fuel to expand.
not overfill tank
not spill fuel. If fuel is spilled, clean up before starting
Allow
fuel to cold
4.
5.
Do
Do
engine.
~
MOVING PARTS
can cause
injury.
Moving parts, such as fans, rotors, and belts can
fingers and hands and catch loose clothing,
2.
Stop eng
ne
covers,
and
guards
Keep hands, hair, loose clothing,
covers
for
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
The coolant in the
under pressure.
r adiator can
Reinstall
panels
finished and
explosive
disconnect
during servicing,
battery.
and tools away from
moving
parts.
6.
ases.
,
5.
before_installing_or_connecting_unit,
Batteries contain acid and generate
.~
To prevent accidental starting
negative () battery cable from
closed and
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin,
~
only qualified people remove guards or
troubleshooting as necessary.
4.
cut
Keep all doors, panels,
securely in place.
(~\
Have
maintenance and
1.
fr.
3.
1.
2.
or
guards
and close doors when
servicing
is
before_starting_engine.
wear a face shield when working on a battery.
Stop engine before disconnecting or connecting battery
Always
cables.
3.
Do not allow tools to
4.
Do not
5.
Observe correct
1.
Do not
use
cause
welder to
remove
sparks when working
charge batteries
polarity (+
and
)
radiator cap when
on
jump
or
on a
battery.
start vehicles.
batteries.
engine
is hot. Allow
engine
to cool.
2.
Wear
gloves and put a rag
3.
Allow pressure to escape before
over
cap
area
when
removing cap.
be very h ot and
completely removing
cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from
Welding Society, 550 N.W. LeJeune Rd. Miami FL 33126
Safety and Health Standards,
American
Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis High.
way, Suite 501, Arlington, VA 22202.
Safe
OSHA 29 CFR 1910, from
dent of Documents, U.S. Government
Superinten
Printing Office, Washington,
D.C. 20402.
Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Ameri
can Welding Society Standard AWS F4.1,from American Welding So
ciety, 550 N.W. LeJeune Rd. Miami, FL 33126
Code for Safety in Welding and Cutting, CSA Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou
levard, Rexdale, Ontario, Canada M9W 1 R3.
Recommended Safe Practices for the
National Electrical Code, NFPA Standard 70, from National Fire Pro
tection Association, Batterymarch Park, Quincy, MA 02269.
sri 9/92
Safe Practices For OccupationAnd Educational EyeAnd Face Protec
tion, ANSI Standard Z87.1, ftom American National Standards
institute. 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51 B, from National
Fire Protection Association, Batteryrnarch Park, Quincy, MA 02269.
EMF INFORMATION
~
N OTE
.1
Considerations About Welding And The Effects Of Low
Magnetic Fields
The
To
of the U.S.
procedures:
following is a quotation from the General Conclusions Section
Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
there is now a very
Government Printing Office, May 1989): .
large volume of scientific findings based on experiments at the
.
reduce
Keep
2.
Arrange
3.
Do not coil
people which clearly
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
risk
or
or
draw definite conclusions about
to offer clear science-based advice on
avoid
questions of possible
strategies to minimize
or
workplace,
or
use
taping
the
following
them.
side and away from the operator.
one
drape cables
4.
Keep welding power
practical.
5.
Connect work
clamp
around the
source and
to
body.
cables
workpiece
as
as
far away
as
close to the weld
as
possible.
About Pacemakers:
The
above
procedures are among those also
pacemaker wearers. Consult your
recommended for
complete information.
risks.
potential
cables to
the
together by twisting
cables close
1.
establish that low
us to
fields in
Electric And
.
cellular level and from studies with animals and
allow
magnetic
Frequency
normally
doctor for
dlO
4/93
TABLE OF CONTENTS
SECTION 1
SAFETY INFORMATION
SECTION 2
SPECIFICATIONS
2-1.
2-2.
Volt-Ampere Curves
Duty Cycle
2
2
SECTION 3INSTALLATION
3-4.
Typical Process Connections
Selecting A Location And Moving Welding Power
Selecting And Preparing Weld Output Cables
Connecting To Weld Output Receptacles
3-5.
Remote 14
3-6.
Installing Gas Supply
Connecting Input Power
3-1.
3-2.
3-3.
3-7.
3
Source
Receptacle Information And Connections
4
5
6
6
7
8
9
SECTION 4OPERATION
SECTION 5- MAINTENANCE & TROUBLESHOOTING
5-1.
Routine Maintenance
5-2.
Removing Case
5-3.
Overload Protection
5-4.
5-5.
And
15
Measuring Input Capacitor Voltage
Changing AmperageNoltage
Troubleshooting
17
Meter Hold Function
SECTION 6
ELECTRICAL DIAGRAMS
SECTION 7
TUNGSTEN ELECTRODE
7-1.
7-2.
HIGH FREQUENCY
SECTION 9
PARTS LIST
Figure
Figure
Figure
9-1. Main
20
Assembly (208-230/460 V
28
29
30
Model
Illustrated)
Chassis, Mid (208-230/460V Model Illustrated)
9-3. Panel, Front w/Components
9-2.
17
18
Selecting Tungsten Electrode
Preparing Tungsten
SECTION 8
16
32
36
38
OM-2204C 4/93
SECTION 1
SAFETY IN FORMATION
modl,l 2/93
Read all
Obey
all
safety messages throughout
safety
Learn the
messages to avoid
meaning
this manual.
injury.
of WARNING and CAUTION.
2
1
Safety
Alert
2
Signal
Word
2
\
WARNING
or
CAUTION
3
L~
can
kiII.~
________
MOVING PARTS
Do not touch live electrical parts.
Disconnect
nstalling
or
input
power
Keep away from moving parts
J~
f<eep
all
when
operating.
panels and
injury
inlure.
~
before
servicing
can
covers
closed
means
injury
possible death
happen.
can
CAUTION
________
ELECTRIC SHOCK
serious
Symbol
or
means possible minor
equipment damage can
I
happen.
I
3
Statement Of Hazard And
Result
4
Safety
I
/
5
Instructions To Avoid
Hazard
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
5
Hazard
6
Safety
Read
~
Turn Off switch when
safety
blocks for each sym
bol shown.
NOTE
7
NOTE
Symbol (If Available)
Banner
using high frequency.
Special
ation
instructions for best oper
not related to
safety.
Figure 1.~1. Safety Information
SECTION 2
Table 2-1.
SPECIFICATIONS
Welding Power Source
Specification
Type Of Output
Welding
Input
Processes
Power Cord
Description
Constant Current/Direct Current (CC/DC)
Gas
Tungsten
(SMAW)
Arc
(GTAW), Gas Tungsten
Length: 21-3/4
Weight
Net: 84 lb
Options
See Rear Cover
in
(522 mm); Width:
(38 kg); Ship:
89 lb
Pulsed
(GTAW-P), Shielded
Metal Arc
Welding
Amperes, 32 Volts DC
(See Section 2-2)
300
12 in
(305 mm); Height: 17-3/8
in
(441 mm)
(40 kg)
With Three-Phase
Output
-
l2ft(3.7m)
Overall Dimensions
Rated Weld
Arc
With
Input
At 60%
Duty Cycle
Single-Phase Input
Amperes, 29 Volts DC
(See Section 2-2)
225
At 60%
Duty Cycle
Type Of Input
230, 460, Or 575 Volts AC; 50/60 Hz
230, 460, Or 575 Volts AC; 50/60 Hz
Input Amperes At Rated Output
42AAt230V,21 AAt46OV, 164AAt575V
50.8 A At 230 V, 29 A At 460 V, 23.6 A At 575 V
KVAIKW Used At Rated Output
16.1 kVA111.3kW
12.8 kVAJ7.8 kW
Amperage Range
5-375 A
5-225 A
80 Volts DC
80 Volts DC
Max.
Open-Circuit Voltage
OM-2204
Page
1
Volt-Ampere Curves
2-1.
The
volt-ampere
minimum
and
show the
curves
maximum
voltage
and amperage output capabilities
of the welding power source.
Curves of other settings fall be
tween the curves shown.
A.
B.
230/460 Volt Models
100
100
go
90
80
80
70
70
60
60
460/575 Volt Models
575
460
MAX.
SMAW
~
50
40
-
30
_
OTAW
MIN.
20
OTAW
MIN.
30
ARC
20
CONTROL
10
ARC
CONTROL
10
OZ
26X
50X
75X
~
0
~00x
0
-
0
100
200
300
400
0
AMPERES
300
ssbl .110/91
Figure
2-2.
400
AMPERES
2-1
-
SB-136 507/ SB-141 457
Volt-Ampere Curves
Duty Cycle
CAUTION
a
EXCEEDING DUTY CYCLE RATINGS will
Do not exceed indicated
damage
unit.
duty cycles.
waml.1 V92
Duty cycle
600
operate
without
600
is how
long
the unit can
within a ten minute
period
causing overheating or
damage.
This unit is rated at 60% duty cycle
when operated at 300 amperes
400
from three-phase input power, or at
225 amperes from single-phase
input power. This allows welding 6
minutes out of every 10 minutes.
Cl)
LU
a.
~
3 PHASE
OPERATION
(
200
a
-J
SINGLE
PHASE
LU
160
OPERATION
0
~3
16
20
~30
40
60I0~e090~0
% DUTY CYCLE
Figure
OM-2204
Page
2
sbl.r 10191 / SB136
2-2.
Duty Cycle Chart
510
SECTION 3INSTALLATION
a
WARNING
HIGH-FREQUENCY RADIATION can interfere with radio
and communications equipment.
Have
only qualified person
familiar with electronic
equipment perform
Read and follow entire Section 8 for proper location and installation
installing unit.
3-1.
Typical
navigation, safety services, computers,
this installation.
requirements
for
high-frequency equipment
before
Process Connections
Remote
14 Pin
Work
+
GTAW
Pulse
Control
Scratch Start
Pulsed GTAW
Or
GTAW
+
–
Figure
3-1.
Typical Process Connections
OM-2204
Page
3
3-2.
Selecting
A Location And
Moving Welding Power
Source
WARNING
a
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
from
conductors
power
line BEFORE moving welding
Disconnect
input
deenergized supply
power
source.
r
~
~
FIRE OR EXPLOSION can result from
placing unit on, over, or near
combustible surfaces.
Do not locate unit on, over,
or near
combustible
surfaces.
Do not install unit
near
overheating
and
Do not breathe
welding fumes.
Place unit only where there is
supply and proper ventilation.
a
good
fresh air
FALLING EQUIPMENT can cause
serious personal injury and equipment
damage.
Lift unit at handles.
flammables.
AIRFLOW
BLOCKED
FUMES can be hazardous; LACK OF
AIR
FRESH
AND
PROPER
VENTILATION can be harmful.
causes
possible damage
Have two persons of
adequate physical strength lift
unit.
to
unit.
Move unit with
hand
cart
similar device of
or
adequate capacity.
Do not block
Warranty is
or
filter airflow.
void if any
If
type of filter is used.
using
a
fork lift vehicle,
skid before
secure
unit on a proper
transporting.
swarnhli
1
3 in
(78 mm) Open Space
2/92
At
Sides, 6 in (156 mm) At Rear
For Good Airflow
2
Lifting
Handles
Use handles to
3
Rating
move
unit.
Label
2
Locate unit
er
near
correct
input pow
supply.
3
ST.146 123-A / Ref. 5T-151 556
Figure
OM-2204
Page
4
3-2. Location And Movement Of
Welding
Power Source
3-3.
Selecting
And
Preparing
Weld
Output Cables
Weld
1
Output Cable
Determine total cable
in
length
weld Circuit and maximum
welding amperes. Use
Table 3-1 to select proper
cable size.
Use shortest cables
Do not
2
possible.
damaged
use
Terminal
cables.
Lug
Use
lugs of proper amperage
capacity and hole size for connect
ing to work clamp or electrode hold
er.
For Example,
Total Cable
Length In Weld
20 ft (6 m)
Circuit
6
5
Tools Needed:
3
Insulated Electrode Holder
4
GTAW Torch
Install
according
to manufacturers
instructions.
=
5
Work
Clamp
Install onto work cable.
Dinse-Type Connector
6
Install onto weld cable
Figure 3-4.
sber
Figure
3-3.
Selecting
And
Preparing
Weld
Output
as
shown in
S-0056
11192
Cables
Output
1
Weld
2
Handle
3
Sleeve
Cable
Slide handle onto cable;
and install sleeve.
4
Connector
5
Setscrew
strip
Body
Insert cable with sleeve
connector
If
fully
into
body, tighten setscrew,
and slide handle
3
cable
job requires
over connector.
cable
larger than 3/0
AWG, use 2 ft (610mm) or shorter
piece of 3/0 AWG cable for Dinse
Type
connector installation. Con
nect other end of short cable to the
4/0
Tools Needed:
or
larger
weld cable.
ST-156 496
Figure
3-4.
Dinse-Type Connector Assembly
Table 3-1. Weld Cable Size*
Total Cable
(Copper) Length
150ft
lOOft(30m)Or
Less
(45m)
I
In Weld Circuit Not
200ft
I
(60m)
250ff
I
(70m)
Exceeding
300ff
I
(90m)
350ff
I
(105m)
400ft
(120m)
Welding
Amperes
10 To 60%
60 Thru 100%
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
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
10 Thru 100%
Duty Cycle
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
*WeId cable size
(AWG)
is based on either a 4 volts
or
less drop
or a current
density
of not
more
than 300 circular mils per ampere.
OM-2204
s-oooi-c
Page
5
3-4.
Connecting
To Weld
Output Receptacles
WARNING
a
ELECTRIC SHOCK
can
kill; ARCING
can
burn skin
or
damage electrical equipment.
Do not touch live electrical parts.
Turn Off
Do not
Be
welding
power
change position
source
of
before
welding
sure connectors are secure in
making
any weld output connections.
cable connectors while
welding.
receptacles before welding.
swami 22 2/9~
1
Positive
2
Negative ()
(+)
Receptacle
Weld
Output
Weld
Output
Receptacle
Connector
3
For DC Electrode Positive
(DCEP),
connect work cable connector to
negative ()
trode
receptacle and elec
holder cable connector to
positive (+) receptacle.
For
2
DC
(DCEN),
Electrode
reverse
Negative
cable
connec
tions.
See
Figure
3-1 for
typical polarity
choices.
To connect to receptacle, align keyway, insert connector, and turn
clockwise until tight.
Ret. ST-155 091 / Ret. ST-153 625
Figure
3-5.
Remote 14
1
3-5.
Connecting
To Weld
Output Receptacles
Receptacle Information And Connections
1
Remote 14
2
Keyway
Receptacle RC2
2
3
Plug
4
Threaded Collar
To connect
keyway,
th this receptacle, align
insert
plug,
and
tighten
threaded collar.
Socket Information:
Remote Contactor
A
24 volts ac. Protected
B
Contact closure to
pin
by
A
fuse F2.
completes
24 volts ac contactor control
circuit.
Remote
AmperageNoltage Control
C
Command reference; +10 volts dc.
D
Control circuit
E
Input command signal (potentiometerwiper or 0 to
K
Chassis
The
remaining
common.
sockets
are
OM-2204
Page
6
10 volts dc).
not used.
sb7 18/92
Figure
+
common.
3-6. Remote 14 Connections
Ret. ST-i 53625 / Ret. S-0004-A / S-0750
3-6.
Installing Gas Supply
WARNING
a
CYLINDERS
can
explode
if
BUILDUP OF SHIELDING GAS
health or kill.
damaged.
Keep cylinders away from welding
and
other
electrical circuits.
Never touch
.
Shutoff
cylinder
with
Always secure cylinder
other stationary support.
welding
to
shielding gas supply
can
when not in
harm
use.
electrode.
running gear, wall,
or
warn4.1 9/91
Obtain gas cylinder and chain to
running gear, wall, or other station
ary support so cylinder cannot fall
and break oft valve.
1
Cap
2
Cylinder
Valve
Remove cap, stand to side of
valve, and open valve slightly. Gas
flow blows dust and dirt from valve.
Close valve.
3
Cylinder
4
Regulator/Flowmeter
Install
5
so
face is vertical.
Gas Hose Connection
Fitting
has
5/8-18
right-hand
threads.
6
Flow
Adjust
Typical flow rate is 20 cfh (cubic
feet per hour). Check wire man
ufacturers
recommended
flow
2
rate.
I--
CO2 Adapter
8
0-Ring
Install
adapter with 0-ring between
and
regulator/flowmeter
CO2
cylinder.
3
I
7
9
Gas In
10
Gas Out
Fitting (Rear
Of Unit)
Fitting (Front Of
Unit)
OR
The Gas In and Gas Out
Argon Gas
have 5/8-18
Obtain
2
as
size,
proper
length hose and
5
fittings
hand threads.
right
and
type,
make connections
follows:
4
Connect hose from
shielding gas
supply regulator/flowmeter to Gas
In fitting.
Connect
3
r
shielding gas
fitting.
hose from
torch to Gas Out
CO2 Gas
GAS IN
9
Tools Needed:
~ 1-1/8,5/8
ssb3. I
Figure
3-7.
*
12/92
in
ST~158 697-A / Ref. S.0004.A / Ref. ST-I 53625 / ~f ~.o5~1 .~
Typical Regulator/Flowmeter Installation
OM-2204
Page
7
Connecting Input
3-7.
A
Power
WARNING
HIGH-FREQUENCY RADIATION
ELECTRIC SHOCK
can
interfere with radio
navigation, safety
and
services,
computers,
communications equipment.
can
kill.
Do not touch live electrical parts.
Turn Off
only qualified person familiar with electronic
equipment periorm this installation.
Have
welding
power source, and disconnect
input
power before
inspecting
Have
only qualified
persons install unit.
or
installing.
Installation must meet National Electrical Code and
all other codes.
Read and follow entire Section 8 for proper location
and installation requirements for high-frequency
equipment before installing unit.
Have
only qualified
persons make
this installation.
Three-Phase
System
.
Single-Phase System
1
Rating
Use
Hz,
Label
single
three-phase, 50/60
or
input
power which matches
one of the voltages shown. The
AUTO-LINK circuitry senses the in
ac
put voltage and automatically links
operation.
the unit for
2
Line Disconnect Device Of
Proper Rating
2
3
Input Power Cord
4
Grounding
Conductor
Green Or Green With Yellow
Stripe(s)
Install
conductors
and
input
grounding conductor from unit to
line
disconnect
deenergized
device.
9
Be
sure
grounding conductor
ground.
goes
to an earth
4
5
Black And White
Input Con
ductor
6
Insulation
7
Electrical
8
Red
Sleeving
Tape
Input Conductor
Red conductor not used in singlephase system. Insulate and isolate
conductor by sliding insulation
sleeving over end of lead, bending
lead back, and taping to power
cord.
9
Overcurrent Protection
Select fuses or Circuit breakers us
ing Table 3~2. Install into deener
gized line disconnect device (fused
disconnect switch
Pet. ST144
Figure
OM-2204
Page
8
3-8. Location And
Input
221 / Ret
shown).
ST.070 399-C / Ret. ST-146 123-A / 5-0657 / Ret. S-0092-A
Power Connections
Table 3-2. Electrical Service
Requirements*
Single-Phase
Three-Phase
230
460
575
230
460
575
42
21
16.4
50.8
29
23.6
60
30
25
80
40
35
Output
Rated
Fuse Or
In
These values
1
are
calculated from the 1990 edition of the National Electrical Code
Recommended fuse
allows fuse
or
Amperes
or
(NEC).
input amperage of the welding
circuit breaker size is that closest to 150% of rated
circuit breaker
sizing
up to 200% of rated
power
source.
Article 630-12(a) of NEC
input amperage.
Res. S-0092-F
SECTION 4OPERATION
WARNING
a
ELECTRIC SHOCK
Always
wear
Insulate
can
yourself from
,~
work and
all
panels
and
covers
Wear
~
ground.
~
Do not touch live electrical parts.
Keep
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
kill.
dry insulating gloves.
securely
in
Keep your
be hazardous
can
or use
breathing
can cause
Do not weld
near
Watch for fire;
Do not weld
on
Allow work and
injury.
fire
Keep
and
or
explosion.
panels,
place.
Pacemaker
wearers
~
~
covers, and
guards
closed
keep away.
Wearers should consult their doctor before
.
near arc
~
welding, gouging,
or
going
spot welding opera
tions.
combustible surfaces.
closed containers.
equipment
all doors,
in
securely
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
flammable material.
over
can cause
device.
keep extinguisher nearby.
Do not locate unit
MOVING PARTS
r
Read Material Safety Data Sheets (MSDSs) and
manufacturers instructions for material used.
WELDING
body protection.
Keep away from moving parts.
head out of the fumes.
Ventilate area,
helmet with correct shade of filter.
place
~-~
FUMES AND GASES
to your health.
welding
Wear correct eye, ear, and
Safety Precautions at beginning of manual for
welding safety information.
swa~6 I
See
to cool before
handling.
sic
10
1
I
Power Switch
2
Pilot
3
Preflow Time Control
ba
10/91
Li~ht
4
Amperage Control
2
5
Postflow Time Control
3
6
Arc Force
4
7
Output (Contactor) Switch
8
Amperage
(Dig) Control
Control Switch
9
Process Selector Switch
10
Optional AmperageNoltage
Meter And Switch
ST-146 125-A
Figure
4-1. Controls
OM-2204
Page
9
1
3
2
/
~ S8
1
Insulating Gloves
2
Safety Glasses
With Side
Shields
3
Welding
Helmet
Wear
dry insulating gloves, safety
glasses with side shields, and a
welding helmet with a correct
shade of filter (see ANSI Z491).
sb3.1
Figure
4-2.
10191
Safety Equipment
~
1
Work
Clamp
Use wire brush
Tools Needed:
~
sandpaper to
joint area. Use
to remove slag
or
clean metal at weld
chipping hammer
after welding.
Connect work clamp
paint-free
as
location
close t o weld
to
a
clean,
workpiece,
as possible.
on
area
sb4 1 5/92
Figure
4-3. Work
Clamp
1
Process Selector Switch
Use switch to select
type of weld
output. Use left position for SMAW
Welding. Use right position for
GTAW Welding with High Frequen
cy for arc starting, and center posi
tion for GTAW Welding without
1-figh Frequency.
Switch position determines the op
eration of the Arc Force (Dig), Pre
flow, and Postflow controls (see
Figure
4-6 and
Figure 4-9).
Ref ST-153 625
Figure
4-4. Process Selector Switch
Figure
OM-2204
Page
10
4-5.
Amperage
Control
Arc Force Control
1
This control
is
welding
and
cess
Selector
Figure 4-4)
used
only
(Dig)
for
SMAW
works when Pro
switch
is in the SMAW
(see
posi
tion.
Use control to
help
make vertical
or
start an arc or
overhead welds
increases
short-circuit
(control
amperage,
shown
as
in
Figure 2-1).
When set at 0, short-circuit amper
age is the same as normal welding
amperage.
When
set at 100, short-circuit
amperage increases to help arc
starting.
Select
cation.
are
setting
best suited for
Numbers
for reference
around
only.
Set control at 0 for GTAW
Figure
a
4-6. Arc Force Control
appli
control
welding.
(Dig)
WARNING
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Do not touch weld output terminals when contactor is
Do not touch electrode and work
clamp
energized.
at the same time.
swarn7 I 10/91
1
Output (Contactor) Switch
Use switch to select way of control
ling output.
For weld output, place switch in On
position.
For remote output control and to
preset amperage using optional
digital meter, place switch in Re
mote 14 position (see Section 3-5).
Weidoutputterminaisareenergized
when switch is On and Power is On.
Figure
4-7.
Output (Contactor) Switch
OM-2204
Page
11
1
Amperage Control
Switch
Use switch to select way of control
ling amperage.
For
a
~14
panel control,
position.
place
For remote control, place switch in
Remote 14 position (see Section
PANEL
3-5).
Remote control at Remote 14 is
A
EXAMPLE Of Combination Remote
front
switch in Panel
percent of front panel control
ting. See Example below.
Amperage
175
Control
2
Remote Foot Control
3
Remote Hand Control
4
Remote
set
Fingertip Control
200
0
PANEL
100~
A
75
ION
(3~ OUTPUT (CONTACTOR)
Set Switches
5
......................)
A
375
Set Control
Adjust
Remote Control
ST.1 59059 / S-0769 / S-0774
Figure
4-8.
Amperage Control Switch
The scale around each control is
marked in seconds.
I
Preflow Time Control
Use control to adjust the time that
gas flows before the welding arc is
started.
2
Postflow Time Control
Use control to adjust the time that
gas flows after the welding arc
stops.
These controls
ing
Figure
Page
12
only
are
for GTAW weld
work when Process
Selector switch (see Figure 4-4) is
ri one of the GTAW positions.
2.
OM-2204
and
4-9. Preflow/Postflow Time Controls
1
AmperageNoltage
Meter
Use meter to read amperage and
voltage output. The preset value is
displayed when not welding. The
actual value is displayed while
welding and is held for 15 seconds
after welding stops (see Section
5-4).
See tabte for the values
2
for AN switch
2
displayed
settings.
Meter Switch
Use switch to select amperage
or
voltage display.
Meter
A/V Switch
Positions
Display
When Not
When
Welding
Welding
A
Preset
Amps
Actual
V
Preset
Amps
Actual Volts
Figure
4-10.
Amps
AmperageNoltage
Meter And Switch
(Optional)
I
Pilot
2
Power Switch
Light
Use this switch to turn unit and pilot
light On and Off.
There is a 5 second time delay be
fore the unit is ready to weld.
Fan motor is
trolled and
thermostatically con
only runs when cooling
is needed.
2
Figure
4-11. Power Switch And Pilot
Light
OM-2204
Page
13
WARNING
a
BUILDUP OF SHIELDING GAS
harm health
can
Shut off shielding gas supply when not in
or
kill.
use.
warnl.1 9/91
1
Shielding
2
Valve
3
Torch
4
Foot Control
Output
Open valve
welding.
OR
Gas
on
Cylinder
Control
cylinder just
before
Torch output control or foot control
turns weld output and gas flow on
and off.
Close valve
ished
on
sb5.2
4-12.
Figure
~\
Install &
Connect
J
)
Equipment
\
Select
Section 7)
Insert
~
I
)
Tungsten
)
JJ
Into Torch
JJ
)
S-0621-C
2/92
Gas
~~~C\
Put On
Personal Safety
)
Equipment
JJ
)
Set Controls
)
Turn On
Gas
Shielding
I
~\\
TurnOn
Power
Source
)
Welding
J
~
) Tungsten (See
JJ
Shielding
when fin
cylinder
welding.
j
Begin Welding
JJ
ssb8
Figure
Install &
Connect
,
Equipment
))
Connec~i\
Install &
Pul ser Control
Unit
Turn On
Shielding Gas
)
Turn
))
Onj) Control))
Select
)
) Welding
Install &
Connect
J
4-14.
) I
I)
Turn On
Welding Powe
Pulsing
Begin
Source
)~~ntrol~~
Put On
Personal Safety
Equipment
Welding
_________________
Sequence Of
Select
Electrode
Equipment
________________
\ ~\
Insert
Tunasten
Into Thrch
Tungsten
( Section 7)
_________________
Figure
12192
Sequence Of Gas Tungsten Arc Welding (GTAW)
4-13.
________________
)
1
))
Gas
Tungsten
Arc
Welding
~\
Put On
Personal Safety
)
Equipment
JJ
)
Set Controls
))
Pulsed
(GTAW-P)
Insert
Electrode
Into Holder
~
Source
_______________
Begin
Ssb71 9/92
Figure
OM-2204
Page
14
4-15.
Sequence
Of Shielded Metal Arc
Welding (SMAW)
SECTION 5
a
MAINTENANCE & TROUBLESHOOTING
WARNING
ELECTRIC
SHOCK
can
kill;
SIGNIFICANT DC VOLTAGE exists after
removal of input power.
Do not touch live electrical parts.
~
~
MOVING PARTS
injury.
can cause
Keep away from moving parts.
,
Turn Off welding power source, disconnect input
power, wait 60 seconds, measure voltage on input
capacitors according to Section 5-2, and wait for
voltage to drop to zero before touching any parts.
HOT PARTS
can cause severe
STATIC ELECTRICITY
on circuit boards.
Put on
boards
grounded
or
burns.
cooling
servicing.
period
before
maintaining
damage parts
wrist strap BEFORE
handling
parts.
Use proper
Allow
can
static-proof bags
and boxes.
or
Maintenance
to
be
performed only by qualified
persons.
swarn81
5-1.
2/93
Routine Maintenance
Turn Off aI~ power before
maintaining.
Replace
Cracked
Parts
Torch Cable
Figure
ST~46
123-A
OM-2204
Page
5-1. Maintenance Schedule
15
5-2.
Removing
Case And
Measuring Input Capacitor Voltage
I
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
Turn Off welding power source and
disconnect input power.
Significant DC voltage can remain on capacitors af
Always check capacitors as shown to
be sure they have discharged before working on unit.
1
Top Of Case
ter unit is Off.
2
Handles
3
Outside Handle Screws
4
Side Bolts
To loosen top, remove two outside
handle screws from both handles
and all side bolts.
5
Bottom Of Case
6
Mounts
To loosen bottom,
remove
bolts, carefully place unit
on
all side
its side
and remove the four mounts.
7
Input Capacitors C12, C13
8
Input Capacitors C8, C9
Locate
9
on
lower left side.
Voltmeter
Check
both
of
sets
input
capacitors.
Measure dc
tive
voltage across posi
(+) and negative () terminals
every
30
drops
to 0
until
seconds
(zero)
voltage
volts.
After task is completed, reinstall
case.
9
5
7
Tools Needed:
~~
5/32 in
3/8,7/l6in
Ref. ST-152 114-0
Figure
OM-2204
Page
16
5-2.
Removing Case
And
Measuring Input Capacitor Voltage
Overload Protection
5-3.
I
A.
READ SAFETY BLOCKS at start of~
Section 5 before proceeding.
Overheating
Thermostat TP1 protects the unit from damage due to overheating. If power module PM2 gets too hot, TP1 opens and
weld output stops. The pilot light stays on, and the fan keeps running to cool the power module. Wait several minutes
before
B.
trying
to weld.
Fuses
Off
Turn
welding power source.
input power, and check
voltage on input capacitors accord
ing to Section 5-2 before proceed
ing.
disconnect
1
Fuse Fl
Fl protects control transformer T2
primary and the control circuitry
from
2
If
overload.
welding
power
Fl
source
opens, the
shuts down.
Fuse F2
F2 protects the 24 volts ac winding
of control transformer T2. If F2
opens, remote control devices con
nected to Remote 14 receptacle
RC2 shut down.
Check fuses and replace
as
need
ed.
See Parts List for fuse sizes. Use
proper tool when
3
removing fuses.
Fuse Holder
5T.146 12e.E / Ref. ST.146 122.5
Figure
Changing AmperageNoltage
5-4.
a
5-3. Overload Protection
Meter Hold Function
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
WARNING
The Amperage/Voltage meter is
able to hold the displayed weld out
put value for 15 seconds after weld
ing stops. If the hold function is not
used, the displayed value leaves
when welding stops.
This
procedure allows the hold
function to be turned On or Off.
Turn Off
welding power source,
input power, and check
voltage on input capacitors accord
Section
5-2
before
to
ing
proceeding.
disconnect
Front Panel
(Controls Vary
According To Model)
Tools Needed:
I
A/V Meter Board PC5
2
DIP Switch S2
S2 is accessible from the right side
of the unit.
3
Toggle
I
4
Toggle
2
Set
toggles
in desired
position.
Non-Conductive
Reinstall
Figure
5-4.
Changing Amperage/Voltage
case.
5T-159 050-A
Meter Hold Function
OM-2204
Page
17
5-5.
Troubleshooting
WARNING
a
MOVING PARTS
SHOCK
ELECTRIC
can
kill;
SIGNIFICANT DC VOLTAGE exists after
removal of
Keep
aw ay
from
c an cause
mo
injury.
ving parts.
input power.
Do not touch live electrical parts.
Turn Ott welding power source, disconnect input
power, wait 60 seconds, measure voltage on input
capacitors according to Section 5-2, and wait for
voltage to drop to zero before touching any parts.
STATIC ELECTRICITY
on
Put
on
boards
HOT PARTS
Allow
can cause severe
cooling period
before
burns.
can
damag e parts
circuit boards.
grounded
or
wrist
strap BEFORE handling
parts.
Use proper
static-proof bags
and boxes.
servicing.
Troubleshooting
to be
performed only by qualified
persons.
swarn8 1.2/93
Table 5-1.
Welding
Trouble
No weld output; unit
erative.
No weld
output; fan
light
Section
Remedy
completely mop-
Be
sure
Power switch is On.
Be
sure
line disconnect switch is On.
motor FM
running
-~
Figure4-11
3-7
Check and replace line fuse(s) if necessary. Reset circuit breakers.
3-7
Check for proper input connections.
3-7
Check and
and pilot
Trouble
Check
replace fuse
Fl if necessary.
position of Output (Contactor)
5-3B
switch 53.
-~
Thermostat TP1 open (overheating). Allow fan to run; the thermo
stat will close when the unit has cooled.
Low weld output with
no
Check position of
control.
Limited output and
low
open-circuit
-~
voltage.
Check
open
improper weld output.
-a
Tighten
Service
power for correct
reset circuit breaker.
incoming
or
Check for proper
or
all
input
welding
Check for proper
voltage. Replace
Replace
Page
18
electrode.
line fuse if
and output connections.
3-7
-a
and output connections.
cable connections.
input
5-3A
Station/Service Distributor
Check for proper size and type of cable.
OM-2204
4-7
Control switch S4.
Amperage
Have Factory Authorized
check control board PCi.
Erratic
Figure
on.
-~
3-3, 3.4, 3-7
-a
3-3,3-4
-a
3-3
3-3, 3-4, 3-7
7-1,7-2
Remedy
Trouble
Remotedevicecompletely inoperative.
-~
1
run.
-~
J
Wandering
arc; poor control of arc di-
-~
1-.~
j-s.~
Connect remote control to Remote 14 receptacle RC2.
Check fuse F2 and
Fan motor FM does not
Section
replace
if necessary.
Have Factory Authorized Service Station/Service
check thermostats TP2 and/or TP3 and fan motor.
Distributor
Reduce flow rate.
__________
5-3B
-~
--..
--
rection.
Tungsten electrode oxidizing and not
remaining bright after conclusion of
-~
Select proper size tungsten.
7-1
Properly prepare tungsten.
7-2
Shield weld
zone
from drafts.
--0.
--
weld.
Increase
postflow
Check and
tighten
time.
all gas
--0.
fittings.
--0.
Water in torch. Refer to torch Owners
replacement,
Lack of high frequency; difficulty
tablishing an arc.
in es-
-~
Be
sure
and
repair torch
torch cable is not
as
near
Manual for
part(s) requiring
necessary.
any
grounded
metal.
Check work and torch cable for damaged insulation
tions, and repair as necessary.
No
high frequency.
1
or
bad
connec
Check position of Process Selector switch.
Have
check
Factory Authorized Service Station/Service Distributor
high frequency board PC2.
-~
--a
Figure
4-4
--
OM-2204
Page
19
SECTION 6
ELECTRICAL DIAGRAMS
r
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ID
LI
W2
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8
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(DI)
1011
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C2.EI
I
I
L
/9
(82)
26
1621
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,
L_
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ar
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III
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60
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CONTACTOP
Figure
OM-2204
Page
20
6-1. Circuit
Diagram
For 230/460 Volt Models
8/
53
POSTFLOW
PPEFLOW
H~
I
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TONCH/
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SO-158 644-A
OM-2204
Page
21
C8
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A
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5
7
PCS
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RC30/PLG3O
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56
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CONTROL
SAIAW
HF
l~c
Figure
OM-2204 Page 22
6-2. Circuit
~F/GA5 al~i
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ON/GAS ON
0
Diagram
I
L~ATEO al~l
D~UT REd.
lATSD(
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TPI
S~A
For 460/575 Volt Models
85
8/
S.F
_________________
ha
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OM-2204
Page
23
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OM-2204 Page 26
6-4.
Wiring Diagram
For 460/575 Volt Models
7
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(I
In.
ID 0 -4 4 0 1
~
6~
P17
0
0
~
1
0
CoIIIC)>IZU)-
(~~~5:)
2.) Id)
934 (C
93E(P14)268CR
(0 9 C 3
0
Cl) 0
-U CD
Cl) ~1
SECTION 7
TUNGSTEN ELECTRODE
n,0d2 I 3/93
NOTE ~
For additional in formation,
Arc
Welding (G TA W)
Wear clean
Selecting Tungsten
7-1.
gloves
to
see
your distributor fora handbook on the Gas
Tungsten
process.
prevent contamination of tungsten electrode.
Electrode
Table 7-1. Tungsten Size
Amperage Range
DC
Electrode Diameter
Argon Electrode
Negative/Straight Polarity
-
Gas
DC
Argon Electrode
Positive/Reverse Polarity
Type
-
Polarity
AC
Argon Using
High Frequency
AC
Argon
Wave Using
Balanced
High Freq.
Pure
Tungsten
(Green Band)
.010
Uptol5
.020
5-20
*
5-20
10-20
.040
15-80
*
10-60
20-30
Uptol5
UptolO
1/16
70-150
10-20
50-100
30-80
3/32
125-225
15-30
100-160
60-130
1/8
225-360
25-40
150-210
100-180
5/32
360-450
40-55
200-275
160-240
3/16
450-720
55-80
250-350
190-300
1/4
720-950
80-125
325-450
250-400
*
Upto20
Upto
15-40
*
15-35
.040
25-85
*
20-80
20-60
1/16
50-160
10-20
50-150
60-120
100-180
2% Thorium
Alloyed
Tungsten (Red Band)
.010
Up
.020
.
to 25
15
5-20
3/32
135-235
15-30
130-250
1/8
250-400
25-40
225-360
160-250
5/32
400-500
40-55
300-450
200-320
3/16
500-750
55-80
400-500
290-390
1/4
750-1000
80-125
600-800
340-525
Upto2O
Uptol5
Zirconium
Alloyed
Tungsten (Brown Band)
Typical
.010
*
.020
*
*
15-35
5-20
.040
*
*
20-80
20-60
1/16
*
*
50-150
60-120
3/32
*
*
130-250
100-180
1/8
*
*
225-360
160-250
5/32
*
*
300-450
200-320
3/16
*
*
400-550
290-390
1/4
*
A
600-800
340-525
argon
shielding
gas ftow rates
are
15 to 35 cfh
(cubic feet
per
hour),
*Not Recommended.
The figures listed
manufacturers.
OM-2204
Page
28
are
intended
as a
guide
and
are a
composite of
recommendations from American
Welding Society (AWS)
and electrode
S-0009
7-2.
Preparing Tungsten
I
Tungsten Electrode
2
Balled End
Ball end of tungsten before welding
by applying either an ac amperage
slightly higher than what is recom
mended for a given electrode diam
eter (see Table 7-1), or a dc elec
trode positive amperage.
Ref 50161
Figure
a
~
7-1.
Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding
CAUTION
FLYING SPARKS AND HOT METAL
Shape tungsten
electrode
can cause
injury
and start fires.
only on grinder with proper guards in a safe location wearing
proper face, hand, and
body protection.
Keep flammables away.
warn2.1 9/91
2
1
Tungsten
2
Tapered
Electrode
End
Grind end of tungsten on fine grit,
hard abrasive wheel before weld-
ing. Donotusewheelforotherjobs
or
tungsten
nated
can
causing
become contami
lower weld
quality.
2-1/2 Times
Electrode Diameter
Ref. S-016l
1
i~~~
1
Stable Arc
2
Flat
2
Diameter of this flat determines
amperage
3
capacity.
3
Grinding
4
Straight Ground
Wheel
4
Ideal
Tungsten Preparation
Stable Arc
2
Ref. S-0162
1
Arc Wander
2
Point
3
Grinding
4
Radial Ground
Wheel
3
Wrong Tungsten Preparation
Figure
7-2.
Wandering Arc
Ref. 9-0162
Preparing Tungsten For DC Electrode Negative (OCEN) Welding
OM-2204
Page
29
SECTION 8
HIGH FREQUENCY
mod6,1 11/92
WARNING
a
HIGH-FREQUENCY RADIATION can interfere with radio
and communications equipment.
Have
H~))) )
c~t~.V
~
only qualified person familiar
The user is responsible for
installation.
S
~--~
If notified
by
the FCC about
Have the installation
with electronic
having
a
equipment perform this installation.
electrician
qualified
promptly
interference, stop using the equipment
regularly
navigation, safety services, computers,
correct any interference
problem resulting from the
at once.
checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting,
shown in Figure 8-3 to minimize the possibility of interference.
and
use
grounding
and
shielding
as
1
Gas
2
High-Frequency Voltage
Used to
Tungsten
help
arc
tween torch and
stabilize the
Arc Torch
jump air gap be
workpiece and/or
arc.
4
3
Submerged
4
Flux
5
High-Frequency Voltage
Used to
Submerged Arc
Welding (SAW)
Tungsten Arc
Welding (GTAW)
Gas
Figure
8-1.
through
Arc
Welding
Gun
help arc reach workpiece
granules.
flux
S 0693
Welding Processes Requiring High-Frequency
1
Sources Of Direct HighFrequency Radiation
High-frequency
with built-in
HF
source
(welder
separate HF
cables, torch, work
or
unit), weld
clamp, workpiece, and work table.
2
Sources of Conduction Of
High-Frequency
power cable, line disconnect
switch, and input supply wiring.
Input
3
Sources Of Reradiation Of
High-Frequency
Ungrounded metal objects, light
ing, wiring, water pipe and fixtures,
external phone and power lines.
-
~~-
-
50694
Figure
8-2. Sources Of
OM-2204 Page 30
High-Frequency Radiation
From Incorrect Installation Of
High-Frequency Source
/
/
/
Nonmetal
\~uilding
/
Metal
Building
10
S-0695
1
High-Frequency Source (Welder With
Built-In HF Or Separate HF Unit)
Ground metal machine case, work output
terminal, line disconnect switch, input sup
ply,
and worktable.
2
Center Point Of
Zone
Welding
A circle 50 ft
center
point
source
7
Weld
Keep
Water
Pipe
9
And Fixtures
External Power Or
Locate
Grounding
Rod
Consult National Electrical Code for
cations.
10
in all di
Telephone
and
8
Bonding
source
Metal
Building
Panel
Lines
at least 50 ft
high-frequency
(15 m) away from power
Windows And
specifi
Doorways
Cover
1/4 in
phone lines.
Meth
all
grounded
11
(6.4
windows and doorways with
copper screen of not more than
mm) mesh.
Overhead Door Track
ods
rections.
4
Bonding
Ground water pipe every 50 ft (15 m).
Zone
(1 5m) from
Conduit Joint
Electrically join (bond) all conduit sections
using copper straps or braided wire (ground
conduit every 50 ft 15 m]).
6
Welding
Midpoint between high-frequency
and welding torch.
3
5
Output
Bolt
Cables
cables short and close
together.
Figure
or
weld
building panels together,
copper straps or braided wire
and ground frame.
8-3. Correct Installation Of
install
Ground the track.
across seams
High-Frequency Source
OM-2204
Page
31
Cl) m C.) -I 0 z Co
-I Cl) r Cl) -I
12t-C
9-2
.35
26
24
Fig
ST-146
36
28
I
23
-~
38
Ilustraed)
23
Model
22
21
40
(208-3/46V
41
Asembly
15
44
45
Main
11
46
9-1.
47
Figure
Fig
4
48
49
50
$
0
r) F) a
-u
CD
C.) F)
51
:~
Quantity
Model
Part
No.
Dia.
Item
No.
Mkgs.
Description
Figure
..
.
8
..
9
..
.
.
126 416
.
.
138 442
.
.
+141 350
.
.
+141 574
.
.
.
.
.
.
.
.
C25
SR4
6
7
.
126 415
135289
149 219
136 191
R17
136 185
10
Fig
.
.
9-3
.
.
ii
133 405
.
.
..
12
108 105
.
.
..
13
136 227
.
.
.
.
..
..
Li -4
14
133 639
..
15
145 245
.
.
..
16
155 642
.
.
..
135786
.
.
..
140981
.
.
157 661
.
.
158567
.
.
157 660
.
.
158567
.
.
158 568
.
.
146 112
.
.
158 555
.
.
020 265
.
.
158570
.
.
139812
.
.
.
.
158 466
.
.
114066
.
.
158 465
.
.
113633
.
.
131 059
.
.
114 656
.
.
115 093
.
.
113 746
.
.
17..
..
..
.
17..
.
C8,9,12,13
C8,9,12,13
..
18
W1A
..
19
Wi
..
..
..
..
..
..
..
..
..
CT1
20
21
22
Ti
23..
..
R13-i6
.
.
..
24
Fig 9-2
RC7
25
PLG7
26
RC2O
27
28
.
.
..
PLG2O
..
.
.
.
.
..
..
..
2
2
2
2
2
2
CASE
1
1
CASE, bottom
1
1
CAPACITOR
KIT, rectifier integ 35A
CAP, protective vinyl .313 ID x .500 Ig
RESISTOR
PANEL, front w/components
NUT, speed 10-24 fIat type rectangular
1
1
1
1
1
1
1
1
2
CHOKE, DVDT
INSULATOR, elctlt
SCREW, set .250-28 x 1.000 cup pt sch stl
CAPACITOR, eIctIt4000uf25OVDC
CAPACITOR, eIctIt2800uf300VDC
INTERLOCK, cntor IEC 2NO-2NC 1OA 4P
LINK, jumper
2
2
2
2
8
8
CONTACTOR, IEC 25A 4P 2NO-2NC
1
1
TRANSFORMER,
i
1
.
6
6
1
1
.
.
148 330
.
.
134 229
.
.
135 635
.
.
.
.
.
.
.
..
113 746
..
34
604 939
.
.
..
34
152 710
.
.
..
35
Zi,2
141 437
.
.
.
36
T2
159 214
.
.
..
36
T2
162 166
.
.
..
37
140 894
.
.
..
38
605 227
.
.
..
39
GS1
158 583
..
40
T3
134 383
.
.
.
1
12
.
.
131 054
1
12
1
.
..
1
12
6
.
.
1
12
1
148 329
.
4
1
6
137 198
PLG21
1
4
.
.
..
1
HF
.
.
.
2
CONNECTOR, rect skt 20-l4ga Amp 350536-1
CONNECTOR, rect 12P/S plug Amp 1-480708-0
(partofl2)
CONNECTOR, rectpin20-14gaAmp350218-1
CONNECTOR & PINS, (consisting of)
CONNECTOR, rect pin 24-l8ga Molex 39-00-0040
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-i8ga Molex 39-00-0038
LABEL, warning electric shock
CASE SECTION, front/bottom/back (consisting of)
NUT, insert .312-18 panel mtg
NUT, insert 10-24 panel mtg
LABEL, caution incorrect voltage will damage unit
LABEL, caution incorrect voltage will damage unit
BUSHING, strain relief .640/.770 x 1.47Omtg hole....
CONNECTOR & PINS, (consisting of)
CONNECTOR, rect pin 24-l8ga Molex 39-00-0040
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-lBga Molex 39-00-0038
CABLE, pwr No. 8ga 4/c (order by It)
CABLE, port No. 10 4/c (order by It)
.
.
1
RESISTOR, WW fxd 30W 5K ohm
CHASSIS, mid
CONNECTOR, rect 1 2P/S rcpt Amp 1-480709-0
137 197
33
3
contacts
TRANSFORMER, current
CABLE TIE, 0-1.750 bundle
.
..
4
1
1
.
114 656
4
LINK,jumper
LINK, jumper large
BLANK, snap-in nyl .2i8mtg hole
.
..
1
4
.
.
.
2
126 026
.
.
4
+161 438
RC21
.
4
30
32
injury
4
29
..
can cause
CLAMP, capacitor 2.SOOdia
STRIP, mtg capacitor bracket
..
31
460/575V
Assembly
CLAMP, saddle
HANDLE, molded plastic
LABEL, caution falling equipment
.
..
9-1. Main
208-230/460V
...
.
.
.
.
.
.
1
1
4
4
4
4
1
1
1
.
1
2
1
2
.
.
.
.
1
1
2
1
2
1 2ft
STABILIZER
2
TRANSFORMER, control
TRANSFORMER, control
BRACKET, mtg stab
NUT, nyl hex jam .75ONPST
VALVE, 24VAC 2way custom port 1/8 orf
ARC STARTER, pulser HF
1
i2ft
2
1
1
1
1
1
1
1
1
1
OM-2204 Page 33
Quantity
Item
No.
Model
Part
No.
Dia.
Mkgs.
Description
Figure
136 190
.
.
.
138 115
.
.
.
031 613
.
.
601 394
.
.
41
..
..
..
..
42
C7
43
44
C26
RiB
45
R6
.
134 198
.
.
46
162 960
.
.
137 198
015 712
.
.
47
.
.
..
48
141 690
.
.
..
49
134 386
.
.
..
50
..
..
.
..
PC2
PLG5
PLG14
.
151 248
.
.
146 099
.
.
125748
.
.
128 336
.
.
125 748
.
.
51
134 327
.
.
..
52
133 948
.
.
..
53
143 915
.
.
134 421
.
.
143 748
.
.
..
+When
ordering
a
9-1. Main
208-230/460V
Assembly (Continued)
NUT, speed U type 10-32
2
2
CAPACITOR
1
1
CAPACITOR, elctlt lOOuf 15OVDC
RESISTOR, C 2W 10K ohm
RESISTOR, WW fxd 40W 500 ohm
ENCLOSURE, arc starter (consisting of)
1
1
1
1
NU1~ insert 10-24
GROMME1 rbr .625 ID x .875mtg hole
GROMME1 scr No. 8/10 panel hole .281 sq .197
.
high
INSULATOR, arc starter
KIT, circuit card arc starter
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rectskt22-18gaJSTSVH-21T-1.1
CONNECTOR, rect 3skt plug JST VHR-3N
CONNECTOR, rect skt 22-18gaJST SVH-21T-i.1
LABEL, warning general precautionary
FOOT, mtg
MOUN1~ sgl stud 1 .5dia x 1.000 Ig .312-18 stud
BUS BAR, (across leads of T3)
BUS BAR, (across C8,9 & Cl 2,13)
.
.
component originally displaying
.
a
precautionary label,
.
.
1
1
1
1
2
2
1
1
4
4
1
1
1
1
1
1
4
4
1
1
3
3
2
2
4
4
4
4
1
1
2
2
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-2204 Page 34
460/575V
Quantity
Item
No.
Model
Part
No.
Dia.
Mkgs.
Description
Figure
..
HD1
1
156313
PLG62
..
2
..
3
....
.
.
083 147
.
.
158 337
.
.
.
130 203
.
.
113 746
.
.
....
131 054
.
.
113 746
.
.
.
.
.
.
.
.
.
.
.
.
.
.
113 746
.
.
115 093
.
.
113 746
.
.
092
.
.
113 746
.
.
115 091
.
.
.
010 116
154 719
154 723
4
..
5
..
5
PCi
PCi
PLG2
....
131 054
113 746
.
...
PLG4
....
.
...
PLG6
....
.
PLG5,18,28
PLG1O
.
.
115 094
115
....
PLG12
.
.
.
PLG11,13.
..
.
.
PC3
PLG19
130 204
114 066
....
113 746
.
.
130 203
.
.
113 746
.
.
162 096
.
.
7
137 768
.
.
..
8
141 588
.
.
..
9
161 246
.
.
.
.
..
PC6
PLG1
....
PLG22
..
..
..
..
..
..
..
9
.
.
..
....
R27,28
....
Fl
F2
14
.
.
.
.
.
.
.
136 076
.
.
.
.
.
.
.
.
.
.
152 776
.
.
152 785
.
.
C40-43
031 689
149 209
086 323
.
.
.
.
.
.
.
.
.
16
113 746
SN1
TP3
16
.
.
09-12
.
.
.
012 571
*012 654
15
..
.
131 054
....
12
13
113 746
095 847
*099 398
10
11
115 091
..
C14,15
.
.
.
.
.
.
.
.
.
.
.
.
.
(consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
.
133290
.
..
072 253
.
..
158 549
.
.
.
.
.
.
.
150 912
.
.
.
.
.
.
123231
.
.
.
133 288
.
..
162168
.
..
17
152 780
.
.
..
18
..
19
000 527
146 581
..
.
.
..
20
133 295
..
21
..
22
135 661
132 232
FM
.
.
.
.
.
.
.
.
.
.
1
2
.
2
1
2
.
.2
1
4
.
1
6
.
.6
3
8
.
.8
1
10
.
10
1
12
.
12
1
1
4
1
1
10
1
2
2
1
1
1
1
.
1
1
.
1
1
1
1
.
.
.
KIT, diode fast recovery
THERMOSTAT, NO
HEATSINK,rect
STUD, connection single 10-32 x .500 x 1 .25Omtg
IGBT, LH (consisting of)
IGBT~ LH (consisting of)
CAPACITOR, polye met film .Oiuf 1600V
KIT, transistor IGBT module
150 913
12
.
1
CAPACITOR
..
2
2
RECTIFIER, si diode LH (consisting of)
.
1
2
2
.
SUPPRESSOR
.
10
1
.
.
1
3
.
1
12
.
.
RESISTOR, WW fxd 30W 200 ohm
HOLDER, fuse crtg 30A 600V
FUSE, crtg 3A 500V time delay
HOLDER, fuse miritr
FUSE, mintr gI 2A
1
10
.
PM1
..
3
.
.
PM1
R9,i0
.
1
1
CONNECTOR & SOCKETS,
.
157 451
.
.
.
460/575V
Chassis, Mid (Fig 9-1 Item 24)
TRANSDUCER,current300A
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 20-l4ga Amp 350536-1
GROMMET, scr No. 8/10 panel hole .312 sq .500 high
CIRCUIT CARD, hF preflow/postflow
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-lBga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
GROMMET, rbr .375 ID x .500mtg hole
CIRCUIT CARD, control
CIRCUIT CARD, control
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
TRAY, mtg PC card
GROMMET, rbr .750 ID x .875mtg hole
STAND-OFF, 8-32 x .500 Ig
CIRCUIT CARD, driver
.
161 221
9-2.
208-230/460V
..
1
1
4
4
4
4
1
1
1
1
4
4
1
1
.
.
2
2
1
KIT, transistor IGBT module
RESISTOR,WWfxd5OW35ohm
HEAT SINK, IGBT LH
HEATSINK,IGBTLH
BAFFLE, air wind tunnel LH
BLANK, snap-in nyl .875mtg hole
WIND TUNNEL, 6.500 in
CHAMBER, plenum 6.500 in
EDGE TRIM, style 3100-1/16 (order by ft)
MOTOR, fan 220/230V 50/60Hz 3000RPM
1
.
.
2
2
1
1
1
.
.
.
.
.
.
1
2
1
1
1
1
1
2ft
2ft
1
1
OM-2204
Page
35
23
2
27
26
18
28
48
29
30
47
31
46
45~~
~36
37
44
43~
38
37
39
/
41
40
ST-148 122-B
Figure
OM-2204 Page 36
9-2.
Chassis, Mid (208-230/460V Model Illustrated)
Quantity
Item
No.
Dia.
Model
Part
No.
Mkgs.
Description
Figure
..23..
155426
24..
134209
25..
PLG9
131 054
113746
26...
RC9.
24-l8ga Molex
(consisting of)
pin 24-l8ga Molex
39-00-0038
VCM1
151 199
146689
31
158815
161 222
016,17
157451
PM2.
150912
PM2.
150913
R11,12
123231
....SR1.
149208
....TP1.
006 334
TP2.
155053
158816
161 234
133968
031 689
149209
.
THERMOSTAT, NC
THERMOSTAT, NO
HEAT SINK, IGBT RH
HEAT SINK, IGBT RH
RECTIFIER, si diode RH (consisting of)
CAPACITOR
126026
145053
WASHER, shldr nyl .298 OD
42.
010493
006 426
BUSHING, snap-in nyl. 625 ID x .875mtg hole
CLAMP, capacitor 2.000dia
NUT, speed 10-24 flat type rectangular
CAPACITOR, polyp film 2.luf 1000VDC
INSULATOR, heat sink upper
STRIP, bus rect
STAND-OFF SUPPORT, PC card .l56dia
BUS BAR, interconnecting (across Cl ,2)
047 838
35.
030170
145407
Wi
145407
SN2
37
152775
136190
38
+158442
099 037
x
.203 ID
x
1.000
.O62shldr
44.
133405
01,2
132844
46.
47.
158443
158444
48.
134058
158557
PLG8
is part of 042 517
*Recommended
Spare
+When
a
ordering
Optional
2
1
1
1
1
1
1
1
41
34.
2
1
40.
139743
2
I
153178
601 835
..33.
1
1
39.
072 253
45.
1
..2
KIT, diode fast recovery
HEATSINK,rect
STUD, connection single 10-32 x .500 x 1 .25Omtg
NUT, brs hex 10-32
INSULATOR, heat sink lower
BLANK, snap-in nyl 1 .000mtg hole
BUSHING, snap-in nyl .750 ID x 1 .000mtg hole
CONTACTOR, def prp 25A 2P 24VAC
CONTACTOR, def prp 25A 2P 24VAC
SNUBBER, poly met film .1uf600VDC
NUT, speed U type 10-32
PANEL, center
EDGE TRIM, style 62-1/16 (order by ft)
LABEL, warning exploding parts
LABEL, warning electric shock
133290
43.
2
....
162097
30...
36.
2
1
29...
W2
1
BAFFLE, air wind tunnel RH
IGBT, RH (consisting of)
IGBT, RH (consisting of)
CAPACITOR, polye met film .Oluf 1600V
KIT, transistor IGBT module
KIT, transistor IGBT module
RESISTOR, WW fxd 50W 35 ohm
KIT, diode pwr module
29...
36.
.
1
1
1
114215
C44-47
Dl 3-16
rect skt
1
1
2
136076
32.
CONNECTOR,
1
39-00-0040
2
CONNECTOR, rect
1
RESISTOR, WW fxd 30W 200 ohm
RELAY,encI24VDCDPDT
1
CAPACITOR, polye film 2.3uf 25OVAC
1
MODULE, varistor/capacitor 3 220 joule 73OVDC
MODULE, varistor/capacitor 3 400 joule 1620-198OVDC
052 964
31
KIT, fan blade (consisting of)
NUT, speed push-on type .250
CONNECTOR & SOCKETS, (consisting of)
114656
R27.
.
24) (Continued)
1
CR1
050.
VCM1
.
9-1 Item
CONNECTOR & PINS,
27...
.
Chassis, Mid (Fig
460/575V
135635
27...
28...
9-2.
208-230/460V
1
1
4
4
4
4
1
1
4
4
14
1
1
1
1
1
1
1
6....
.6
1....
lft
2....
2....
x
4
1
2
2
2
1
1
2
.2
1
Meter Kit.
Parts.
component originally displaying
a
precautionary label,
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-2204 Page 37
3
7
8
(
Ac
I
10
112 I
I
C
-J
13
17
26
%-
26
25
19
22
19
20
L
21
81-146 120-6
Figure
OM-2204
Page
38
9-3. Panel, Front
w/Components
Item
No.
Part
No.
Dia.
Mkgs.
Description
Figure
1
R2
073 562..
2
R3
035 897..
3
134849..
..
..
..
5
S5
S4
S3
..
6
P05
...
PLG5O
.
..
..
4
134848..
011
..
089
222
..
7
134
058..
..
8
158
563..
..
..
..
.
9
136 339.
.
120 304.
.
.
.
..
Si
PLG3.
128 755..
..
.
131 054..
113 746.
..
RC3
12
...
.
..
..
13
14
15
R4,5
.
.
.
.
RC2
.
.
.
.
..
16
PC4
...
PLG3O,31
.
.
.
..
18
19.
C6
.
.
Pos,Neg
.
.
.
134 734
.
134 731
.
.
079 739.
.
143922.
.
.
147608..
130 203.
.
.
.
138 115..
129 525..
042418..
..
..
..
..
..
20
134834..
120854..
039 885..
21
22
23
24
093 551
..
..
25
..
26
097 924..
27
135 299..
28
097 922..
..
..
Part
PL1
of 042 517
.
..
.
.
143976..
113 746
..
.
115440..
17
.
146684..
121 770..
079 534.
..
.
135635..
114 656.
..
.
148297..
10
11
.
157 958..
Optional Meter
w/Components (Fig
9-1 Item
10)
POTENTIOMETER, C std slot 1/1 2W 10K ohm
POTENTIOMETER, C std slot l/T 2W 1K ohm
SWITCH, tgl DPDT 15A 125VAC
SWITCH, tgl SPOT 15A 125VAC
SWITCH, tgl DPDT 15A 125VAC
CIRCUIT CARD, meter
134 847..
157
9-3. Panel, Front
Quantity
.
1
1
1
1
1
1
CONNECTOR, rect llskt plug Amp 1-640440-1
STAND-OFF SUPPORT, PC card .l56dia
STRIP, protector PC card
COVER, opening meter (not used when unit has Meter Kit)
BLANK, snap-in nyl .25Orntg hole (not used when unit has Meter Kit)
NUT, speed U type 10-32
SWITCH, tgl DPST 40A 600VAC
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-lBga Molex 39-00-0038
CONNECTOR & PINS, (consisting of)
CONNECTOR, rect pin 24-1 8ga Molex 39-00-0040
1
4
1
1
1
2
1
1
.
2
.
2
INSULATOR, switch power
POTENTIOMETER, C sltd sft l/T 1W lOOK ohm
CONNECTOR w/SOCKETS, (consisting of)
CONNECTOR, circ skt push-in 14-1 Bga Amp 66358-6
CONNECTOR, circ 14 pin plug Amp 213571-2
CONNECTOR, circ pin push-in 14-lBga Amp 21 3603-1
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2 (or)
CONNECTOR, circ clamp str rif sz 17-20 Amp 206070-3
STAND-OFF, 6-32 x .687 Ig
CIRCUIT CARD, receptacle bypass
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-lBga Molex 39-00-0038
1
1
2
1
14
.
4
1
2
12
..
CAPACITOR
1
RECEPTACLE, twlk insul fern (Dinse type) 50/70 series
CONNECTOR KIT, Dinse male 50 series
2
2
HOSE,SAE.18710x.41000(orderbyft)
FITTING,gas
2ft
1
CONNECTOR, circ protective cap Arnphenol 9760-20
NAMEPLATE, (order by model and serial number)
KNOB, .l25dia shaft w/.125 setscrews
LIGHT, md wht lens 28V
KNOB, pointer
LOCK, shaft knob .375-32 x .25Odia shaft
KNOB, pointer
1
1
2
1
1
1
1
Kit.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-2204
Page
39
OPTIONS AND ACCESSORIES
INTELLlTIG~ 4 PRECISION
(#042 598)
Provides
Frequency: Adjust
within
TIG CONTROLLER
highfrequency
arc
starting, timed gas solenoid control
and metering, pulsing, sequencing,
sloping, onscreen voltage and
amperage metering, and two relay
contacts for fixtu ring. The control
provides four modes of operation:
Automatic, Semiautomatic, Manual
a
the
pulse
to 200
pulsespersecond
pulsespersecond.
Pulse Width: Adjust the amount
of on
time. Maintains arc stability.
Adjusts from 1 to 5 milliseconds.
Peak Current Level: Set the
peak
wave
amperage that the pulse
form will allow (25% to 100%
GTAW and SMAW. For detailed
information, refer
electrode droplet.
to
product
(DC TIG)
CONTROL
can
be
use
with
an
external
highfrequency unit. The control
has two internally switchable
scales:
0.5 to 20
a
pulsespersecond
scale for both
inverter and noninverter
type
power sources, and
a
pulsespersecond
scale for
inverter power
10 to 300
interconnecting
14pin Amphenol plug.
AMTV REMOTE CONTACTOR
AND CURRENT CONTROL
(#152 608)
Fastens to TIG torch handle
source).
sizes, gases, materials, and joint
configurations.
Includes 25 ft. (7.6 m) connector
a 17pin
plug for direct
connection to the front of the
cord and
source.
using
two Velcro
strips. The control
allows complete current and
fingertips
a
operators
practical alternative
to a foot control. Includes 28 ft.
(8.5 m)
plug.
control cord with
14pin
EXTENSION CORDS FOR
REMOTE CONTROLS AND
24 VAC WIRE FEEDERS
14pin Amphenol plug to a 14-pin
Amphenol socket.
10 ft. (3 m)
(#122 972)
25 ft. (7.6 m)
(#122 973)
50 ft. (15.2 m) (#122 974)
75 ft. (22.8 m) (#122 975)
XMT RACK
REMOTE CONTROLS
(#042 648)
Compatible with
cord and 115 VAC
RFC-14 FOOT CONTROL
power sources, this rugged rack
houses and powers up to eight
XMT 300 power sources. The rack
power cord. Front panel controls
provide:
Peak
Amperage Adjustment
Background Amperage
Adjustment
PulsesPerSecond
Adjustment
(0.5 to 20 pulsespersecond
or
to 25% of
This control allows precision pulse
welding with a wide variety of wire
power
Includes 28 ft. (8.5 m) cord and
only.
(2.4 m)
sources
Control includes 8 ft.
scale
current level to
(3%
maximum output of power
(#042 297)
it
background
(#129 338)
Fastens to TIG torch handle.
contactor control at the
Current Level: Set
sustain the arc
Can be used with power sources
that have builtin high frequency,
or
Background
the
PULSED GTAW
PC300
FTC-14 REMOTE CONTACTOR
AND CURRENT CONTROL
of maximum output of power
source). Helps pinch off the
Literature Index No. AY/9.0.
rate
range of 20
10 to 300
pulsespersecond
scale)
Percent On Time Control
Amperage Remote/Panel Control
Output Contactor On/Off Control
(#129 339)
Foot current and contactor control.
Includes 20 ft. (6 m) cord and
Remote Control Receptacle (for
remote hand or foot controls)
63 in. (1 .6 m) wide x 40
(1.01 m) deep x 64 in. (1626
mm) tall and weighs 1700 lbs. (771
measures
14pin plug.
in.
RHC-14 HAND CONTROL
kg). The rack uses 230/460 VAC
primary voltage to power all the
(#129 340)
Miniature hand control for remote
power
current and contactor control.
The XMl Rack provides many
important features:
Dimensions: 4 in. (102 mm) x 4 in.
(102 mm) x 31/4 in. (82 mm).
Includes 20 ft. (6 m) cord and
14pin plug.
sources.
Pilot
light
indicates when rack has
power
Two
115 VAC, 20 Amp GFCI
duplex receptacles for auxiliary
-
Pulser On/Off
Power On/Off
all XMT 300
TORCHMOUNTED
REMOTE HAND
tools
Provisions
for
paralleling
CONTROLS
sources or common
MMP MANUAL MIG PULSER
RMLS1
connections
PENDANT CONTROL
(#129 337)
Momentary
(#042 727)
The MMP Manual MIG Pulser
4
Power
and
pulse wave form. This control
provides independent control of the
maintainedcontact rocker switch
for contactor control. Push forward
for maintained contact and back for
momentary contact. Includes 20 ft.
four parameters that affect the
(6 m)
pulse process:
plug.
Control allows manual control of
the
cord and
14-pin Amphenol
power
work
sources can
be locked
down to prevent theft
Captured secondary cable
hangers for work leads and weld
cables
Center
Rugged
pushing
lifting
eye
skids for
dragging
or
OPTIONS AND ACCESSORIES
XMT ECONOMY CART
tray above power
(#134 505)
Small and lightweight. Slanted for
convenient access to front panel
controls. Storage compartment for
gloves, helmet, etc. Can be used
used with the MaxtronTM, Miller Arc
with Maxtron~
or
PakTM
or
supplies.
source.
Can be
XMT inverter power
Also accommodates
Radiator, WatermateT~,
or
BACKLIT
XMl WIRE FEEDER QUICK
(#042
(#042
DISCONNECT
(#042 491)
Attaches S21
E
feeder to XMT
case.
SOURCES VIDEOTAPE
or
S22A
LCD DIGITAL
describing
slanted for convenient
access
a
to
front panel controls.
Carries two 160 lb. (72.6 kg) gas
cylinders, or one gas cylinder and
source
coolant system for GTAW
(TIG) welding. Feeder mounted
to
INTERNATIONALSTYLE
sources are
Internationalstyle connectors
secondary connections.
(Power source is shipped with
for
mm
517
518
hold
operator
function that allows
after
welding is stopped. Weld
setting is held for 15 seconds
before meter is automatically
cleared. Meters are easy to read in
indoor or outdoor environment.
CONNECTORS
(win accept Dinsev
EXTENSION KIT FOR
INTERNATIONALSTYLE
CONNECTORS
Used to
adapt
and/or work cables.
INTERNATIONALSTYLE
CONNECTOR KIT
Kit includes
one
male
Internationalstyle plug and one
inline female Internationalstyle
receptacle.
(#042 419) 50 mm
Accepts #1 or #2 AWG
with power source must be
replaced, if additional plugs are
(#042 534) 70 mm
Accepts #1/0 or #2/0 AWG
needed.
cable.
if #1/0
or
male
plug
one
Internationalstyle
work and/or weld cables and
on
plugs
style
the power
in.)
must be
Miiier
or
specified when ordering any
Expert Program diskette.
other International
source.
connectors.)
ADAPTER
A
onepiece adapter which has an
male plug (to
power source) on one end and a
CamLok receptacle (for weld
cable connection) on other end.
INTERNATIONAL1~IG TORCH
CONNECTOR
Required
for direct connection of
torches with
size
torches
a
or
aircooled
one-piece cable
assembly.
Torches
INTERNATIONALiTWECOfi
Kit includes gas hose, gas hose
fitting, and Internationalstyle TIG
ADAPTER
Block.
(#042 465)
which attaches to the
receptacles
size cable.
cable
#2/0 AWG size
into the International
Note: The serial number of the power
and diskette size (51/4 or 31/2
source
watercooled
cable is to be used.
Kit includes
Expert Program
Literature Index No. AV/6.0.
For AIrCooled
size.
Required
For detailed information,
reference Miller
Internationalstyle
(#042 418) 50 mm
Accepts #1 or #2 AWG cable size.
Required if male plugs shipped
(#042 533) 70 mm
Accepts #1/0 or #2/0 AWG
software program used to
diagnose and service the power
(#042 466)
male
Internationalstyle plugs for use
with #1 or #2 AWG size cable.)
(#042 623)
Easytouse computerized
INTERNATIONAL/CAM-LOK
CABLE
extend weld
or
sources.
MILLER EXPERT PROGRAM~
source.
to read actual weld values
videotape
family of
the XMT
inverter power
Factory)
Field)
presettability and real time
display of voltage and amperage.
Presetting welding current and
voltage helps to provide optimum
welding conditions. Meters feature
wire
(#042 537)
Has adjustable handles and is
two -50
(#137 760)
An 8 minute VHS
Allows
XMT CYLINDER CART
All XMT power
equipped with
XMT INVERTER POWER
Coolmate~ coolant systems.
METERS
one
(#039 885)
XMT inverter
power supplies.
power
DUST CONNECTOR CAP
A
onepiece adapter which has an
Internationalstyle male plug (to
power source) on one end and a
female Tweco receptacle (for weld
cable connection) on other end.
(#135 492)
For 80 Amp, air-cooled torch with
onepiece
cable
assembly.
(#135 493)
For 150 Amp, air-cooled torch with
onepiece
cable
assembly.
9/92
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