Miller | KE621826 | Owner Manual | Miller XMT 400 CC 50HZ User manual

Miller XMT 400 CC 50HZ User manual
Miller
April
Form:
1994
OM-155 152B
Effective With Serial No. KE621 826
OWNERS
MANUAL
XMTfi 400 CC
CC/DC
Welding
Power Source
For GTAW, GTAW-P, And SMAW
400
Amperes,
Welding
36 Volts DC At 60%
Uses Three-Phase
Input
Protection For Control
14-Pin Remote Control
See Rear Cover For
Duty Cycle
Power
Circuit,
24
VAC, And Overheating
Receptacle
Options
And Accessories
Read and follow these instructions and all
blocks carefully.
U
Give this manual to the operator.
safety
Have
and qualified persons
service this unit.
only trained
install, operate,
or
Call your distributor if you do not understand
the directions.
cover
1/94
ST-i 52 303-A
~
'
U
1I~fl
1994 MILLER Electric
For
or:
help,
MILLER Electric
Appleton,
Mfg.
Co.
call your distributor
WI 54912
Mfg. Co.,
P.O. Box 1079,
414-734-9821
PRINTED IN USA
iJ
MILLERS
TRUE BLUETM LIMITED WARRANTY
(Equipment with
warranty supersedes all previous MILLER warranties and is exclusive
This limited
LIMITED WARRANTY
Effective January 1, 1992
serial number preface of KC
Subject
or
a
with no other
newer)
guarantees
to the terms and conditions below. MILLER Electric
Remote Controls
warrants to its
Accessory Kits
Replacement Parts
MIg. Co., Appleton, Wisconsin,
original
retail
purchaser
that new
MILLER equipment sold after the effective date of this limited warranty is tree of de
facts in material and workmanship at the time it is shipped by MILLER. THIS WAR
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES. EXPRESS OR
IMPUED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT
NESS.
MILLERS
True
BlueTM
Items fumlshed
1.
Limited
or
warranties expressed
Warranty
trade accessories. These items
ranted parts
any.
periods listed below. MILLER will repair or replace any war
components that fail due to such defects in material or workmanship.
MILLER must be notified in writing within thIrty (30) days of such defect or failure, at
which time MILLER will provide instructions on the warranty claim procedures to be
Consumable components; such
2.
and
followed.
MILLER shall honor warranty claims on warranted equipment listed below in the
event of auch a failure within the warranty time periods. All warranty time periods
atari on the date that the equIpment was delivered to the Original retail purchaser, or
one year after the equipment Is sent to the distributor.
relays
Equipment
3.
or
Original
main power rectifiers
3YearsPartaandLabor
Plasma Arc
Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Robots
Parts and Labor
2 Years
Engine Driven Welding Generators
(NOTE:. Engines are warranted separately by
for a period of iwo years.)
Air Compressors
4.
as
contact
tips, cutting nozzlas,
contactors
to normal wear.
that has been modified
by any party
Other than MILLER.
or
equip
improperly installed, improperly operatod or misused
based upon industry standards, or equipment whIch has not had reasonable
and necessary maintenance, or equipment which has been used for operation
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER
CIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUiPMENT.
Transformer/Rectifier Power Sources
3.
parts that fail due
5YearsParts3YearaLabor
*
2.~
to:
ment that has been
outside of the
1.
apply
implied.
by MILLER. but manufactured by others, such as engInes or
are covered by the manufacturers warranty, if
Within the warranty
or
shall not
or
1 Year
the
engine
manufacturer
TO THE EXTENT PERMITTEDBY 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
TRACT. TORT OR ANY OTHER LEGAL THEORY.
Parts and Labor
Motor Driven Guns
Process Controllers
Water Coolant
In the event of a warranty claim covered by this warranty, the exclusive remedies
shall be, at MILLERS option: (I) repair~ or (2) replacement; or, where authorized in
writing by MILLER inappropriate cases, (3) the reasonable Cost of repair or replacemental an authorized MILLER service station; or (4) payment of or ci edit for the pur
chase price (less reasonable depreciation based upon actual use) upon return of the
goods at customers risk and expense. MILLERS option of repair or replacement
will be FOB., Factory atAppleton. Wisconsin, or F.O.B. ala MILLER authorized ser
vice facility as determined by MILLER. Therefore no compensation or reimburse
ment for transportation costa of any kind will be allowed.
Systems
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR
RANTY, GUARANTY OR REPRESENTATION ASTO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY OIHER LEGAL
THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION.
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 IS EXCLUDED AND DISCLAIMED BY MILLER.
HFUnits
Grids
Spot Welders
Load Banks
SDX Transformers
Running Gear/Trailers
Options
Field
Some states In the U.S.A. do not allow limitations of how long an implied warranty
or the exclusion of Incidental, indirect, special or consequential damages, so
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.
(NOTE: Field options are covered under True BIueTM for the remaining
warranty period of the product they are installed in, or for a minimum of
is greater.)
one year whichever
5.
8 Months
6.
90
lasts,
Batteries
In
Days
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
set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be available, but may
from
to
province
province.
vary
or
Parts and Labor
waived, the lImitations and exclusions
MiG GunalTIG Torches
Plasma
Cutting
Torches
RECEIVING-HANDLING
Before Unpacking equipment, check carton for any damage that may have occurred during shipment. File any claims for loss or damage
with the delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment manufacturers
Transportation Department.
equipment, always provide Model Designation
When requesting information about this
Use the following spaces to record Model
or
Designation
and Serial
or
and Serial
or
Style Number.
Style Number of your Unit. The information is located on the rating label
nameplate.
Model
Serial
or
Style
No.
Date of Purchase
miller 9/93
ERRATA SHEET
July 19,
1994
FORM: OM-155 152B
Use above FORM number when
After this manual was printed, refinements in
appearing later in this manual.
ordering
extra manuals.
equipment design occurred. This sheet lists exceptions to data
CHANGES TO SECTION 8- PARTS LIST
Change
**
Parts List
as
follows:
Part
No.
25-
Added
2930-
152300
166 250
Replaced
With
169772
Description
.
169402.
169 403
.
.
.
.
SPACER,
case (Effw/KE679384)
HEATSINK,IGBTLH
HEAT SINK, IGBT RH
digit represents page no digits following dash represent item no.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
**First
Quantity
8
1
1
ARC WELDING SAFETY PRECAUTIONS
WARNING
a
ARC WELDING
can
be hazardous.
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, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
ELECTRIC SHOCK
can
terminal in disconnect box
kill.
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 touchin9 the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
1.
Do not touch live electrical parts.
2.
Wear
3.
4.
5.
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 poweraccording
to OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install and ground this equipment according to its
Owners
6.
Always verify
check and be
supply ground
sure
that
input
ARC RAYS can burn eyes and skin;
NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes.
(/~
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays that
can burn eyes and skin. Noise from some processes
can damage hearing. Chipping, grinding, and welds
cooling throw off pieces of metal or slag.
..
--
NOISE
1.
Use
approved
I
I
I
ear
plugs
or ear
FUMES AND GASES
can
2.
If inside, ventilate the
remove
welding
area
use
4.
Read the
manufacturers
be hazardous
arc
3.
poorly spliced
grounding of the workpiece is required, ground it directly
with
a
over
separate cable
your body.
do not
use
work
clamp
or
work cable.
13.
Do not touch electrode if you are in contact with the work,
ground, or another electrode from a different machine.
14.
Use only well-maintained equipment. Repair or replace
damaged parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to
15.
17.
workoiece
or
worktable
as near
the weld
as
oractical.
ARC RAYS
2.
Wear
a
welding helmet fitted with
a
proper shade of filter to
protect yourface and eyes when welding orwatching (see ANSI
Z49.1 and Z87.1 listed in
3.
Wear approved
4.
Use
and
5.
Wear
5.
to
Safety Standards).
safety glasses
with side shields.
protective screens or barriers to protect
glare; warn others not to watch the arc.
others from flash
protective clothing made from durable, flame-resistant
(wool and leather) and foot protection.
Work in
a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained
watchperson nearby. Welding fumes and gases can displace air
and lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
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.
Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the
area
is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
coatings,
4.
Never
5.
Never allow
drape
Protect
8.
mechanical shocks,
9.
Keep protective cap
explode
contain
damaged.
under
high
gas
pressure. If damaged, a cylinder can explode. Since
are
normally part of the welding
gas cylinders
process, be sure to treat them carefully.
2.
or
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.
can
Shielding gas cylinders
1.
use.
drape cables
7,
if
when not in
damaged, undersized,
If earth
cleaners, and degreasers.
CYLINDERS
worn,
Do not
use an
instruction for metals, consumables,
equipment
use
11.
approved air-supplied respirator.
Material Safety Data Sheets (MSDSs) and the
If ventilation is poor,
Do not
material
fumes and gases.
3.
grounding
12.
high.
exhaust at the
attach proper
cables.
be hazardous to your health,
and/or
a
double-check connections.
Turn off all
6.
Keep your
making input connections,
9.
10.
head out of the fumes. Do not breathe the fumes.
1.
is connected to
plug
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
Welding produces fumes and gases. Breathing these
can
that cord
8.
to your health.
fumes and gases
.......J
muffs if noise level is
When
conductor first
cord around wire is Drooerlv connected to around
oower
-
the
7.
16.
Manual and national, state, and local codes.
or
properly grounded receptacle outlet.
Touching
compressed gas cylinders from excessive heat,
slag, open flames, sparks. and arcs.
Install 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
circuits.
6.
7.
in
10.
use or
a
a
in
place over valve except when cylinder
connected for
is
use.
Read and follow instructions on compressed gas cylinders,
associatedequipment,andCGApublicationP-1 listedinSafety
Standards.
srl1.1 2194
WELDING
can cause
fire
explosion.
or
Welding on closed containers, such as tanks, drums,
or pipes, can cause them to blow up. Sparks can fly
off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating, or
fire. Check and be sure the area is safe before doing
any welding.
yourself
and others from
Protect
Do not weld where
3.
Remove all flammables within 35 ft
4.
5.
flying sparks
and hot metal.
flying sparks
1.
2.
can
strike flammable material.
(10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be
aware
ENGINE EXHAUST GASES
Engines produce
ENGINE
7.
can
can
kill.
fire
cause
or
explosion.
fuel is
highly
Do not weld
Stop engine
Do not add fuel while
smoking
or
MOVING PARTS
on
on a
ceiling, floor, bulkhead,
or
partition
the hidden side.
on
closed containers such
as
tanks, drums,
or
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.
8.
Connect work cable to the work
9.
Do not
welder to thaw frozen
use
pipes.
Remove stick electrode from holder
10.
contact
tip when
Wear oil-free
11.
not in
or
welding wire
at
protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and
12.
cut off
use.
a
cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
be hazardous.
can
1.
Use equipment outside in open, well-ventilated
2.
If used in
a closed area, vent engine exhaust outside and
away from any building air intakes.
3.
Do not overfill tank
4.
Do not
allow
If fuel is
spill fuel.
room
for fuel to
spilled,
areas.
expand.
clean up before
starting
engine.
checking
if unit is
welding
pipes, unless they are properly prepared according to AWS F4. 1
(see Safety Standards).
flammable.
and let it cool off before
1.
2.
fire
ENGINES
harmful exhaust gases.
FUEL
that
can cause
WARNING
a
Engine
6.
or
near
adding fuel.
any sparks
can cause
or
injury.
3.
Have
only qualified people
remove
guards
or
covers
for
maintenance and
Moving parts, such as fans, rotors, and belts can
fingers and hands and catch loose clothing.
4.
cut
5.
1.
Keep all doors, panels,
securely in place.
2.
Stoo
covers,
engine before installing
and
guards
closed and
6.
or
connecting
unit
Keep hands, hair,
parts.
Reinstall
panels
loose
or
disconnect
clothing, and tools away from moving
guards and close doors when servicing is
starting engine.
finished and before
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin.
Batteries contain acid and generate
gases.
troubleshooting as necessary.
To prevent accidental starting during servicing,
negative () battery cable from battery.
explosive
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
It is best to check coolant level when engine is cold
to avoid scalding.
1.
2.
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.
If the
use
cause
welder to
engine
is
sparks when working
charge
batteries
polarity ( and )
warm
and
on
checking
or
jump
on a
battery.
start vehicles.
batteries.
is needed, follow
steps 2
and 3.
2.
Wear
3.
Turn cap
safety glasses and gloves and put a rag over cap.
slightly and let pressure escape slowly before
completely removing cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49. 1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA
29 CFR 1910, from
dent of Documents, U.S. Government
D.C. 20402.
Superinten
Printing Office, Washington,
Recommended Safe Practices for the Preparafion for Welding and
Cutting of Containers That Have Held Hazardous Substances, Ameri
can Welding Society Standard AWS F4.i,from American Welding So
ciety,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Pro
tection Association, Batterymarch Park, Quincy, MA 02269.
srl.1.1 2/94
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis High
way, Suite 501, Arlington, VA 22202.
Code for
Safety in Welding and Cutting,
GSA Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou
levard, Rexdate. Ontario, Canada M9W 1 R3.
Safe Practices For Occupation And Educational Eye And Face Protec
tion, ANSI Standard Z87. 1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting
And
Welding Processes, NFPA Standard 51 B, from National
Batterymarch Park, Qilincy, MA 02269.
Fire Protection Association,
EMF INFORMATION
NOTE ~
Considerations About
Magnetic Fields
Welding
And The Effects Of Low
The
To reduce
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
Backg round 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
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.
.
Keep
1.
magnetic
fields in the
cables close
cables to
Frequency
workplace,
together by twisting
or
use
taping
the
following
them.
side and away from the operator.
2.
Arrange
3.
Do not coil
4.
Keep welding power
practical.
source
5.
Connect work
to
one
Electric And
.
or
drape
cables around the
clamp
body.
and cables
workpiece
as
as
far away
as
close to the weld
as
possible.
About Pacemakers:
The
above
procedures
are
recommended for pacemaker
complete information.
among
wearers.
those
also
normally
Consult your doctor for
modlO.1 4/93
TABLE OF CONTENTS
SECTION 1
SAFETY INFORMATION
SECTION 2
SPECIFICATIONS
2-1.
2-2.
1
1
2
Volt-Ampere Curves
Duty Cycle
2
3
SECTION 3-INSTALLATION
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
Typical Process Connections
Selecting A Location And Moving Welding Power Source
Selecting And Preparing Weld Output Cables
Connecting To Weld Output Receptacles
Remote 14 Receptacle Information And Connections
Connecting Input Power
MAINTENANCE & TROUBLESHOOTING
5-1.
Routine Maintenance
5-2.
Removing Top
5-3.
Overload Protection
5-4.
5-5.
Of Case And
3
4
6
6
7
8
SECTION 4-OPERATION
SECTION 5
3
13
13
Measuring Input Capacitor Voltage
Changing AmperageNoltage
Troubleshooting
14
15
Meter Hold Function
16
16
ELECTRICAL DIAGRAMS
18
SECTION 7- TUNGSTEN ELECTRODE
22
SECTION 6
7-1.
7-2.
Selecting Tungsten Electrode
Preparing Tungsten
SECTION 8
Figure
Figure
Figure
PARTS LIST
22
23
24
8-1. Main
24
8-2.
26
Assembly
Panel, Front w/Components
8-3. Chassis, Mid
28
OM-155 152B4~94
SECTION 1
SAFETY INFORMATION
-
modl.1 2/93
Read all
safety messages throughout
Obey
safety messages
all
Learn the
1
meaning
to avoid
this manual.
injury.
of WARNING and CAUTION.
2
1
Safety
Alert
2
Signal
Word
2
\
ELECTRIC SHOCK
can
instslling
or
input power
sersicing.
before
I
MOVING PARTS
I~~III~I.
Do not touch live electncal parts.
Disconnect
WARNING means possible death
or serious iniury can happen.
a CAUTION
kIIl.~
Keep
away from
Keep
all panels and
operating.
when
CAUTION
Injure. I
can
I
closed I
moving parts.
covers
READ SAFETY BLOCKS at start of
SectIon 3-1 before proceeding.
WARNING
NOTE
~
Turn Off switch when
4
Safety
5
Hazard
6
Safety
Instructions To Avoid
Hazard
Read
Safety
safety
blocks for each sym
NOTE
Special instructions
ation
1-1.
Symbol (If Available)
Banner
bol shown.
using high frequency.
Figure
can
Statement Of Hazard And
Result
7
7H
possible minor
3
I
/
a
means
injury or equipment damage
happen.
5
6
Symbol
for best oper
not related to
safety.
Information
SECTION 2- SPECIFICATIONS
Table 2-1.
Welding
Power Source
Specification
Description
Type Of Output
Constant Current
Rated Weld
400
Type
Of
Amperes, 36 Volts DC
(See Section 2-2)
Output
Input
(CC), Direct Current (DC)
At 60%
Duty Cycle; 300 Amperes,
32 Volts DC At 100%
Duty Cycle
380 Or 415 Volts AC; 50 Hz; Three-Phase
Power
Input Amperes At Rated Output
32.6 A At 380 V.30.4 A At 415 V
(60% Duty Cycle);
23 A At 380 V.21.6 A At 415 V
(100% Duty
Cycle)
KVA/KW Used At Rated
Output
Amperage Range
Max.
Open-Circuit Voltage
21.7 kVA/16.6 kW
5-400 A
80 Volts DC
Welding Processes
Scratch Start Gas Tungsten Arc (GTAW), Scratch Start Gas
Shielded Metal Arc (SMAW) Welding
Input Power Cord
13.1 ft
Overall Dimensions
Length: 21-3/4
Weight
Net: 77 lb
Tungsten
Arc
-
Pulsed
(GTAW-P),
(4 m)
in
(522 mm);
Width: 12 in
(305 mm); Height:
17-3/8 in
(441 mm)
(35 kg); Ship: 82 lb (37 kg)
OM-155 152
Page
1
2-1.
Curves
Volt-Ampere
The volt-ampere curves show the
minimum and maximum voltage
80
and amperage output capabilities
of the welding power source.
Curves of other settings fall be
70
tween the curves shown.
60
50
40
>
8
30
20
10
0
0
100
50
150
200 250 300 350 400 450 500
DC AMPERES
ssbl.1 10/91 SB-139
Figure
2-2.
2-1.
Curves
Duty Cycle
CAUTION
a
WELDING LONGER THAN RATED DUTY CYCLE
S
Volt-Ampere
721
Do not weld at rated load
longer
can
damage
unit and void warranty.
than shown below.
wam7.1 8/93
Charl
Definition
0
~
10
Duty Cycle is percentage of
minutes that unit
rated load without
can
10
weld at
overheating.
Minutes
100%
60%
Duty Cycle At 300 Amperes
Continuous
Welding
Duty Cycle
At 400
Amperes
10
15
20
25 30
% DUTY
6 Minutes
Welding
4 Minutes
40
50
60 7080
Resting
sbl.4
Figure
OM-155 152
Page
2
100
CYCLE
2-2.
Duty Cycle
Chart
8/93
SB-132 583
SECTION 3-INSTALLATION
3-1.
Typical
Process Connections
+
+
GTAW
Pulse
Control
Pulsed GTAW
Or
GTAW
+
Figure
3-2.
Selecting
A Location And
3-1.
Typical
Process Connections
Moving Welding
WARNING
4~
ELECTRIC SHOCK
FUMES can be hazardous; LACK OF
FRESH AIR AND PROPER VEN
TILATION can be harmful.
kill.
can
Do not touch live electrical parts.
Disconnect input
energized supply
power
Power Source
power conductors from de
line BEFORE moving welding
source.
FIRE OR EXPLOSION
can
unit on, over,
bustible surfaces.
placing
Do not locate unit on, over,
surfaces.
Do not install unit
near
result from
or
near
or near
com
combustible
flammables.
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.
Have two persons of adequate
physical strength lift
unit.
BLOCKED AIRFLOW causes over
heating and possible damage to unit.
Do not block
Warranty is
or
filter airflow.
void if any
type of filter is used.
Move unit with hand cart
or
similar device of ade
quate capacity.
If using a fork lift vehicle,
skid before transporting.
secure
unit
on a
proper
swam11.1~3/93
OM-155 152
Page
3
Movement
Handles
Lilting
I
Use handles to
unit.
move
Hand Cart
2
Use cart
or
similar device to
move
unit.
Rating
3
Label
Use
rating label to determine
power needs.
2
Line Disconnect Device
4
Locate unit
er
input
near
correct
input pow
supply.
Location And Airflow
3 in
(78 mm)
6 in
3
(156 mm)
mm)
ssb9.1
Figure
3-3.
Selecting
And
3-2. Location And Movement Of
Preparing
Weld
Welding
12/93. ST-146 129.81 Ref. ST-151 556
Power Source
Output Cables
1
Weld
Output Cable
Determine total cable length in
weld circuit and maximum welding
amperes. Use Table 3-1 to select
proper cable size.
Use shortest cables
Do not
2
use
possible.
damaged
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
Circuit =20 ft (6 m)
Tools Needed:
3
Insulated Electrode Holder
4
GTAW Torch
Install
to manufacturers
according
instructions.
5
Work
Clamp
Install onto work cable.
Dinse-Type
Connector
Figure
OM-155 152
Page
4
3-3.
Selecting And Preparing Weld Output Cables
~
-
Install onto weld cable
Figure 3-4.
sbL~2
as
shown in
11192 -~-O656
-
6
1
Weld
2
Handle
3
Sleeve
Cable
Output
Slide handle onto cable; strip cable
and install sleeve.
4
Connector Body
5
Setscrew
1 in
Insert cable with sleeve
(26 mm)
connector
fully into
body, tighten setscrew,
and slide handle
over connector.
If job
requires cable larger than 3/0
AWG, use 2 ft (610 mm) or shorter
piece of 3/0 AWG cable for Dinse
Type connector installation. Con
nect other end of short cable to the
4/0
or
larger weld
cable.
5-~
4~
3~
-~
Tools Needed:
ST-156 496
Figure
3-4.
Dinse-Type
Connector
Assembly
Table 3-1. Weld Cable Size*
Total Cable
100 ft
(30 m)
Or Less
(Copper) Length
150ft
(45 m)
In Weld Circuit Not
200ft
250ft
(60 m)
(70 m)
I
Exceeding
300ft
350ft
400 ft
(90 m)
(105 m)
(120 m)
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
210
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
210
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
*Weld cable size
(AWG) is based
on
either
a
4 volts or less
10 Thru 100%
drop
or a
current
density
Duty Cycle
of at least 300 circular mils per ampere.
5-0007-0
OM-155 152 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
cable connectors while
connections.
welding.
receptacles before welding.
swaml2.2 2/93
1
Positive
2
Negative ()
Receptacle
3
Connector
(+)
Receptacle
Weld
Output
I
Weld
Output
For DC Electrode Positive (DCEP),
connect work cable connector to
negative () receptacle and elec
trode holder cable connector to
positive (+) receptacle.
For
DC
Electrode
Negative
reverse
cable
(DCEN),
connections.
To connect to
receptacle, align key
way, insert connector, and turn
clockwise until tight.
3
Ref. ST-154 155A
Figure
3-5.
Remote 14
3-5.
Connecting
Receptace Information
To Weld
I Ref. ST-152 223
Output Receptacles
And Connections
1
Remote 14 Receptacle RC2
Table 3-2)
(See
2
2
Keyway
3
Plug
4
Threaded Collar
To connect to
keyway,
insert
receptacle, align
plug, and tighten
threaded collar.
OR~
sb7.1 12/93
Figure
OM-155 152
Page
6
3-6. Remote 14 Connections
ST-BOO 695/ Ref. S-0004-A / S-0750
Table 3-2. Remote 14 Socket Information
Socket*
REMOTE 14
(~
OUTPUT
(CONTACTOR)
A
The
A
24 volts
B
Contact closure to A completes 24 volts
C
+10 volts dc
D
Remote control circuit
common.
E
0 to +10 volts dc
command
K
Chassis
ac.
Protected
output
by fuse
F2.
ac
contactor control circuit.
to remote control.
AMPERAGE
remaining sockets
3-6.
Socket Information
are not
input
signal
from remote control.
common.
used.
Connecting Input
Power
Table 3-3. Electrical Service
Requirements*
Input Voltage
380
415
Input Amperes At Rated Output
32.6
30.4
50
45
Recommended Standard Fuse Or Circuit Breaker
These values
are
Rating
In
Amperes
calculated from the 1993 edition of the National Electrical Code
1 Recommended fuse or circuit breaker size is that closest to 150% of rated
allows fuse
or
(NEC).
input amperage of the welding power source. Article 630-12(a) of NEC
Ret. S.0092-G
circuit breaker sizing up to 200% of rated input amperage.
a__WARNING
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Turn Off
Have
welding power source, and disconnect input power before inspecting
only qualified persons install unit.
or
installing.
Installation must meet National Electrical Code and all other codes.
A.
Positioning Jumper
swam~.1 2iP.~
Links
Jumper links allow operation on dif
ferent input voltages and are facto
ry set for 380 volts input power.
Check input voltage available at
site.
Remove top of
Section 5-2.
.1
1
case
according
to
Input Voltage Label
Look at jumper links and compare
link position with unit label.
2
Input Voltage Jumper Links
2
Move links to match input voltage.
For example, use 415 volts posi
tion when 415 volts input power is
available.
Reinstall top of
case.
Tools Needed:
ssb5.r 2192
Figure
3-7.
Ref. ST-155 414-A / Ret. S-145 063
Input Voltage Jumper Links Location
O~.1-155 152
Page
7
B.
Connecting
To
Input Power
Have only qualified persons make
this installation.
1
Line Disconnect Device Of
2
Proper Rating
Grounding Conductor
Green Or Green With Yellow
Stripe(s)
Input Conductors
Install grounding conductor
3
input conductors
line
deenergized
and
unit to
disconnect
from
device.
Connect 9rounding conductor first,
then line Input conductors.
Be sure grounding conductor goes
to an earth ground.
4
Overcurrent Protection
Select
type and size using
Table 3-3. Install into deenergized
line disconnect device (fused dis
connect switch shown).
4
3
ssb2.3 11(93
Figure
3-8. Location And
Ret. SC-144 221 / ST-152 303-A / Ret. S-0092C
Input Power Connections
SECTION 4-OPERATION
a
WARNING
ELECTRIC SHOCK
Always
Insulate
wear
can
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
kill.
dry insulating gloves.
yourself from work and ground.
Do not touch live electrical parts.
Keep all panels
and
covers
FUMES AND GASES
to your health.
Keep your
securely
in
9,.~
Wear welding helmet with correct shade of filter.
i.
Wear correct eye, ear, and
MOVING PARTS
be hazardous
can
or use
breathing
can cause
Do not weld
near
Watch for fire:
on
Allow work and
OM-155 152
Page
8
covers, and
guards closed
and
or
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
explosion.
Pacemaker
flammable material.
over
injury.
device.
keep extinguisher nearby.
Do not locate unit
Do not weld
fire
Keep all doors, panels,
securely in place.
~
Read Material Safety Data Sheets (MSDSs) and
manufacturers instructions for material used.
WELDING
can cause
Keep away from moving parts.
head out of the fumes.
Ventilate area,
body protection.
place
combustible surfaces.
closed containers.
equipment to cool before handling.
~
S
~
wearers
keep away.
Wearers should consult their doctor before
near arc
welding, gouging,
or
going
spot welding opera
tions.
See Safety Precautions at beginning of manual for ba
sic welding safety information.
swarn6l 10/91
Power Switch
1
2
Pilot
7~
3
Amperage Control
~
5~
4
Arc Force
o~lt~~1
3
Control
(Dig)
5
Output (Contactor) Switch
6
Amperage Control Switch
7
Process Selector Switch
8
Optional AmperageNoltage
2
4
Light
Meter And Switch
sr.152 224
Figure
1
4-1. Controls
3
2
Wear the
/
~
following
while
welding:
1
Dry, Insulating Gloves
2
Safety Glasses
With Side
Shields
3
Helmet With Correct
Shade Of Filter (See ANSI
Welding
Z49.1)
sb3.1 1/94
Figure
4-2.
Safety Equipment
1
1
Tools Needed:
Work
Clamp
Connect work clamp to
paint-free
as
location
close to weld
on
a
clean,
workpiece,
area as
possible.
Use wire brush or sandpaper to
clean metal at weld joint area. Use
chipping hammer
after welding.
to remove
slag
sb4.1 2/93
Figure
4-3. Work
Clamp
1
Process Selector Switch
1
~
Use switch to select type of weld
output. Use SMAW position for
Shielded Metal Arc Welding. Use
GTAW position for Gas Tungsten
Arc Welding.
Switch position determines the op
eration of the Arc Force (Dig) con
trol (see Figure 4-6).
Ref. 5D-154 155-A
Figure
4-4. Process Selector Switch
OM-155 152
Page
9
1
Amperage Control
Use control to select weld amper
age. Amperage may be adjusted
while welding.
Figure
4-5.
Amperage
Control
1
Arc Force Control
(Dig)
This control is used for SMAW
welding and only works when Pro
cess Selector switch (see Figure
4-4) is in the SMAW position.
1
Use control to
make vertical
help
start an
arc or
overhead welds
Control increases amperage at low
arc
or
voltage (see Figure 2-1).
When set at 0, short-circuit amper
age at low arc voltage is the same
as
normal
welding amperage.
When set at 100, short-circuit am
perage at low arc voltage in
creases to
help
arc
starting.
Select setting best suited for appli
cation. Numbers around control
are for reference only.
Set control at 0 for GTAW welding.
Figure
a
I~
-.
~
(Dig) Control
WARNING
ELECTRIC SHOCK
S
4-6. Arc Force
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.
swam7.1 10/91
1
Weld output terminals are energized
when switch is On and Power is On.
Output (Contactor) Switch
Use switch to select way of control
ling output.
For weld output,
place switch
in On
position.
For remote output control, place
switch in Remote 14 position (see
Section 3-5).
1
Figure
OM-155 152
Page
10
4-7.
Output (Contactor)
Switch
Amperage
1
Control Switch
Use switch to select way of control
ling amperage.
For front panel control,
switch in Panel position.
~14
place
For remote control, place switch in
Remote 14 position (see Section
3-5).
~----f~
Example:
CombInation Remote
Remote control at Remote 14 is
of front panel control
percent
1
setting.
2
Fingertip Control
3
Remote Hand Control
4
Remote Foot Control
See example below.
Amperage Control
175
200
0
143
I
~
A
5
Set Desired Maximum
Set Switches
)
Amperage
Adjust
Remote Control
ST-I 59 059 / S-0769 / S-0774
Figure
4-8.
Amperage
Control Switch
1
AmperageNoltage
Meter
Use meter to read amperage and
is
voltage output. The preset value
displayed when not welding.
When
Meter
AN Switch
Positions
welding,
the meter
displays
weld amperage output of the unit if
amperage is selected, If voltage is
Display
When Not
When
Welding
Welding
selected when welding, the meter
displays voltage at the weld output
terminals, but not necessarily the
welding arc due to cable resis
A
Preset
Amps
Actual
V
Preset
Amps
Actual Volts
Amps
tance, poor connections, etc.
The value
displayed is held for 15
seconds after welding stops if the
hold function is On (see Section
5-4).
See table for the values
for A/V switch settings.
2
2
displayed
Meter Switch
Use switch to select amperage
or
voltage display.
Figure
4-9.
AmperageNoltage
Meter And Switch
(Optional)
OM-155 152
Page
11
1
Pilot
2
Power Switch
Light
Use this switch to turn unit and
and Off.
pilot
light On
There is a 5 second time delay be
fore the unit is ready to weld.
Fan motor is thermostatically con
trolled and only runs when cooling
is needed.
.2
Figure
\
1
J
lnstall&
Connect
Equipment
~\
Install&Conneci\\
~
JJ
Hi9h-Fre9uencY))
Unit
4-10. Power Switch And Pilot
Select
Into
________________
)
torch
________________
~
\
PutOn
Per sonalSafety
Equipment
1)~~in9Powe~)~
~
Sourc
________________
Turn On
Turn On
Set Controls
))
Insert
Tuncisten
Tungsten (Se
Section 7)
Light
Shielding Gas
Begin Weg
Unit
___________________
___________________
___________________
ssb8.1
Figure
1
I
Install&
Connect
~\~\
1
Equipment~,J)
J
Source
Tungsten
Controi)) Hi9h.Fre~uencY)
Unit
______________
__________________
________________
1
Of Gas
InstalI&Connect~\\
Pulser
Unit
Turn On
Welding Power
Sequence
InstalI&Conne~\\
I
______________
_________________
________________
4-11.
Set Controls
~J
______________
_______________
________________
~))
Arc
Select
Insert
Tunasten
~,J}
\
)
4-12.
Turn On
Turn On
lurn On
High-Frequency
Pulsing Control
Unit
Sequence
Select
Electrode
)
) Weldin~
lnstall&
Connect
Of Gas
Tungsten
V\
Put On
Personal Safety 1
1
Arc
Welding
Set Controls
.
Equipment
~,
)
________________
Equipment ~
Equipment
________________
Into iorch
y
_______________
__________________
________________
Shielding Gas
________________
Figure
Welding (GTAW)
Tungsten (See
Section 7)
_______________
_________________
________________
12/92
-
Pulsed
Begin
Welding
________________
(GTAW-P)
Insert
Electrode
Into Holder
Source
y
________________
Begin
ssb7.1 9192
Figure
OM-155 152
Page
12
4-13.
Sequence
Of Shielded Metal Arc
Welding (SMAW)
SECTION 5- MAINTENANCE & TROUBLESHOOTING
A~
WARNING
ELECTRIC
SHOCK
can
kill;
SIGNIFICANT DC VOLTAGE exists after
removal of input power.
Do not touch live electrical parts.
~
Turn Off welding power source, disconnect input
power, wait 60 seconds, measure voltage on input
capacitors according to Section 5-2, and be sure
voltage is near zero before touching any parts.
MOVING PARTS
Keep
away from
Allow
can cause severe
cooling
servicing.
period
before
burns.
maintaining
injury.
moving parts.
STATIC ELECTRICITY
on circuit boards.
Put on
boards
HOT PARTS
can cause
can
damage parts
grounded wrist strap BEFORE handling
or
parts.
Use proper
static-proof bags
and boxes.
or
Maintenance
to
be
performed only by qualified
persons.
swarn8.3 2/94
5-1.
Routine Maintenance
Turn Off all power before
maintaining.
14-Pin Cord
Torch Cable
5T-152 303-A
Figure
5-1. Maintenance Schedule
OM-155 152
Page
13
5-2.
a
Removing Top
Of Case And
Measuring Input Capacitor Voltage
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
WARNING
Significant DC voltage can remain on capacitors after unit
Is Off. Aiways check capacitors as shown to be sure they
have discharged before working on unit.
3
Turn Off welding power source and
disconnect input power.
1
Top Of Case
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
input Rectifier
6
Voltmeter
SRi
Measure the dc votage across the
positive (+) and negative () termi
nals until voltage drops to near 0
4
(zero) volts.
Proceed with job inside unit. Rein
stall top of case when finished.
Tools Needed:
5/32 in
~r
3/8,7/i6in
ST-155 414-A
Figure
OM-155 152
Page
14
5-2.
Removing Top Of Case And Measuring Input Capacitor Voltage
Overload Protection
5-3.
I~I~
A.
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
Overheating
minutes
Let fan
When overheated, thermostat
opens, output stops, and cooling
fan keeps running.
run
for
Start welding.
15 minutes.
ssbl0.1 1/94
Figure
B.
5-3.
ST-152 303-A
Overheating
Fuses
Turn Off welding power source,
disconnect input power, and check
voltage on input capacitors accord
5-2
before
ing to Section
proceeding.
1
Fuse Fl
If Fl
opens, the welding power
shuts down.
source
2
Fuse F2
If F2 opens, remote control devices
connected to Remote 14 recep
tacle RC2 shut down.
Check fuses
needed.
and
replace
as
See Parts List for fuse sizes. Use
proper tool when removing fuses.
3
Fuse Holder
Tools Needed:
Ret. ST-155 414
Figure
5-4. Overload Protection
OM-155 152
Page
15
Changing AmperageNoltage
5-4.
A~
Meter Hold Function
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
WARNING
The
AmperageNoltage meter is
able to hold the displayed weld out
put value for 15 seconds after weld
ing stops. If the hold functien 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
5-2
before
ing to Section
proceeding.
disconnect
1
Digital
2
DIP Switch S2
Meter Board PC5
S2 is accessible from the
of the unit.
3
Toggle
1
4
Toggle
2
Set
both
toggles
in
right side
desired
position.
Reinstall top of
case.
Front Panel
(Controls Vary
According To Model)
Tools Needed:
ST-159 050-A
Figure
5-5.
5-5.
Changing AmperageNoltage
Meter Hold Function
Troubleshooting
a
WARNING
SHOCK
ELECTRIC
kill.
can
SIGNIFICANT DC VOLTAGE exists after
removal of input power.
Do not touch live electrical parts.
Turn Off welding power source, disconnect input
power, wait 60 seconds, measure voltage on input
capacitors according to Section 5-2, and be sure
voltage is near zero before touching any parts.
HOT PARTS
Allow
can cause severe
burns.
~7~ii~
M OVING PARTS
can cause
injury.
Keep away from moving parts.
STATIC ELECTRICITY
on circuit boards.
Put on
boards
grounded
or
wrist
can
damage parts
strap BEFORE handling
parts.
Use proper
static-proof bags
and boxes.
cooling period before servicing.
Troubleshooting
to be
performed only by qualified
persons.
swam9.3 2/94
OM-155 152
Page
16
Table 5-1.
WeldIng
Trouble
Trouble
No weld output; unit
Section
Remedy
~
J
completely mop-
erative.
-~
Be
sure
Power switch is On.
-~
_____________________________________________________
Be
sure
fuse(s)
Check for proper
and
Check fuse Fl and
No weld
and
output; fan
pilot light on.
motor FM
running
-~
replace if necessary. Reset circuit
input connections.
Check position of input
Check position of
voltage jumper
replace
links.
no
control.
J
-~
Check
switch.
Limited
output and low open-circuit
i
-~
Check
open
Check
power for correct
circuit breaker.
incoming
position
of
or
improper weld output.
completely
mnoperativej
-~
voltage. Replace line fuse
if
1
input voltage jumper links.
J_
-~
3-6A
Figure
4-7
5-3A
Figure
4-8
-~
3-6B
-~
3-6A
..i,~_3-3,
3-4, 3-6
Tighten all welding cable connections
-~
3-3, 3-4
Check for proper size and type of cable.
-~
3-3
Check for proper input and output connections.
-~
3-3, 3-4, 3-6
--
Connect remote control to Remote 14
receptacle
RC2
Check fuse F2 and replace if needed.
7-1
7-2
]
-~
3-5
J
-~
5-3B
~
Factory Authorized Service Station/Service Distributor
check thermostats TP2 and/or TP3 and fan motor FM.
Fan motor FM does not run after approximately four minutes of operation at
3-6B
-~
Replace electrode.
Remote device
-~
-
Check for proper input and output connections.
Erratic
3-6B
-~
position of Amperage Control switch
or reset
-~
-~
Have Factory Authorized Service Station/Service Distributor
check control board PCi.
voltage,
3-6B
5-3B
Thermostat TP1 open (overheating). Allow fan to run; thermostat
closes when unit has cooled.
Low weld output with
-~
if needed.
Output (Contactor)
4-10
___________
line disconnect switch is On.
Check line
breakers.
Figure
-~
rated load.
Wandering arc; poorcontrol of arc direction.
~
I
-~
1
Reduce flow rate.
-~
.1
____________________________________________________
_____________
Select proper size
tungsten.
Properly prepare tungsten.
Tungsten electrode oxidizing and not remaining bright after conclusion of weld.
J
-~
Shield weld
Increase
zone
from drafts.
J
-.
7-1
]
-~
7-2
-~
postf low time.
Check and
tighten
all gas
fittings.
Water in torch. Refer to torch Owners Manual for
replacement, and repair torch as necessary.
-~
part(s) requiring
-.
OM 155 152
Page
17
SECTION 6- ELECTRICAL DIAGRAMS
w
5
LI
6
L2 p
____________
7
RC9
PLO9
-I
12
RC2
A
IL(
>
C
0
0
RC6-3
RC6-2
42
RC 10-4
4.2
D
>
REF.
<<RC3I-3
C~4.
PC 10-2
56
PC 12-3
C
E
>-~~
OJT
>REF.
IN
(RC3I-4
PCI2-9
(RC3I-2
p.)
P3
C,
PA~EL
PC4
FILTER
6OARD
RC3O/PL.G30
RC3 I /PLG3 I
~.JTPUT/
ca~TACTa~
~42Tj7
42
K
>
~
_ RC3I -12
0
GTAW
e
R$41
~~RC~3I-~
>
c~1TACT~
I
60
RC3O-II>
Figure
OM-155 152
Page
18
6-1. Circuit
Diagram
For
Welding
Power Source
L3
TIC
J
L4
Pc28-3
Pc28-8
PCI
cI~1TR~. BOARD
RC2/PLG2
PC4/PI..G4
RC6/P106
RCB/PLG8
PC 10/PLC 10
PC 12/PLC 12
PC I 8/PI..G 8
PC28/PL.028
Pc28- I
PC28-6
PCI2-I I
PC 12-10
o
io
POSITIVE
NEGATIVE
SD-166 254
OM-155 152
Page
19
Figure
OM-155 152 Page 20
6-2.
Wiring Diagram
For
Welding
Power Source
E
I
LI
~3TA(RC7-2) <L~9 1PC7-4)
00
1~U
i~1 F~1M~
ir
(Jil
-
-~~
Or!
I.
~
~rL
~ØI
Li
,.~
/~1:IT~
,,
2
0
ii
_
_
GPO
278(F2 42F(BA~
~I351A37(A(PP1.L~
Iu ~
_
~G8-3
r3~
O~G1
~~
SILO)
67A(G
0
r P.)
42P(IGO-l)
42K(Rcw)
~
cl_F.,)
-I
0
r
:1
~~ (~PL
0
-~
2
,.
-
C
I
~08iAt~G:O8j~T
ØI1_i
7
III
Cl Cd 0
0
I)- )~
$
4
GSA
U
T~,I>Itc
N~
10 L
LI
1
-I
PLG8/CB
P
I.
010
-.
-w
LI Cd
-
R~2
LI rO
10 -Cx>
I,
C
69A
SILO)
(POS
It, I.0 I~
-2)
F 4
~1
.84(PLG3I
PS
IA
--
I
LI m 0
rr I. I~I
-I
~
0
~
It
(~ _~
I
-4 0 ~0
-l
C,
r
Dx. ~0_I_LI rn> _r
LI
I
I.,
1~T~
~tUI)1 WHT(PLG4-3)
C-)
4~4
II II
LI m 0
(
i:~i ~i
0
I
!
9
(C9-~EG) (
(PC2-A)
~10L
~
Il)
a
(P
69A
69(L.H
_
r
a, 0 -l -I 0
BLx/WTtPGI2-
RECT)
~S6O(PL.G3I ~
0
r
4~(P1G3l-2_ 18(PC4-) 6O(PIG3
II
_ ~I-tklo.-I1 L _
I~
1~
I~
I~
1~
. It.1I
I
I
LI..
P14
~
I
0
r
0
r (.1
0
0
2
0
0
U P
01 01 - 013 -u 5)
5)
SECTION 7- TUNGSTEN ELECTRODE
mod2.1 1/94
~
N OTE
Foradditional inform ation,
Wear clean
7-1.
Selecting Tungsten
yourdistributorfora handbook on the Gas Tungsten
see
Welding (GTAW) process.
Arc
gloves
to
prevent contamination of tungsten electrode.
Electrode
Table 7-1.
Tungsten
Size
Amperage Range
Electrode Diameter
DC 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
Uptol5
UptolO
.020
5-20
5-20
10-20
.040
15-80
1/16
70-150
10-60
20-30
10-20
50-100
30-80
3/32
125-225
1 5-30
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
to 20
UptolS
2% ThorIum
Alloyed
Tungsten_(Red_Band)
.010
Up
*
to 25
.020
15-40
.040
25-85
1/16
50-160
Up
*
15-35
20-80
20-60
10-20
50-150
60-120
5-20
3/32
135-235
15-30
130-250
100-180
1/8
250-400
25-40
225-360
160-250
5/32
400-500
40-55
300-450
200-320
3/16
500-750
55-80
400-500
290-390
1/4
750-1000
80-125
600-800
340-525
Upto2O
Uptol5
*
*
15-35
5-20
*
20-80
20-60
Zirconium
Alloyed
Tungsten (Brown Band)
.010
.020
.040
*
*
1/16
3/32
60-120
100-1 80
1/8
*
225-360
160-250
5/32
*
300-450
200-320
3/16
*
400-550
290-390
*
600-800
340-525
1/4
Typical argon shielding gas
NOt
50-150
130-250
flow rates are 15 to 35 cfh
(cubic feet per hour).
Recommended.
The figures listed
manufacturers.
are
OM-155 152 Page 22
intended
as a
guide
and
are a
composite
of recommendations from American
Welding Society (AWS)
and electrode
9-0009
7-2.
Preparing Tungsten
Tungsten
2
Balled End
Electrode
Ball end of tungsten before welding
by applying either an ac amperage
slightly higher than what is recom
mendedfora given electrode diam
eter (see Table 7-1), or a dc elec
trode positive amperage.
______________________
1-1/2 Times
Electrode Diameter
_____________________
1
2
Ref. S-0161
-
Figure
a
7-1.
Preparing Tungsten
For AC Or DC Electrode Positive
(DCEP) Welding
CAUTION
FLYING SPARKS AND HOT METAL
can cause
injury
and start fires.
Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.
Keep flammables away.
wam2.1 9/91
1
Tungsten
2
Tapered
Electrode
2
(I
End
Grind end of tungsten on fine grit,
hard abrasive wheel before weld
ing. Do not use wheel for other jobs
or tungsten can become contami
nated causing lower weld quality.
2-1/2 Times
Electrode Diameter
1
2
1
Stable Arc
2
Flat
amperage capacity.
3
Grinding
4
Straight Ground
3
Ideal
Tungsten Preparation
Wheel
Stable Arc
Ref. 5-0162
1
2
Arc Wander
2
Point
3
Grinding
4
Radial Ground
Wheel
3
Wrong Tungsten Preparation
Figure
7-2.
Preparing Tungsten
Wandering Arc
For DC Electrode
Ref. S-0162
Negative (DCEN) Welding
OM.155 152
Page
23
SECTION 8- PARTS LIST
Ii)
cJ
(0
c~J
N
c~J
(0
C
U)
c~)
th
C)
U-
N
0)
~
C
th
C)
U-
/
/
(0
~
C.,
C
ST-159 595-A
Figure
OM-155 152 Page 24
8-1. Main
Assembly
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
.
.
1
126415
2
126416
3
.
+141 350
.
5
.
6
.
7
.
.
.
8
.
.
..
Li-4
.
C10,i1
..
T2
..
.
12
.
13
.
14
.
15
.
16
.
..
....
.
18
...
.
19
.
20
Ti
CT1
.
.
.
.
.
.
.
.
.
21
22
.
23
.
24
.
25
.
26
.
.
1
1
..
6
..
6
1
.
..
2
..
2
..
4
..
2
..
2
..
2
..
2
..
1
..
..
4
.
..
4
.
1
..
1
..
1
..
1
..
1
..
2
..
1
..
1
1
..
Z1 ,2
154 846
..
27
138 515
..
28
139 658
..
.
29
151 630
.
30
.
31
...
.
.
.
...
PC4
.
.
..
8-2
..
.
166064
..
.
130203
Fig
PLG3O,31
..
113 746
.
.
32
115 440
..
.
33
+141 574
..
.
34
134 327
..
.
35
143 915
..
.
36
133 948
When
2
..
...
R13,14
..
17
.
1
2
..
...
C8,9
..
.
.
1
..
.
11
2
..
..
....
9
.
2
..
...
RC7
10
2
HANDLE
..
..
.
CLAMP, saddle
..
PLG7
.
Assembly
LABEL, caution falling equipment can cause injury
CASE, top
149 194
LABEL, warning electric shock can kill
151 399
CHOKE, DVDT
164 812
CAPACITOR, polyp met film iuf 600VDC
146 402
TRANSFORMER, control
CONNECTOR & SOCKETS, (consisting of)
135 556
114 066
CONNECTOR, rect skt 20-i4ga Amp 350536-1
116 045
CONNECTOR & PINS, (consisting of)
113 633
CONNECTOR, rect pin 20-l4ga Amp 350218-1
141 357
BUS BAR, capacitor
139 151
CAPACITOR, elctIt2700uf35OVDC
136 190
NUT, speed U type 10-32
108 105
CLAMP, capacitor 2.500dia
133405
NUT, speed 10-24 flat type rectangular
139 203
RESISTOR, WW fxd 30W 8K ohm
141 422
INSULATOR, flat pack
+151 853
CASE SECTION, front/bottom/back (consisting of)
161 136
NUT, .312-18 stl insert
161 135
NUT, 10-32 stl insert
166263.. TRANSFORMER, HF
158 555
TRANSFORMER, current
CABLE TIE, 0-1.750 bundle
020 265
CHASSIS, mid
Fig 8-3
126 026
LABEL, warning electric shock
117 860
BLANK, snap-in nyl .lB7mtg hole
057 360
BLANK, snap-in nyl 1 .375mtg hole
139041
BUSHING, strain relief .455/.629 ID x 1.il5mtg hole
168 579
CABLE, pwr No. 6mm 4/c 600V x 4M Ig
138 442
4
.
..
8-1. Main
Quantity
ordering
a
.
..
STABILIZER
2
SPACER, plstc .257 ID x .500 OD x 1.375
INSULATOR, stabilizer
PANEL, mtg stab/transformer/cmpts
PANEL, front w/components
CIRCUIT CARD, receptacle bypass
CONNECTOR PLUG & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-i8ga Molex 39-00-0038
STAND-OFF, No. 6-32 x .687 Ig
CASE, bottom
LABEL, warning general precautionary
MOUNT, sgl stud 1 .5dia x 1.375 Ig .312-18 stud
FOOT, mounting
9
1
1
1
1
2
12
..
component originally displaying
a
precautionary label,
4
1
2
4
4
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-155 152
Page
25
5
67
I-~.
8
9
I-
1
i~i
)
i
L~LJ
~
10
11
/
12
21
-~
~13
15
18
See Fig 8-1
Item 16
16
13
ST-159 597
Figure
OM-155 152
Page
26
8-2. Panel, Front
w/Components
Item
No.
Part
No.
Dia.
Mkgs.
Description
Figure
1
2
3
4
5
C6,7
...
138 115
..
....
R2....
073 562
..
....
R3....
035 897
..
134 847
..
220
..
...
S3-5
..
...
PC5
...
159
..
PLG5O
089 222
136 339
..
120 304
..
6
146684
..
7
148 297
..
128 756
.
8
....
9
..
.10
11
12
13
Si
...
R19
R17
..
....
...
.
...
030755
..
..
604178
..
030 044
..
035 561
..
R5....
C39
...
Pos,Neg
.
129 525
042 418
14
...
RC2
..
...
PL1
PLG11
RC11
..
143 976
..
..
134 731
..
079 739
..
143 922
..
...
113 746
135 635
114 656
..
..
..
..
18
135 299
..
19
097 924
..
20
097 922
..
21
.134 843
..
Optional
1
1
1
1
2
1
1
1
1
1
2
2
1
1
14
or
....
039 885
Part of 042 807
1
....
16
17
30)
....
134 734
161 141
131 054
8-1 Item
POTENTIOMETER, C std slot lIT 2W 10K ohm
POTENTIOMETER, C std slot lIT 2W 1K ohm
SWITCH, tgl SPDT 15A 125VAC
CIRCUIT CARD, meter
CONNECTOR, rect llskt plug Amp 1-640440-1
COVER, opening meter
BLANK, snap-in nyl .25Orntg hole
INSULATOR, switch pwr
NUT, speed U-type 10-32
SWITCH, tgl 3PST 40A 600 VAC
RESISTOR, WWfxd lOW 50 ohm
RESISTOR,C2WiOOohm
RESISTOR, MF .5W lOOK ohm
CAPACITOR, polye met film 4uf 200V
RECEPTACLE, twlk insul fern (Dinse type) 50/70 series
CONNECTOR KIT, Dinse male 50 series (consisting of)
WRENCH, hex 5mm short
CONNECTOR w/SOCKETS, (consisting of)
CONNECTOR, circ skt push-in 14-i 8ga Amp 66358-6
CONNECTOR, circ 14 pin plug Amp 213571-2
CONNECTOR, circ pin push-in 14-lBga Amp 213603-1
CONNECTOR, circ clamp str rlf .703 max cable OD Amp 206322-2
CONNECTOR, circ clamp str rlf .453 max cable OD Amp 206070-3
LIGHT, md white lens 28V
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & PINS, (consisting of)
CONNECTOR, rect pin 24-l8ga Molex 39-00-0040
NAMEPLATE, (order by model and serial number)
CONNECTOR, circ protective cap Amphenol 9760-20
LOCK, shaft pot .375-32 x .25Odia shaft
KNOB, pointer
KNOB, pointer
NUT, brs hex .250-40 jam
....
..
..
.
w/Components (Fig
CAPACITOR
134 746
079 534
15
..
8-2. Panel, Front
Quantity
1
1
2
1
2
1
2
1
1
1
1
Meter Kit.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-155 152
Page
27
0)
01
0)
C.)
a
0)
Co
C.)
C.) a
U)
C.)
0)
C)) C.)
C.) Co
01ro
C.)
0)
Cl) 71 Co ID Co (0 P
1
0
UI 01
0) I\)
(a cD
0)
C
C,
U) U) U) U)
a.
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
.
1
HD1
...
.
2
.
3
156 313
..
..
130 204
..
114 066
.
.
012 571
....
F2
010 116
..
083 147
..
...
154 726
..
..
115 094
..
113 746
..
115 093
..
113 746
.
4
.
5
.
6
PCi
PLG4
...
PLG6
.
.
...
..
PLG8,18,28 .115 092
PLG1O
..
PLG12
..
.
.
115 091
..
130 203
113 746
.
.
.
.
7
162 096
.
8
137 768
.
9
010 141
..
038 861
..
601 219
.
11
605 741
..
.
12
079 781
..
.
13
095 847
..
.
14
.
15
.
16
.
10
TEl
...
....
Fl
...
SN1
...
C40-43
D9-12
TP3
.
17
.
18
+162 312
...
..
.
.
.
3
8
1
...
10
1
12
1
1
1
1
1
2
1
1
1
..
..
031 689
..
..
4
..
149 209
..
..
4
...
155053
.
.
..
1
133290
.
.
..
1
072 253
.
.
RECTIFIER, si diode LH (consisting of)
CAPACITOR, rectifier
KIT, diode fast recovery
THERMOSTAT, NO
HEATSINK,rect
STUD, connection single 10-32 x .500 x 1 .2SOmtg
MODULE, capacitor 2 polye met film .0047uf 1 600V
IGBT, LH (consisting of)
KIT, transistor IGBT module
HEATSINK,IGBTLH
BAFFLE, air wind tunnel LH
RESISTOR, WW fxd 55W 35 ohm
SPACER, nylon .312 OD x .194 ID x .437 Ig
BUSHING, snap-in nyl .562 ID x .875mtg hole
WIND TUNNEL, 6.500 in
..
4
..
...
151198
..
152 301
..
150 913
.
152300
...
152 780
..
.
145 084
..
21
143 797
..
.
22
154 408
..
.
23
+146 581
.
24
145 063
..
.
25
133 295
..
.
26
135 661
..
.
27
132232
..
.
28
155 426
..
.
29
134 209
..
..
131 054
..
...
135 635
..
164 849
R9-12
..
.
.
.
113 746
114 656
VCM1
.
..
159 167
...
20
RC9
1
SUPPRESSOR
.
PLG9
1
..
.
.
FM
1
..
..
19
...
6
6
..
.
..
1
2
152776..
CM1 ,2
PM1
1
..
..
.
.
1
3
4
..
.
1
..
..
113 746
113 746
HOLDER, fuse mintr
FUSE, mintr gI 2A
GROMMET, rbr .375 ID x .500mtg hole
GROMMET, scr No. 8/10 panel hole .312sq .500 high
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 39-00-0938
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
CLAMP, nyl .250 clamp dia
BLOCK, term 20A 3P
LINK, jumper term blk 20A
CLIP, mtg resistor .312 ID core
RESISTOR, WW fxd 25W 50 ohm
HOLDER, fuse crtg
FUSE, crtg 5A 600V time delay
..
..
.
current 300A
CONNECTOR PLUG & SOCKETS, (consisting of)
CONNECTOR, rect skt 20-l4ga Amp 350536-1
..
*012 654
..
Chassis, Mid (Fig 8-1 Item 20)
TRANSDUCER,
...
PLG62
8-3.
Quantity
..
.
.
..
.
.
.
30
.
31
010 140
..
.
32
146 689
..
..
1
1
..
.
.2
LABEL, warning electric shock can kill
CHAMBER, plenum 6.500 in
EDGE TRIM, style 31 00-1/16 (order by ft)
2ft
MOTOR, fan 220/230V 50/60Hz 3000RPM
KIT, fan blade (consisting of)
NUT, speed push-on-type .250
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & PINS, (consisting of)
CONNECTOR, rect pin 24-l8ga Molex 39-00-0040
MODULE, varistor/capacitor4 400 joule 1620-198OVDC
CLAMP, nyl .187 clamp dia
BAFFLE, air wind tunnel RH
..
..
..
or1-155 152
Page
29
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
.
33
166 251
PM2
SRi
TP1
TP2
.
.
.
.
.
.
.
.
.
...
..
34
.
..
.
.
..
..
..
.
031 689
.
.
..
.
.
149 209
.
.
..
072 253
.
.
..
133290
.
.
..
35
139 743
..
.
36
000 527
..
.
37
030 170
..
.
38
148 297
..
.
39
.
...
.
40
.
..
.
41
.
..
W
.
VR4
C21
.
.
.
132 889
..
.
.
.
087 156
..
.
.
.
028 294
..
RB....
....
030937..
.
43
+148 296
.
44
153 178
.
45
126 026
..
.
46
145 053
..
.
47
099 037
..
.
48
010 493
..
.
49
006 426
..
110941
..
50
.
51
.
..
C1,2
.
.
.
158 557
.52
..
..
..
158443..
53
154 702
.
54
158444
..
.
55
134 058
..
.
1
1
1
1
1
1
..
.
.
.
IGBT, RH (consisting of)
.
1
..
C44-47
D13-16
.42
Chassis, Mid (Fig 8-1 Item 20) (Continued)
KIT, transistor IGBT module
149 208
KIT, diode pwr module
006 334
THERMOSTAT, NC
155053....THERMOSTAT,NO
166 250
HEAT SINK, IGBT RH
133 968
RECTIFIER, si diode RH (consisting of)
150 913
..
.
8-3.
Quantity
*Recommended
Spare
..
CAPACITOR, rectifier
4
KIT, diode fast recovery
STUD, connection single 10-32 x .500 x 1.25Omtg
HEAT SINK, rect
INSULATOR, heat sink lower
BLANK, snap-in nyl .875mtg hole
BUSHING, snap-in nyl .750 ID x 1 .000mtg hole
NUT, 10-32 push-on stl
CONTACTOR, def prp 40A 3P 24V
VARISTOR, 10 joule 68VDC
CAPACITOR, polye met film luf 25OVDC
4
RESISTOR,C.5WlOohm
1
PANEL, center
LABEL, warning exploding parts etc
LABEL, warning electric shock
WASHER, shldr nyl .298 OD x .203 ID x 1.000
EDGE TRIM, style 62-1/16 (order by ft)
30
1
1
1
4
1
1
1
1
2
2
x
.O62shldr
4
ift
2
BUS BAR,
interconnecting
INSULATOR, heatsinkupper
1
INSULATOR, fuse holder
STRIP, bus rectifier
STAND-OFF SUPPORT, PC card .l56dia
I
Parts.
a
precautionary label,
1
2
1
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Page
1
BUSHING, snap-in nyl .625 ID x .875mtg hole
CLAMP, capacitor 2.000dia
CAPACITOR, polyp film .85uf500VAC/1200VDC
PLG8 is part of 042 807 Optional Meter Kit.
+When ordering a component originally displaying
OM-155 152
4
1
2
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