Miller XMT 400 CC 50HZ Owner's Manual

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Miller XMT 400 CC 50HZ Owner's Manual | Manualzz
March 1992
Millerfi
FORM: OM-146 741
Effective With Serial No. KC179876
MODEL: XMTfi 300 CC
OWNERS
MANUAL
IMPORTANT:
Read and understand the entire contents of this manual, with
special emphasis on the safety material throughout the manual, before installing,
operating, or maintaining this equipment. This unit and these instructions are for
only by persons trained and experienced in the safe operation of welding
equipment. Do not allow untrained persons to install, operate, ormaintain this unit.
use
Contact your distributor if you do not
~ver1 1/92
-
ST-152 303-A
MILLER ELECTRIC
A M~1er
Group
Ltd..
Mfg. Co.
Compeny
P~ Box 1079
Appleton, WI 54912 USA
T~. 414-734-9821
fully understand these instructions.
PRINTED IN USA
u
LIMITED WARRANTY
EFFECTIVE: AUGUST 6. 1990
This warranty supersedes all previous MILLER warranties and
5
exclusive with
LIMITED WARRANTY Subject to the terms and conditions
hereof, MILLER Electric Mfg. Co., Appleton, Wisconsin war
rants to its Distributor/Dealer that all new and unused
Equipment furnished by MILLER is free from defect in
workmanship
and material
by MILLER. No warranty
engines,
as
is
of the time and
place of delivery
MILLER with respect to
other items manufactured by
made
by
trade accessories or
engines, trade accessories and other items
others. Such
are
subject to the warranties of their respective manufacturers,
if any. All engines are warrantied by their manufacturer for two
years from date of original purchase, except Deutz engines
sold
which have a one year, 2000 hour
warranty.
as specified below, MILLERs warranty does not apply
components having normal useful life of less than one (1)
year, such as spot welder tips, relay and coritactor points.
MILLERMATIC parts that come in contact with the welding wire
including nozzles and nozzle insulators where failure does not
result from defect in workmanship or material.
Except
no
other
guarantees
In the case of MILLERS
with respect to the
quality
or
warranties expressed
implied.
breach of warranty or any other duty
goods. the exclusive remedies
of any
therefore shall be, at MILLERs option (1) repair or
ment or, where authorized in writing by MILLER in
(3)
or
(2) replace
appropriate
the reasonable cost of
repair or replacement at an
or (4) payment of or credit
for the purchase 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 at Appleton, Wisconsin, or FOB. at a MILLER
cases,
authorized MILLER
service
station
facility, therefore, no compensation for
transportation costs of any kind will be allowed. Upon receipt of
notice of apparent defect or failure, MILLER shall instruct the
claimant on the warranty claim procedures to be followed.
authorized service
to
MILLER shall be
required
warranty claims
of failure resulting from
to honor
Equipment in the event
the following periods from
Equipment to the original user:
ranted
within
the
date
3.
Arc welders, power sources, robots, and
components
Load banks
Original main power rectifiers
4.
All
5.
All other MILLERMATIC Feeders
6.
Replacement
7.
Batteries
1.
2.
1 year only)
welding guns, feeder/guns
of
on war
a
defect
of
delivery
1 year
1 year
3 years
ANY
EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR REPRE
SENTATION AS TO PERFORMANCE, AND ANY REMEDY
FOR BREACH OF CONTRACT WHICH, BUT FOR THIS
PROVISION. MIGHT ARISE BY IMPLICATION. OPERATION
OF LAW. CUSTOM OF TRADE OR COURSE OF DEALING.
INCLUDING ANY IMPLIED WARRANTY OF MERCHAN
TABILITY OR OF FITNESS FOR PARTICULAR PURPOSE,
WITH
RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
(labor
or
As
a
.
.
.
90
days
1 year
60 days
6 months
matter of
by
.
repair parts, exclusive of labor.
provided that MILLER is notified in
of the date of such failure.
submitted
and torches
writing
within
thirty (30) days
general policy only, MILLER may honor claims
original user within the foregoing periods.
the
EXPRESSLY PROVIDED BY MILLER IN
MILLER PRODUCTS ARE INTENDED FOR
ULTIMATE PURCHASE BY COMMERCIALJINDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED
AND EXPERIENCED IN THE USE AND MAINTENANCE OF
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR
CONSUMER USE. MILLERS
WARRANTIES DO NOT
EXTEND TO. AND NO RESELLER IS AUTHORIZED TO
EXTEND MILLERS WARRANTIES TO, ANY CONSUMER.
EXCEPT
AS
WRITING,
i1
.1
RECEIVING-HANDLING
unpacking equipment, check carton for any damage that may have occurred during shipment. File any claims for
damage with the delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or
equipment manufacturers Transportation Department.
Before
loss
or
When
requesting
information about this
equipment, always provide Model Designation and Serial
Style
Number.
following spaces to record Model Designation and Serial or Style Number of your unit. The information
rating label or nameplate.
Use the
the
or
is
located
on
Model
__________
Serial
or
Style
No.
Date of Purchase
m~iier 8/9i
SUPPLEMENTARY DATA
May 1992
FORM: S155 152
Use above FORM number when ordering extra manuals.
For XMT 400 CC CY50 (50 Hz) Models
The data contained in this supplement is either in addition to or takes exception to data appearing later in this
manual.
CHANGES TO SECTION 2 − SPECIFICATIONS
Replace Table 2-1. Welding Power Source
Table 2-1. Welding Power Source
Specification
Description
Type Of Output
Constant Current (CC), Direct Current (DC)
Rated Weld Output
400 Amperes, 36 Volts DC At 60% Duty Cycle; 300 Amperes, 32 Volts DC At 100% Duty Cycle
(See Section 2-2)
Type Of Input
380 Or 415 Volts AC; 50 Hz; Three Phase
Input Amperes At Rated Output
32.6 Amperes At 380 Volts, 30.4 Amperes At 415 Volts (60 % Duty Cycle); 23 Amperes At 380
Volts, 21.6 Amperes At 415 Volts (100% Duty Cycle)
KVA Used At Rated Output
21.7 kVA
KW Used At Rated Output
16.6 kW
Amperage Range
5-400 Amperes
Max. Open-Circuit Voltage
80 Volts DC
Welding Processes
Scratch Start Gas Tungsten Arc (GTAW), Scratch Start Gas Tungsten Arc - Pulsed (GTAW-P),
Shielded Metal Arc (SMAW) Welding
Input Power Cord
13.1 ft. (4 m)
Overall Dimensions
Length: 21-3/4 in. (522 mm); Width: 12 in. (305 mm); Height: 17-3/8 in. (441 mm)
Weight
Net: 77 lbs. (35 kg); Ship: 82 lbs. (37 kg)
Options
See Rear Cover
Replace Figure 2-1. Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities
of the welding power source.
Curves of other settings fall between the curves shown.
ssb1.1 10/91 − SB-139 721
Figure 2-1. Volt-Ampere Curves
Replace Figure 2-2. Duty Cycle Chart
CAUTION
EXCEEDING DUTY CYCLE RATINGS will damage unit.
•
Do not exceed indicated duty cycles.
warn7.1 2/92
Duty cycle is how long the unit can
operate within a ten minute period
without causing overheating or
damage.
This unit is rated at 60% duty cycle
when operated at 400 amperes, allowing welding 6 minutes out of every 10 minutes. If the welding amperes decrease, the duty cycle increases.
This unit is rated at 100% duty
cycle when operated at 300 amperes, allowing continuous welding.
sb1.4 2/92 − SB-132 583
Figure 2-2. Duty Cycle Chart
CHANGES TO SECTION 3 − INSTALLATION
Replace Table 3-1. Weld Cable Size
Table 3-1. Weld Cable Size*
Total Cable (Copper) Length In Weld Circuit Not Exceeding*
100 ft. (30 m) Or Less
150 ft.
(45 m)
200 ft.
(60 m)
250 ft.
(70 m)
300 ft.
(90 m)
350 ft.
(105 m)
400 ft.
(120 m)
Welding
Amperes
10 To 60%
Duty Cycle
60 Thru 100%
Duty Cycle
100
150
200
250
300
350
400
4
3
3
2
1
1/0
1/0
4
3
2
1
1/0
2/0
2/0
4
2
1
1/0
2/0
3/0
3/0
3
1
1/0
2/0
3/0
4/0
4/0
2
1/0
2/0
3/0
4/0
2-2/0
2-2/0
1
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
1/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
1/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
500
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-3/0
10 Thru 100% Duty Cycle
*Weld 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. Use weld cable
with insulation rating equal to or greater than the open-circuit voltage of the unit.
S-0007-B
S155 152 Page 2
Replace entire Section 3-6. Connecting Input Power
WARNING
ELECTRIC SHOCK can kill.
•
•
•
•
Do not touch live electrical parts.
Turn OFF welding power source, and disconnect input power before inspecting or installing.
Have only qualified persons install unit.
Installation must meet National Electrical Code and all other codes.
swarn3.1 10/91
A. Positioning Jumper Links
380 Volts
Jumper links allow operation on
different input voltages and are
factory set for 380 volts input power.
415 Volts
1
Check input voltage available at
site.
Remove top of case according to
Section 5-2.
1
2
Input Voltage Label
Look at jumper links and compare
link position with unit label.
2
Input Voltage Jumper Links
Move links to match input voltage.
For example, use 415 volts position when 415 volts input power is
available.
Reinstall top of case.
Tools Needed:
ssb5.1* 2/92 − Ref. ST-155 414 / Ref. S-145 063
Figure 3-6. Input Voltage Jumper Links Location
B. Connecting To Input Power
2
Input Voltage
380
415
Circuit Breaker
Size In Amperes1
49
thru
66
45
thru
60
50
45
Fuse Size In
Amperes2
1
1
Circuit breaker range is 150% to not more than
200% of rated input amperage of the welding
power source (Article 630-12(a) of NEC).
2 Standard fuse size is that closest to 150% of
rated input amperage of the welding power
source (Article 630-126 of NEC).
4
3
Have only qualified persons make this installation.
1 Line Disconnect Switch Of Proper
Rating
2 Grounding Conductor − Green Or
Green With Yellow Stripe(s)
3 Input Conductors
4 Line Fuses
Install input conductors and grounding con- Select fuses or circuit breakers using Table.
ductor from unit to deenergized line discon- Install into deenergized line disconnect
nect switch.
switch.
Be sure grounding conductor goes to an
earth ground.
ssb2.3* 3/92 − Ref. SC-144 221 / ST-152 303-A / Ref. S-0092C
Figure 3-6. Location And Input Power Connections
S155 152 Page 3
CHANGES TO SECTION 4 − OPERATION
IMPORTANT: The nameplate for this unit uses different symbols and terminology than what appear in the Owner’s
Manual. Individual front panel controls are covered on this supplement only when their action differs from that described in the Owner’s Manual.
Replace Figure 4-5. Amperage Control
1
Amperage Control
Use control to select weld amperage. Amperage may be adjusted
while welding.
1
Ref. SD-154 155
Figure 4-5. Amperage Control
Replace Figure 4-10. Power Switch And Pilot Light
1
Pilot Light
2
Power Switch
Use this switch to turn unit and pilot
light ON and OFF.
2
There is a 5 second time delay before the unit is ready to weld.
Fan motor is thermostatically controlled and only runs when cooling
is needed.
1
Figure 4-10. Power Switch And Pilot Light
S155 152 Page 4
CHANGES TO SECTION 5 − MAINTENANCE & TROUBLESHOOTING
Add the following IMPORTANT block at the beginning of entire section
IMPORTANT: Some components in unit do not match those shown in views in Owner’s Manual. Location of components pointed out in views is the same.
Replace Figure 5-1. Measuring Input Capacitor Voltage
Turn OFF welding power source
and disconnect input power.
3
2
1
3
4
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 SR1
6
Voltmeter
Measure the dc voltage across the
positive (+) and negative (−) terminals at 30 second intervals until
voltage drops to 0 (zero) volts.
Proceed with job inside unit. Reinstall top of case when finished.
5
6
Tools Needed:
3/8 in.,
7/16 in.
5/32 in.
ST-155 414
Figure 5-1. Removing Top Of Case And Measuring Input Capacitor Voltage
CHANGES TO SECTION 6 − ELECTRICAL DIAGRAMS
Replace Figure 6-1. Circuit Diagram For Welding Power Source (see Pages 6 and 7 on this Supplement)
Replace Figure 6-2. Wiring Diagram For Welding Power Source (see Pages 8 and 9 on this Supplement)
S155 152 Page 5
Figure 6-1. Circuit Diagram For Welding Power Source
S155 152 Page 6
SD-154 158
S155 152 Page 7
Figure 6-2. Wiring Diagram For Welding Power Source
S155 152 Page 8
SD-154 160
S155 152 Page 9
CHANGES TO SECTION 8 − PARTS LIST
Change Parts List as follows:
**
Dia.
Mkgs.
Part
No.
Replaced
With
Description
Quantity
. . 23-6 . . . . . . . . . . . . . 146 727 . . . +151 853 . . . CASE SECTION, front/bottom/rear (consisting of) . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 197 . . . . . NUT, insert 312-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 198 . . . . . NUT, insert No. 10-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. 23-10 . PLG17 . . . 150 319 . . . . . 131 054 . . . HOUSING RECEPTACLE & SOCKETS, (consisting of) . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . . TERMINAL, female 1skt 24-18 wire . . . . . . . . . . . . . . . . . 2
. 23-11 . . RC17 . . . 151 490 . . . . . 135 635 . . . HOUSING PLUG & PINS, (consisting of) . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 656 . . . . . TERMINAL, male 1 pin 24-18 wire . . . . . . . . . . . . . . . . . . 2
. 23-15 . . Z1,2 . . . . 139 219 . . . . . 154 846 . . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. 23-20 . . L1-4 . . . . 145 426 . . . . . 151 399 . . . CHOKE, DVDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. 23-24 . . . . . . . . . . . . 151 226 . . . . . 151 630 . . . PANEL, mtg stab/transformer/cmpts . . . . . . . . . . . . . . . . . . . 1
. 23-25 . . . CT1 . . . . 149 418 . . . . . 140 328 . . . COIL, current transformer 500/1 . . . . . . . . . . . . . . . . . . . . . . 1
. 23-26 . . . T1 . . . . . 146 287 . . . . . 139 576 . . . TRANSFORMER, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 23-27 . . . PC4 . . . . 151 154 . . . . . 147 608 . . . CIRCUIT CARD, receptacle bypass . . . . . . . . . . . . . . . . . . . 1
. . 23- . PLG30,31 . . 147 993 . . . . . 130 203 . . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . . TERMINAL, female 1skt 24-18 wire . . . . . . . . . . . . . . . . 12
. 23-33 . . . . . . . . . . . . 152 196 . . . . . 133 948 . . . FOOT, mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 23- . . . . . . . . . . . . . . Added . . . . . 097 863 . . . CORE, ferrite E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 23- . . . . . . . . . . . . . . Added . . . . . 122 681 . . . INSULATOR, coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 23- . . . . . . . . . . . . . . Added . . . . . 109 312 . . . STRIP, clamping transformer current . . . . . . . . . . . . . . . . . . 1
. . 23- . . . . . . . . . . . . . . Added . . . . . 117 860 . . . BLANK, snap-in nyl .187mtg hole . . . . . . . . . . . . . . . . . . . . . 2
. . 23- . . . . . . . . . . . . . . Added . . . . . 057 360 . . . BLANK, snap-in nyl 1.375mtg hole . . . . . . . . . . . . . . . . . . . . 1
. . 25-4 . . . . S5 . . . . . 134 848 . . . . . 134 847 . . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . 1
. . 25-6 . . . . PC5 . . . . 147 824 . . . ♦154 509 . . . CIRCUIT CARD, meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 25- . . . . R5 . . . . . . Added . . . . . 028 271 . . . RESISTOR, C .5W 100K ohm . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 27-5 . . . . PC1 . . . . 153 736 . . . . . 150 889 . . . CIRCUIT CARD, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 27- . . . PLG4 . . . 148 439 . . . . . 115 094 . . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . . TERMINAL, female 1skt 24-18 wire . . . . . . . . . . . . . . . . . 4
. . 27- . . . PLG6 . . . 148 439 . . . . . 115 093 . . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . . TERMINAL, female 1skt 24-18 wire . . . . . . . . . . . . . . . . . 6
. . 27- . . . PLG8 . . . 148 439 . . . ♦115 092 . . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . . TERMINAL, female 1skt 24-18 wire . . . . . . . . . . . . . . . . . 8
. . 27- . . PLG10 . . . 148 439 . . . . . 115 091 . . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . . TERMINAL, female 1skt 24-18 wire . . . . . . . . . . . . . . . . 10
. . 27- . PLG18,28 . . 148 439 . . . . . 115 092 . . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . . TERMINAL, female 1skt 24-18 wire . . . . . . . . . . . . . . . . . 8
. . 27- . . PLG12 . . . 147 993 . . . . . 130 203 . . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . . TERMINAL, female 1skt 24-18 wire . . . . . . . . . . . . . . . . 12
. 27-11 . . . . . . . . . . . . 146 673 . . ++152 301 . . . IGBT, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 27- . . . . . . . . . . . . . 146 613 . . . . . 152 300 . . . HEAT SINK, IGBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 27-26 . . . . . . . . . . . . 146 674 . . ++154 157 . . . IGBT, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 27- . . . . SR1 . . . . 149 208 . . . . . 149 217 . . . KIT, rectifier integ 100A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 27- . . . VCM1 . . . 151 199 . . . . . Deleted
. . 27- . . . . . . . . . . . . . 145 742 . . . . . 152 298 . . . HEAT SINK, IGBT RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 27- . . C50-52 . . . . Added . . . . . 148 480 . . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 27- . . . . TP2 . . . . . Added . . . . . 155 053 . . . THERMOSTAT, NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 27-27 . CM1,2 . . . 151 198 . . . . . Deleted
. 27-28 . . C1,2 . . . . 152 101 . . . . . 110 941 . . . CAPACITOR, polyp film .85uf 500VAC/1200VDC . . . . . . . . 2
. 27-30 . . . . . . . . . . . . 000 527 . . . . . 000 527 . . . BLANK, (qty chg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 27-30 . . . . . . . . . . . . 000 527 . . . . . 010 493 . . . BUSHING, snap-in nyl .625 ID x .875mtg hole . . . . . . . . . . 1
. 27-36 . . . . . . . . . . . . 136 190 . . . . . 136 190 . . . NUT, (qty chg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. 27-40 . . . . . . . . . . . . 149 917 . . . . . Deleted
. 28-45 . . . . . . . . . . . . 150 233 . . ++153 062 . . . RECTIFIER, si diode RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 28- . . . . . . . . . . . . . 149 801 . . . . . Deleted
. . 28- . . . . . . . . . . . . . 149 918 . . . . . Deleted
. . 28- . . . . . . . . . . . . . 605 538 . . . . . Deleted
S155 152 Page 10
Parts List continued:
**
Dia.
Mkgs.
Part
No.
Replaced
With
. 28-46 . . . . . . . . . . . . 150 234 . . ++154 156 . . .
. . 28- . . . . SN1 . . . . . Added . . . . . 152 776 . . .
. . 28- . . . . TP3 . . . . . Added . . . . . 086 323 . . .
. . 28- . . C14-17 . . . . Added . . . . . 093 085 . . .
. . 28- . . . VR1-3 . . . . Added . . . . . 090 304 . . .
. . 28- . . . . . . . . . . . . . . Added . . . . . 006 426 . . .
. . 28- . . . . . . . . . . . . . . Added . . . . . 133 405 . . .
. . 28- . . . . . . . . . . . . . . Added . . . . . 141 422 . . .
. . 28- . . . . . . . . . . . . . . Added . . . . . 010 141 . . .
Description
Quantity
RECTIFIER, si diode LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPPRESSOR (part of LH Rectifier) . . . . . . . . . . . . . . . . . .
THERMOSTAT, NO (part of LH Rectifier) . . . . . . . . . . . . . . .
CAPACITOR, polye MF .0047uf 1000V . . . . . . . . . . . . . . . .
VARISTOR, 220 joule 730VDC . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, capacitor 2.000dia . . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT, speed 10-24 flat type rectangular . . . . . . . . . . . . . . . .
INSULATOR, flat pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, nyl .250 clamp dia . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
4
3
2
2
2
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦ Part of 042 807 Meter Kit Option
++All components remain the same with listed exceptions.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
S155 152 Page 11
ERRATA SHEET
June 10, 1992
FORM: OM-146 741
Use above FORM number when
After this manual
to data
was
printed, refinements
appearing later
in
equipment design
ordering
occurred. This sheet lists
extra manuals.
exceptions
in this manual.
CHANGES TO SECTION 8- PARTS LIST
Change
Parts List
as
Mkgs.
Part
No.
PC5
147824
Dia.
--
25-6...
042517
25-
27-5...
PCi
27-5...
PCi
C44-47
013-16
C40-43
D9-12
28-
..
28-
..
28-
..
28-
..
28-
~First
Part
follows:
153736
Replaced
With
155
520
042 805
+155480
+155 605
.
.138114
031 689
149209
138 114
155634
031 689
149209
155634
042517
042 805
digit represents page no digits following
of 042 805 Meter Kit Option
Description
CIRCUIT CARD, meter
METER KIT OPTION, (see footnote)
CIRCUIT CARD, control or
CIRCUIT CARD, control
CAPACITOR, rectifier
KIT, diode fast recovery
CAPACITOR, rectifier
KIT, diode fast recovery
METER KIT OPTION, (see footnote)
dash represent item
no.
+For correct part number of circuit card, check part number located on the circuit card in unit.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Quantity
I
1
1
4
1
4
1
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
Welding is safe when precautions are taken. The
summary of the more complete safety information that will be found in the
next page. Read and follow all Safety Standards.
jobs, exposure
is
safety information given below
Safety Standards listed on the
only
to certain hazards occurs.
a
HAVE ALL INSTALLATION, OPERATION,
REPAIR WORK PERFORMED ONLY BY
MAINTENANCE, AND
QUALIFIED PEOPLE.
ELECTRIC SHOCK
can
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 touching the welding wire are
5.
Properly install and ground this equipment according to
Owners Manual and national, state, and local codes.
6.
Turn oft all
7.
Do not
Touching
electrically live. Incorrectly installed
grounded equipment is a hazard.
1.
Do not touch live electrical parts.
2.
Wear
3.
Insulate
or
improperly
input power
servicing this equipment.
/)
or
stop engine before installing
Do not wrap cables around your
body.
9.
Ground the workpiece to
electrical (earth)
11
Use only well-maintained
damaged parts at once.
12.
Wear
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
I.
Arc rays from the welding process produce intense
heat arid strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can damage
2.
3.
safety
a
FUMES AND GASES can be hazardous
to your health.
Wear
Use
If inside, ventilate the area and/or use exhaust at the arc to
4.
welding
Do not weld where
yourself
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.
FLYING SPARKS AND HOT METAL
cause
can
cool, they
and
can
grinding
muffs if noise level is
degreasing, cleaning,
steel, unless the
area
high.
or
while
can
or
sure
the
react with vapors to
as galvanized, lead, or
coating is removed from the
is well ventilated, and if necessary, while
aware
that
fire
keep
welding
on
a
fire
on a
extinguisher nearby.
ceiling, floor, bulkhead,
7.
Do not weld
Connect work cable to the work
on
or
partition
the hidden side.
8.
closed containers such
as
as
tanks
or
drums.
welding area as
traveling long, possibly
close to the
practical to prevent welding current from
unknown paths and causing electric shock and fire hazards.
9.
Do not
use
welder to thaw frozen
pipes.
10.
Remove stick electrode from holder
contact tip when not in use.
11.
Wear oil.free
or
cutoff
welding
wire at
protective garments such as leather gloves. heavy
high shoes, and a cap.
shirt. cuffless trousers,
1.
Wear
approved face
shield
or
safety goggles. Side
shields
recommended.
injury.
Chipping
or ear
coated metals, Such
on
plated
can cause
and others from
flying sparks and hot metal.
flying sparks can strike flammable material.
Removeallflammableswithin35ft(10.7m)oftheweldingarc.lf
others from flash
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
this is not
4.
Do not weld
weld area, the
fire.
Protect
(see
spraying
Be
1.
proper shade of filter
The heat and rays of the arc
toxic and irritating gases.
Watch for fire, and
2.
place.
Do not weld in locations near
5.
or
a
in
used for
6.
fire
securely
confined space only if it is well ventilated,
a
explosion.
can cause
above floor
leather) and foot protection.
plugs
ear
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
Sparks
working
replace
wearing an air-supplied respirator. Shielding gases
welding can displace air causing injury or death. Be
breathing air is safe.
cadmium
approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the
manufacturers instruction for metals, consumables, coatings,
and cleaners,
3.
approved
operations.
form highly
use an
WELDING
or
made from durable, flame-resistant
clothing
Wear protective
Work in
7.
fumes and gases.
If ventilation is poor,
if
falling
Repair
protective screens or barriers to protect
glare. warn others not to watch the arc.
5.
your head out of the fumes. Do not breath the fumes.
Keep
remove
(ground)
Safety Standards) to protect your face and
eyes when welding or watching.
Wear approved safety gfasses. Side shields recommended,
Use
these
be hazardous to your health.
1.
covers
helmet fitted with
welding
a
5.
Welding producesfumesandgases. Breathing
2.
equipment.
harness to prevent
Keep all panels and
and
6.
3.
ground.
contact with the work
ANSI Z49.1 listed in
4.
can
in
level.
13.
fumes and gases
good
a
Do not touch electrode while
material (wool and
~
poorly spliced
8.
or
hearing.
.~.
or
circuit.
dry, hole-free insulating gloves and body protection.
yourself from work and ground using dry insulating
Disconnect
damaged. undersized,
worn,
cables.
1 0
mats or covers.
4.
not in use.
equipment when
use
its
cause
throw off
flying
metal. As welds
2.
Wear proper
body protection
to protect skin.
slag.
Sri 9/91
CYLINDERS
explode
can
damaged.
if
from any
Keep cylinders away
3.
welding
other
or
electrical
circuits.
Shielding gas cylinders contain gas under high
damaged. a cylinder can explode. Since
pressure. If
gas cylinders are normally part of the
process, be sure to treat them carefully.
welding
welding electrode to touch any cylinder.
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
4.
Never allow
5
Use only correct
6.
upright position by chaining
equipment cylinder rack to
8.
2.
cylinders in
them to a stationary support
prevent falling or tipping.
secure
:
~
or
in use or connected for use.
Read and fotlow instructions
associated
ENGINE EXHAUST GASES
Engines produce harmful
ENGINE
on compressed gas cylinders,
equipment, and CGA publication P-i listed in Safety
Standards.
WARNING
a
.
an
excessive
7.
compressed gas cytinders
mechanical shocks, and arcs.
Protect
Install and
from
heat,
1.
a
FUEL
ENGINES
can
kill.
can
cause
fire
or
be hazardous.
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.
1.
Stop engine before checking
2.
Do not add fuel while
exhaust gases.
explosion.
can
or
smoking
areas.
adding fuel.
or if
unit is
near
any sparks
or
open flames.
3.
Allow
.
Engine
fuel
is
highly flammable.
engine to cool before fueling. If possible,
engine before beginning job.
check and add
fuel to cold
4.
Do not overfill tank
5.
Do not spill fuel. If fuel is spilled, clean up before
allow
for fuel to
room
expand.
starting
enQine.
MOVING PARTS
can cause
injury.
3.
only qualified people remove guards or
troubleshooting as necessary.
Have
covers
for
maintenance and
Moving parts, such as fans, rotors, and belts can
fingers and hands and catch loose clothing.
4.
cut
negative () battery
5.
I.
Keep all
securely
2.
Stop engine
doors, panels,
in
covers,
and
guards closed and
place.
before
or
connecting
and generate
explosive
gases.
STEAM
.t
~
~_.
-
~
AND
COOLANT
can
PRESSURIZED HOT
burn face, eyes, and
skIn.
The coolant in the radiator
under pressure.
can
disconnect
Keep hands, hair, loose clothing,
and tools away from moving
Reinstall
panels
or
guards and close
starting engine.
doors when
servicing
is
finished and before
unit,
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin,
Batteries contain acid
starting during servicing,
battery.
cable from
parts.
6.
installing
To prevent accidental
1.
Always
2.
Stop engine
wear a
face shield when
before
working
disconnecting
on a
battery.
or
connecting battery
when
working on a battery.
jump start vehicles.
cables.
3.
Do not allow tools to
4.
Do not
5.
Observe correct polarity (+ and )
I.
Do not
use
cause
welder to
remove
sparks
charge
batteries or
radiater cap when
on
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 NW. LeJeune Pd, Miami FL 33126
American
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Ameri
can Welding Society Standard AWS F4.1, 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,
srI 9/91
Batterymarch Park. Quincy,
MA 02269.
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.
Safety in Welding and Cutting, CSA Standard WI 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou
levard, Rexdale, Ontario, Canada M9W I P3.
Cede for
Safe Practices For Occupation And Educational Eye And Face Protec
tion, ANSI Standard Z87.1, from American National Standards lnsti
tue. 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51 B, from National
Fire Protection Association, Batterymarch Park. Quincy, MA 02269.
TABLE OF CONTENTS
SECTION 1
-
SECTION 2
SAFETY SIGNAL WORDS
1
SPECIFICATIONS
2-1.
Volt-Ampere Curves
2
2-2.
Duty Cycle
2
SECTION 3INSTALLATION
3-1.
3-2.
3-3.
3-4.
3-5.
Selecting A Location And Moving Welding Power Source
Selecting And Preparing Weld Output Cables
Connecting To Weld Output Receptacles
Information And Connections
Remote 14 Receptacle
Connecting Input Power
OPERATION
SECTION 5
MAINTENANCE & TROUBLESHOOTING
Routine Maintenance
5-2.
Removing Top Of Case
5-3.
Overload Protection
.
.
.
And
Changing AmperageNoltage
5-5.
Troubleshooting
7-2.
Figure
Figure
Figure
5
11
12
13
Meter Hold Function
14
15
ELECTRICAL DIAGRAMS
17
ELECTRODE
Selecting Tungsten Electrode
Preparing Tungsten
SECTION 8
.
Measuring Input Capacitor Voltage
5-4.
7-1.
5
7
5-1.
SECTION 7TUNGSTEN
4
6
SECTION 4
SECTION 6
3
20
21
PARTS LIST
8-1. Main
Assembly
w/Components
22
8-2. Panel, Front
24
8-3. Chassis, Mid
26
OM.146 741
3/92
SAFETY SIGNAL WORDS
SECTION 1
mO~I
following safety alert symbol and signal words
different levels of hazard and special instructions.
The
WARNING statements
injury or loss of life.
identify procedures
CAUTION statements identify procedures
damage
throughout
to this
or
practices which must be followed
or
practices which
Table 2-1.
(DC)
300 Amperes, 32 Volts DC At 60% Duty
Type 01 Input
380 Or 415 Volts AC; 50 Hz; Three Phase
At Rated
Output
Output
Output
Amperage Range
Max.
personal
Description
Rated Weld Output
KW Used At Rated
must be followed to avoid minor
Welding Power Source
Constant Current (CC), Direct Current
Output
IC/A Used At Rated
personal
SPECIFICATIONS
Specification
Input Amperes
to avoid serious
identify special instructions necessary for the most efficient operation of this equipment.
SECTION 2
Of
identify
equipment.
~ IMPORTANT: statements
Type
this manual to call attention to and
CAUTION
a
or
used
WARNING
a
~~jury
are
9,91
Open-Circuit Voltage
25
Amperes At 380 Volts, 23 Amperes
Cycle (See Sectlon 2.2)
At 415 Volts
16.4 kVA
11.3kW
5-375 Amperes
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
ShIpping:
Options
PC-300, RFC.14, Foot Control, RHC-14, RMLS-14, FTC14 Hand Controls, Extension Cords, Econo
my Cart, Cylinder Cart, Wire Feeder Quick Disconnect. Digital LCD AN Meter, HF-251 D-1 High Fre
quency Unit, VHS Video
Tungsten
Arc. Pulsed
(GTAW-P),
(4 m)
in.
82 lbs.
(522 mm); WIdth: 12
(37 kg); Net:
77 lbs.
in.
(305mm); HeIght: 17.3/8
In.
(441 mm)
(35 kg)
OM-146 741 Page 1
2-1.
Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
100
and amperage output capabilities
of the welding power source.
90
Curves of other settings fall be
tween the curves shown.
80
70
>4Ol~TMI~~~
v/1~Mh1W
30
20
I
I
10
MIN
~-.....
~c cotrrRot.
~0X
I
5~
I
0
~
%50X
%75~~ioox
Ii
II
I
100
0
I
I
400
300
200
AMPERES
S8.146 879-8
ssbl.I 10/91
Figure
2-2.
Volt-Ampere Curves
Duty Cycle
CAUTION
a
EXCEEDING DUTY CYCLE RATINGS will
S
2-1.
Do not exceed indicated
damage
unit.
duty cycles.
warnl,1 2/92
Duty cycle
is how
operate within
=
:
=
:
:
:
:
damage.
:
:
Thisunitisratedat6o%dutycycle
allowingwelding6minutesoutof
-
:
:
=
:
=
:
=
=
-
:
~
~
(
-
900
s~::
:::
--~3PHASE
-
-
::
-
-
causing overheating
dutycycleincreases.
OPERATION
::
--
-
-.
-
-.
::
w
3
~-
-
100
--
--
0-
~
10
10
20
%
a
30
-
-
4050
-
eo~eoso10o
DUTY CYCLE
sbl.2 2/92
Figure
OM-146 741
Page
or
every 10 minutes at rated load. If
theweldingamperesdecrease, the
-
:::
-
period
without
=:
~-
the unit can
minute
:
:
~.
long
a ten
2
2-2.
Duty Cycle Chart
SB.153 910
SECTION 3INSTALLATION
3-1.
Selecting
A Location And
a
can
Do not touch live electrical
Disconnect
input
deenergized supply
kill.
parts.
from
conductors
power
line BEFORE moving welding
power source.
FIRE OR EXPLOSION can result from
unit
near
or
over,
on,
placing
combustible surfaces.
Do not locate unit on, over,
or near
combustible
surfaces.
Do not install unit
BLOCKED
overheating
near
AIRFLOW
and possible
FUMES can be hazardous; LACK OF
AIR
FRESH
AND
PROPER
VENTILATION can be harmful.
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.
causes
damage
to
Unit.
Have two person of
unit.
Move unit with
adequate physical strength lift
hand
cart
similar device of
or
adequate capacity.
Do not block
Warranty
Source
WARNING
ELECTRIC SHOCK
S
Moving Welding Power
or
filter airflow.
is void 1 any
type of fitter is used.
If using a fork lift vehicle,
skid before transporting.
secure
unit on
a
proper
Swarnhl
1
2/92
3 in.
(78 mm) Open Space At
Sides, 6 in. (156 mm) At Rear
For Good Airflow
2
Lifting
Handles
Use handles to
3
2
Rating
Locate unit
er
move
unit.
Label
near correct
input
pow
supply.
S7-152303-A/Rf. ST-t51 558
Figure
3-1. Location And Movement Of
Welding
Power Source
OM-146 741
Page
3
Selecting
3-2.
And
Weld
Preparing
Output
Cables
Output Cable
Weld
1
Determine total cable length in
weld Circuit and maximum welding
amperes. Use Table 3-1 to select
proper cable size.
Use shortest cables possible.
Do not use
2
damaged
Terminal
cables.
Lug
Use lugs of proper amperage Ca
pacity and hole size for connecting
to work clamp, electrode holder, or
wire feeder.
Insulated Electrode Holder
3
For
Install
Example,
according
to manufacturers
instructions.
Total Cable
Length In Weld
Circuit
20 ft. (6 m)
Clamp
Work
4
=
Install onto work cable.
5
Dinse-Type Connector
6
Weld
7
Insulator
Output Cable
Slide cable
through
in.
1
remove
insulator and
(25 mm)
insulation
from end of cable.
8
Sleeve
9
Connector
Insert cable with sleeve into
body
nector
so
cable
is
con
snug
against bottom.
10
Setscrew
Tighten
tor fully
If
setscrew and push insula
over connector.
lob 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.
Tools Needed:
sb6.2 12/91
Figure
3-2.
Selecting
And
-
S-0656 / S-0288-8
Preparing Weld Output Cables
Table 3-1. Weld Cable Size*
Total Cable
100 ft.
(30 m) Or
Less
(Copper) Length
150 ft.
(45 m)
I
In Weld Circuit Not
200 ft.
250 ft.
(60 m)
(70 m)
I
Exceeding*
300 ft.
I
(90 m)
350 ft.
1
400 ft.
(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
210
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
2.210
2-2/0
300
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
350
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
10 Thru 100%
Duty Cycle
S-0001AfT-91
(AWG) is based on either a 4 volts or less drop or a current density of not more than 300 circular mils per ampere. Use weld cable with
insulation rating equal to or greater than the open-circuit voltage of the unit.
Weld
cable size
OM-146 741
Page
4
3-3.
To Weld
Connecting
Output Receptacles
WARNING
a
ELECTRIC SHOCK
can
kill; ARCiNG
burn skin
can
damage
or
electrical
equipment.
Do not touch live electrical parts.
welding power source before making any
change position of welding cable connectors
Turn OFF
Do not
e
Be
sure
connectors
are secure
weld output connections.
while
in receptacles before
welding.
welding.
swarnl2 2 2/92
Positive (+) Weld Output Re
1
2
ceptacle
2
Negative ()
ceptacle
3
Connector
Electrode
For
Weld
Output Re
Positive,
connect
work cable connector to
negative
() receptacle and electrode holder
cable connector to positive (+) re
ceptacle.
For Electrode
Negative,
reverse
cable connections.
To connectto receptacle, align keyway, insert connector, and turn
clockwise until tight.
3
Ref. 5Q.t34 ~62/Ref. Sr.15222~
Figure
3-4.
Remote 14
Receptacle
3-3.
Connecting
To Weld
Output Receptacles
Information And Connections
2
1
Remote 14 Receptacle RC2
2
Keyway
3
Plug
4
Threaded Collar
To connect to this receptacle, align
keyway, insert plug, and tighten
threaded collar.
Socket Information:
Remote Contactor
A, B
Contact closure completes the 24 volts
control circuit. Protected by fuse F2.
Remote
Amperage/Voltage Control
C
Command reference ;+10 volts dc.
0
Control circuit
E
ac contactor
common.
Input command signal (potentiometer wiper
source); 0 to #10 volts dc.
or
0-10
volts dc
K
The
Chassis
remaining
common.
sockets are not used.
ebl.1 1)52
Figure
Rel. S0.134 162-B / Ret. 5-0004-A / 5-0626
3-4. Remote 14 ConnectIons
OM-146 741 Page 5
Connecting tnput Power
3-5.
a
WARNING
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Turn OFF
Have
welding
power source, and disconnect
only qualified
input
power before
inspecting
or
instafling.
persons install unit.
Installation must meet National Electrical Code and all other codes.
Positioning Jumper
A.
swarr3.1
10/91
Links
415 Volts
380 Volts
A
A
Jumper links allow operation on dif
ferent input voltages and are facto
ry set for 380 volts input power.
L
Check input voltage available at
_______
________
site.
Remove top of
according
case
to
Section 5-2.
I
Input Voltage Label
Look at jumper links and compare
link position with unit label.
2
Input Voltage Jumper Links
Move links to match input voltage.
For example, use 415 volts posi
tion when 415 volts
input
power is
available.
Reinstall top of
case.
Tools Needed:
ssb5.12/92ST-152225/R&
Figure
B.
Connecting
To
Input
3-5.
S-145063
Input Voltage Jumper Links Location
Power
2
Input Voltage
380
Circuit Breaker
Size In Amperes
t4~i
415
Fuse Size in
35
Amperes2
Circuit breaker range is 150% to not more than
200% of rated input amperage of the welding
power source (Article 630-12(a) of NEC).
2
Standard fuse size is that closest to 150% of
input amperage of the welding power
source (Article 630-126 of NEC).
rated
4
3
Input Conductors
Have only qualified persons make this instal-
3
lation.
Rating
Install input conductors and groufldifl9 conductor from unit to deenergized line disconnect switch.
Grounding Conductor Green Or
Green With Yellow Stripe(s)
Be sure grounding conductor goes to
earth ground.
1
2
Line Disconnect Switch Of
Proper
FIgure
OM-146 741
Page
6
3-6. LocatIon And
4
Line Fuses
Select fuses
Install into
or
Circuit breakers
line
deenargized
using Table.
disconnect
switch.
an
i$b2.3 3~52
-
Rsf. SC-I 44221 / ST-I 52 303-A / R&. 5-0092C
Input Power Connections
SECTION 4
a
WARNING
ELECTRIC SHOCK
Always
Insulate
OPERATION
wear
can
,~
dry insulating gloves.
yourself
from work and
~
ground.
covers
S
:._~..
Do not touch live electrical parts.
Keep all panels and
ARC RAYS can burn eyes and
NOISE can damage hearing.
kill.
securely
in
Wear
welding
helmet with correct shade of filter.
Wear correct eye, ear, and
Keep your head
Ventilate area,
S
breathing
can cause
Do not weld
near
Watch for fire;
on
covers, and
guards closed
device.
or
MAGNETIC FIELDS FROM HIGH CUR
RENTS can aftect pacemaker operation.
explosion.
Pacemaker
flammable material.
over
injury.
and
wearers
keep away.
Wearers should consult their doctor before
keep extinguisher nearby.
Do not locate unit
Do not weld
fire
Keep
away from moving parts.
Keep all doors, panels,
securely in place.
~11
Read Material Safety Data Sheets (MSDSs) and
manufacturers instructions for material used.
WELDING
can cause
be hazardous
can
out of the fumes.
or use
body protection.
place.
MOVING PARTS
FUMES AND GASES
to your health.
skin;
near arc
welding, gouging,
or
combustible surfaces.
closed containers.
Safety Precautions at beginning
welding safety information.
See
Allow work and equipment to cool before
going
spot welding opera
tions.
handling.
sic
of manual for ba
swarn6 110/91
Power Switch
8
2
2
Pilot
3
Amperage
Control
4
Arc Force
(Dig) Control
5
Output (Contactor) Switch
6
Amperage Control Switch
7
Process Selector Switch
8
Optional AmperageNoltage
3
Light
Meter And Switch
ST152
FIgure
224
4-1. Controls
2
3
/
1
Insulating Gloves
2
Safety Glasses With Side
Shields
3
Welding
l4elmet
Wear
_______
dry insulating gloves, safety
glasses with side shields, and a
welding helmet with a correct
shade of filter (see ANSI Z49. 1).
sb3.1 10/91
Figure
4-2.
Safety Equipment
OM-146 741
Page
7
Clamp
Work
I
I
Use wire brush or sandpaper to clean
metal at weld joint area.
~
Connect
work
clamp
paint-free location
Tools Needed:
close to weld
on
area as
to
a
clean,
workpiece,
possible.
as
~
sb4
Figure
4-3. Work
10/91
Clamp
I
Process Selector Switch
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)
control (see
1
Figure 4-6).
Ref SO-134 162
Figure
4.4. Process Selector Switch
I
Amperage Control
Use control to select wel d amper
age. Amperage may be adjusted
while welding.
Figure
4-5.
Amperage Control
I
Arc Force Control
(Dig)
This control is used for SMAW
welding
and
only
works when Pro.
Selector switch (see Figure
4.4) is in the SMAW position.
cess
I
Use control to
make vertical
(control
help
start an arc or
overhead welds
increases short-circuit am
or
perage).
When set at 0, short-circuit amper
age is the same as normal welding
amperage.
When set at 100, short-circuit am
perage increases to help arc start
ing.
Select
setting best suited
for appli
Numbers around control
for reference only.
cation.
are
Set control at 0 for GTAW
Figure
OM-146 741
Page
8
4-6. Arc Control
(Dig) Control
welding.
Amperage Control Switch
I
Use switch to select way of control
ling amperage.
front panel control. place
switch in the PANEL position.
For
For remote control, place switch in
REMOTE 14 position (see Section
3.4). Remote control gives percent
affront panel Amperage Control
(see Figure 4.5). For example, if
front panel control is set at 200 A,
remote control provides minimum
to 200 A.
Figure
4-7.
Amperage Control Switch
WARNING
E LECTRIC 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
at the
same
energized.
time.
swam?
Output (Contactor)
1
r~~~i
(CONTACTOR)~,)
m
Switch
Use Switch to select way of control.
ling output.
For
front
switch
fl
panel control,
ON position.
place
For remote control, place switch in
REMOTE 14 position (see Section
OUTPUT
3.4).
Weld
output terminals are energized
when switch Is ON and POWER Is ON.
Figure
4-8.
Output (Contactor) Switch
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).
I
See table for the values
for AIV switch settings.
2
2
displayed
Meter Switch
Use switch to select amperage
or
voltage display.
Meter
Display
AN Switch
Positions
Figure
4-9.
Amperage/Voltage Meter
When Not
When
Welding
Welding
A
Preset Amps
Actual
V
Preset
Actual Volts
And Switch
Amps
Amps
(Optional)
OM-146 741 Page 9
Figure
~\ ~
Install &
Connect
)
Install &
)
)
Connec~\\
))
Turn On
Turn On
I
Into
Welding Power
Unit
Source
J
Thrch
On~~~)
Turn
~1igh-Frequency
Light
))
Welding~)
Put On
Pe rsonal Safety
Tunasten
Tungsten
JJ (See Section
Unit
Shielding Gas
Insert
Select
) )
High-Frequency
Equipment~J
4-10. Power Switch And Pilot
Equipment
Begin
_________________
_________________
ssb8
Figure
Install &
Connect
)
Equipment
1 1
},J
________________
_____
)
4-11.
Sequence Of Gas Tungsten
Connec))
Install &
Pulser Control
Unit
________________
_____
Install &
Unit
~JJ
(See Section
_____
Shielding
I
Insert
Tungsten
j
Welding (GTAW)
Select
)
High -Frequency
Turn On
Gas
Set Controls
Connec\\
Arc
I
})
Unit
Of Gas
Tungsten
))
Tungsten
7)])
_____
Turn On
} High-Frequency
2192
Into iorch
_____
Turn Qn
Power
Source
Welding
1 1 Begin
)
~~pment
~
WeIdin9~
________________
Figure
I
)
Install &
Connect
Equipment~}
4-12.
Sequence
Select
Electrode
D)
Put On
Personal Safety
Equipment
Arc
Welding
Set Contro
_____
_____
)
Begin
_____
-
Pulsed
(GTAW-P)
Electrode
Into Holder
_____
~__~e
~
_____
Weldin~
ssb7.1 2/92
Figure
OM-146 741 Page 10
4-13.
Sequence Of Shielded
Metal Arc
Welding (SMAW)
SECTION 5
a
MAINTENANCE & TROUBLESHOOTING
WARNING
kill.
SHOCK
ELECTRIC
can
SIGNIFICANT DC VOLTAGE exists after
removal of input power.
Do not touch live electrical
parts.
welding power source, disconnect input
power, wait 60 seconds, measure voltage on input
capacitors according to Section 5-3, and wait for
,~
HOT PARTS
~
MOVING PARTS
Allow
can cause severe
cooling
servicing.
penod
before
burns.
maintaining
or
Turn OFF
voltage
to
drop
to zero before
touching any parts.
can cause
iniury.
Keep away from moving parts.
Maintenance
to
be
performed
only by qualified
persons.
swarn8 1
5-1.
10/91
Routine Maintenance
Table 5-1. Routine Maintenance
Maintenance
Time
Every
month
equipment use: Check all labels (see 6 month entry),
insulation
or replace weld cables if necessary. Clean and
any damaged
cable connections. Clean internal parts (see 6 month entry).
Every
3 months
Repair any damaged insulation
tighten cable connections.
Every
6 months
Replace any labels that are unreadable or damaged (see Section 8 for part
number). Remove unit outer enclosure to blow Out or vacuum dust and dirt from
inside using a clean, dry airstream or vacuum suction.
More than normal
or
Repair
tighten
replace weld cables if necessary. Clean and
OM-146 741
Page
11
5-2.
LA
Removing Top Of
Case And
Measuring Input Capacitor Voltage
ELECTRIC SHOCK, HOT PARTS, AND MOVING PARTS HAZARDS. Read safety infor
beginning of Section 5 before proceeding.
WARNING
mation at
CAUTION
a
STATIC ELECTRICITY
Put
on
grounded
can
damage parts
wrist strap BEFORE
handling
on
boards
circuit boards.
or
parts.
fwarn5.
I
9/91
Turn OFF welding power source
and disconnect input power.
3
I
lop Of Case
2
Handles
3
Outside Handle Screws
4
Side Bolts
4
To loosen top, remove two outside
handle screws from both handles
and all side bolts.
5
Input Rectifier SRi
6
Voltmeter
Measure the dc voltage across the
positive (+) and negative () termi
nals at 30 second intervals until
vottage drops
to 0
(zero)
volts.
Proceed with job inside unit. Rein
stall top of case when finished.
5
Tools Needed:
5/32 in.
51-153 512/Pet. 51-153 512
FIgure
OM-146 741
Page
12
5-1.
RemovIng Top Of Case
And
MeasurIng Input Capacitor Voltage
5-3.
a
Overload Protection
WARNING
ELECTRIC SHOCK, HOT PARTS, AND MOVING PARTS HAZARDS. Read safety infor
beginning of Section 5 before proceeding.
mation at
A.
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
CAUTION
a
STATIC ELECTRICITY
Put
on
grounded
can
damage parts
wrist strap BEFORE
handling
on
boards
circuit boards.
or
parts.
~warn5.1
9/9i
Turn OFF welding power source.
disconnect input power, and check
voltage on input capacitors accord.
ing to Section 5-2 before proceed.
ing.
1
Ft
Fuse Fl
protects control transformer T2
primary
and the control circuitry
If Fl opens, the
from overload,
welding
power
source
would shut
down.
2
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 wilt shut down.
Check fuses and replace
as
need-
ed.
See Parts List for fuse sizes, use
proper tool when removing fuses.
3
Fuse Holder
R&. ST-152 Vt / $T-t52 225
Figure
5-2. Overload Protection
OM-148 741 Page 13
Changing Amperage/Voltage
5-4.
a
WARNING
Meter Hold Function
ELECTRIC SHOCK, HOT PARTS, AND MOVING PARTS HAZARDS. Read safety infor
beginning of Section 5 before proceeding.
mation at
CAUTION
a
STATIC ELECTRICITY
Put
S
on
grounded
wrist
can
damage parts
on
strap BEFORE handling boards
circuit boards.
or
parts.
fwarr,5
9/91
The
AmperageNoltage meter is
displayed weld out
putvalue for 15 seconds after weld
ing stops. This procedure allows
able to hold the
the hold function to be turned ON
or
OFF.
If the hold function is not used, the
displayed value leaves
ing stops.
when weld
I
Turn OFF
disconnect
welding power source.
input power, and check
voltage on input capacitors accord
ing to Section 5-2 before proceed
ing.
r
1
API Meter Board PC5
2
Meter Switch
3
Securing Screw
4
Securing
5
Leads
Nut
Remove both securing screws and
nut from meter switch. Carefully re
move
PC5 from unit. Do not dis
connect leads.
6
DIP Switch S2
7
Toggle
I
8
Toggle
2
Set both
tion.
Reinstall
3
toggles
PC5.
in desired
Reinstall
posi
top of
case.
4
Tools Needed:
~J
5/16 in.
5T-153 715-A
Figure 5-3. ChangIng AmperageNoltage Meter Hold FunctIon
I
I
~
D~1~
5-5.
Troubleshooting
WARNiNG
a
H OT PARTS
kill.
SHOCK
can
ELECTRIC
SIGNIFICANT DC VOLTAGE exists after
removal of input power.
Do not touch live electrical
c an cau se severe
cooling
servicing.
Allow
period
before
burns.
maintaining
or
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.
MOVING PARTS
S
can cause
injury.
Keep away from moving parts.
ir
Troubleshooting
to
be
performed only by qualified
persons.
swarn9
Table 5-2.
Welding
No weld output; unit
Trouble
Remedy
Trouble
completely
Be
sure
10/91
Section
line disconnect switch is ON.
3-5B
inoperative.
Check and replace line fuse(s) if necessary.
3-5B
Check for proper input connections.
3-5B
Check position of input voltage jumper links.
3-5A
Check and replace fuse Fl if necessary.
5-3B
Check and replace POWER switch Si if necessary.
No weld output; fan motor FM
ning and pilot light on.
run-
Check position of
OUTPUT(CONTACTOR)
switch S3.
Figure
Thermostat TP1 open (overheating). Allow fan to run; the thermostat will close when the unit has cooled.
Low weld output with
no
control.
Check position of Amperage Control switch S4.
Have
Factory
4-8
5-3A
Figure
4-7
Authorized Service Station check Main Control
Board PCi.
Limited output and low opencircuit
voltage,
Check incoming power for correct voltage. Replace line fuse if
open.
3-5B
Check position of input voltage jumper links.
3-5A
Check for proper input and output connections.
3-2, 3-3,
3-5B
Erratic
or
improper weld output.
Tighten
all
welding
cable connections.
3-2, 3-3
Check for proper size arid type of cable.
3-2
.
Check for proper input and output connections.
3-2, 3-3,
3-5B
Replace electrode.
Remote device
erative.
completely mop-
Connect remote control to REMOTE 14 receptacle RC2.
Check and replace fuse F2 if necessary.
Fan motor does not
run.
7-i, 7-2
3-4
.
5-3B
Check and replace fan motor FM if necessary.
OM-146 741 Page 15
Wandering
arc; poor control of arc
Section
Remedy
Trouble
Use proper size tungsten.
7-1
direction.
Use properly
prepared tungsten.
7-2
Reduce flow rate.
Tungsten electrode oxidizing and
not remaining bright after conclu
Shield weld
zone
from drafts.
sion of weld.
Increase
postflow
Check and
tighten
time.
all gas
fittings.
Water in torch. Refer to Parts List for
ment, and repair torch as necessary.
OM-146 741 Page 16
part(s) requiring replace
(1) rn C)
0 z 0)
m r m C) I
C,
C)
I
(1)
E
037
SD-46
Source
Power
Welding
For
Diagr m
Circuit
6-1.
Figure
cCsu-.
>
a
~
*
a.
-C I
~dJ
~
.
~
)
C
I
> ~
~
r70
-
ol
Figure
OM-146741
Page
18
6-2.
Wiring Diagram For Welding
Power Source
fl
L
(
9 (ft
2 Ca
~
I
1-~L
~
RED(1l4)
2 0
2
rn
~I01 l~ 0
~
I
(C9-l~G 1C9POS)
I
wHrlPM~-GI CPH2-6
5E0~PH2-)QED(P142-l)
WIlT
S1~1~
42A( ~
~ OIRC7-21 ICEO87-lI
LJ1~G-~w-sp.
~
F
-621 -61
-E21
-El
~IflPH bIT(~4I EDCPHI _ EDCPMI _
538-1)4
L~
l38A
to bce
-
Lu
-
-
A
4AP).
(j~ Ll
~
IcE~ X Ta~,Icr
100 ON a
2 (U
N
_
(1 (1
~L
10c~3J
I
4~(6ASE
0 -
~
£
~-tJ
(0
o
-
II
{1~
0
0
0)
T~D(PLG4
6) 0 rI)
0 Ii.)
_~or
C, (,1 0
SlID
69AIPOST.D)
61A(I&6
II
-~)
r.),
-
4~(G3l-0) 18(PCI IP~G3I
~~j564J(PLG3I-
bEd)
~ Q7Ac3i. JT~O9ARUI
Sonic.
0
12)REO/YLJ T2(~U/WH1)
I4ALS-~T1
69(L.Il
-
1-10)
(
I~I ~I~
~
C)
0 I.
a
TUNGSTEN ELECTRODE
SECTION 7
mo~2
~lMPORTANT: For additional information,
(GTAW)
Selecting Tungsten
7-1.
see
your distributor for
a
handbook
on
the Gas
Tungsten Arc Welding
process.
Electrode
Table 7-1.
Tungsten
Size
Amperage Range
-
Gas
Type
Polarity
-
AC
Argon Using
High Frequency
AC
Argon
Wave Using
Balanced
DC
Argon Electrode
Negative/Straight Polarity
DC
Argon Electrode
Positive/Reverse Polarity
010
Uptol5
*
UptolS
020
5-20
*
5-20
10-20
.040
15-80
*
10-60
20-30
Electrode Diameter
High Freq.
Pure
Tungsten
(Green Band)
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
Up
Up
-
2% Thorium Alloyed
Tungsten (Red Band)
Up
.010
*
to 25
to 20
to 15
020
15-40
*
.040
25-85
*
20-80
20-60
1/16
50-160
10-20
50-150
60-120
100-180
15-35
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
Alloyed
Tungsten (Brown Band)
Zirconium
.010
*
.020
*
a
15-35
5-20
.040
*
a
20-80
20-60
1/16
a
*
50-150
60-120
3/32
*
a
130-250
100-180
1/8
a
*
225-360
160-250
5/32
*
a
300-450
200-320
*
400-550
290-390
a
600-800
340-525
3/16
*
1/4
Typ~cal
argon
shielding gas
flow rates
are
15 to 35 cTh
(cubic feet per hour).
Not Recommended,
The figures listed
manufacturers.
are
intended
as a
guide and
are a
composite
of recommendations from American
Welding Society (AWS) and
electrode
s-000g
OM-146 741
Page
20
7-2.
Preparing Tungsten
1
Tungsten Electrode
2
Balled End
Ball end of tungsten before welding
by applying either an ac amperage
slightly higher
1-1/2 times
ectrode Diameter
mended for a
eter
than what is
recom
given electrode diam
(see Table 7-1), or a dc elec
positive amperage.
trode
2
Ref
Figure
a
~
7-1.
Preparing Tungsten
For AC Or DC Electrode Positive
(DCEP) Welding
CAUTION
FLYING SPARKS AND HOT METAL
can cause
injury
Shape tungsten electrode only on grinder with proper guards in
S
S.O~61
a
and start fires.
safe location
wearing proper face, hand,
and
body protection.
Keep flammables away.
wern~1 9/9
1
Tungsten Electrode
2
Tapered
2
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
causing lower weld quality.
nated
2-1/2 Times
Electrode Diameter
1
~~//
1
Stable Arc
2
FIat
2
am perage
capacity.
3
Grinding Wheel
4
Straight
3
Ideal
Tungsten Preparation
Stable Arc
Wrong Tungsten Preparation Wandering
Figure
7-2.
PreparIng Tungsten
Ground
Ref S-Of 62
1
Arc Wander
2
Point
3
Grinding
4
Radial Ground
Wheel
Arc
For DC Electrode
Ref. S-0162
Negative (DCEN) Welding
OM-146 741 Page 21
SECTION 8
PARTS LIST
0)
0)
0
0
2
0,
\~) ~J;T47,
_
(4
(4
(1
C-,
(4
C,
C,
(4
(4
-
U-
\
.,
p7
(4
E
U,
U)
4
(1
C
a)
L..
U
(0
U,
o~
c\l
0
c~,
C.,
(4
C,
OM-146 741
Page
22
C,
C)
Part
No.
Dia.
Item
No.
Mkgs.
Figure
126415
126416
.1
.2
.3
.
.4
.5
.6
.
151 490
147996
Fig 8-3
116045
12
.13..
RC7.
113633
135556
.14..PLG7
114066
139219
Z1,2..
15
16
138515
17
139658
18
19
146402
T2
136190
20
L1-4..
21
C8,9..
145426
139151
22
108105
23
133405
151 226
24
25 ..CT1..
Ti
26
PC4..
149418
146287
151 154
PLG3O,3 1
147 993
27
147995
115440
28
29
Fig
30
8-2
+141 574
31
32
33
134 327
143 915
152 196
+When
ordering
a
1
4
4
1
150319
.
.2
1
147995
.
.2
.
LABEL, warning electric shock can kill
BUSHING, strain relief .6401.770 ID x 1 .47Omtg hole
TUBING, nprn .625 ID x .O93wall (order by It)
CABLE, pwr No. 6mm 4/c 600V rbr jkt 4M Ig
HOUSING, term plug nyl 2 cont
TERMINAL, female lskt 22-18 wire
HOUSING, term plug nyl 2 cont
TERMINAL, male 1 pin 22-18 wire
CHASSIS, mid
HOUSING PLUG & PINS, (consisting of)
TERMINAL, male 1 pin 20-14 wire
HOUSING PLUG & SOCKETS, (consisting of)
TERMINAL, female lskt 20-14 wire
.9
RC17
.2
HANDLE
126026
134229
11
CLAMP, saddle
NUT, brs hex .250-20 jam hvy
605 564
134838
PLG17
Assembly
601 836
.8
.
8-1. Main
LABEL, caution falling equipment can cause injury
+141 350 ..CASE
149194
LABEL, warning electric shock can kill
CASE SECTION, front/bottom/rear (consisting of)
+146 727
137197
NUT, insert .312-18
137198
NUT, insert No. 10-24
138442
.7
10
Quantity
Description
lIt
.2
.2
.6
.6
STABILIZER
.2
SPACER, plstc .257 ID x .500 OD x 1 .375 high
INSULATOR, stabilizer
TRANSFORMER, control
NUT, speed U type 10-32
CHOKE, DVDT
CAPACITOR, elctlt 2700uf 350 VOC
CLAMP, capacitor 2.500dia
NUT, speed 10-24 fIat type rectangular
PANEL, mtg stab/transformer/cmpts
TRANSFORMER, current
TRANSFORMER, HF
CIRCUIT CARD, receptacle bypass
.4
.2
.2
.2
1
1
1
HOUSING, term plug nyl 12 cont
TERMINAL, female lskt 22-18 wire
STAND-OFF, No. 6-32 x .637 19
2
12
4
PANEL, front w/components
CASE, bottom
LABEL, warning general precautionary
MOUNT, sgl stud 1 .5dia x 1.000 19 .312-18 stud
FOOT, mtg
component originally displaying
a
precautionary label,
.2
.4
.4
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-146 741
Page
23
8
(
~I\
9
0
13
20
15
See Fig 8-1
Item 6
13
17
ST152
13
Figure
OM-148 741 Page 24
8-2.
Panel, Front w/Components
210
Part
No.
Dia.
Item
No.
Mkgs.
Description
Figure
1
C6,7... 138115
..
.2...R2...073562
.3...R3...035897
134848
.4...S5.
134847
.5
S3,4.
..
.6..
PC5.
147
824
PLG5O
089
222
136339
120304
148297
.7
.8..
Rig.
.9.51
.
.
.12..
13
128756
146684
10
11
030755
.
R17
604178
C39... 035 561
PosNeg
.14..
129525
131 605
042418
RC2... 143976
079 534
134734
134731
079739
.15
PL1
135199
16
17
039885
18
19
135299
097924
20
097922
Part
8-2. Panel, Front
w/Components (Fig 8-1
Quantity
Item
29)
CAPACITOR
.2
POTENTIOMETER, C sltd sft l/T 2W 10K ohm
POTENTIOMETER, C sltd sft l/T 2W 1K ohm
SWITCH, tgl DPDT iSA 125VAC
SWITCH, tgl SPOT 15A 125VAC..
CIRCUIT CARD, meter
CONNECTOR, plug 11 posn
.2
1
COVER, opening meter
BLANK, snap-in nyl .25Omtg hole
NUT, speed U type 10-32
RESISTOR, WW fxd lOW 50 ohm
SWITCH, tgl 3PST 40A 600 VAC
INSULATOR, switch pwr
RESISTOR, C 2W 100 ohm
CAPACITOR, polye MF 4uf 200V
RECEPTACLE, twik insul fern (Dinse type) 50/70 series...
.2
1
.2
TERMINAL, connector friction
CONNECTOR KIT, Dinse male 50 series
RECEPTACLE w/SOCKETS, (consisting of)
TERMINAL, female lskt 18-14 wire
HOUSING, term plug plstc 14 cont shell sz 20 Amp 213571-2
TERMINAL, male 1 pin 18-14 wire Amp 21 3603-1
.2
.2
14
CLAMP, cable strain relief sz 17 Amp 206322-2
LIGHT, md red lens 28V
NAMEPLATE, (order by model and serial number)
CAP, dust connector 9760-20
LOCK, shaft pot .375-32 x .25Odia shaft
KNOB, pointer 1 .625dia x .250 ID
KNOB, pointer .875dia x .250 ID
.1
.1
.1
.1
.1
.1
of 042 517 Meter Kit Option
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-146 741
Page
25
11
6
14
7
8
\22
24
50
15
S-.-
>
49
47
25
26
46
27
28
45
3v4
35
36
37
38
41
39
ST152
Figure
OM146
741
Page
28
8-3.
ChassIs,
Mid
211-A
Part
No.
Dia.
Item
No.
Mkgs.
Description
Figure
083 147
124 684
1
.
2
.
HD1
..
..
PLG62
.
.
130 204
114 066
.
012571
3
.
4
.
...
5
.
..
.
P2
PCi
..
.
.
.
PLG4,6,8,
10,18,28 148
.
PLG12
.
*012 654
153 736
..
.
.
.
.
.
.
.
.
.
A 13,14.
139 203
.
...
Ri
.
.
605 741
079 781
146 673
.
.
.
150 913
.
146 613
152 780
R9-12
15
.
16
+146 581
17
145 063
.
18
.
19
133 295
132 232
132 951
..
.
.
14
...
FM
.
.
.
20
21
.
22
..
PLG9
.
23
..
RC9
24
TEl
..
.
.
.
.
.
.
.
.
25
26
PM2.
SRi
TPI
.
.
.
.
.
.
.
.
.
.
VCMI
.
27
28
.
29
30
.
31
.
32
.
.
.
.
33
34
35
.36
.
37
.
38
.
.
.
.
.
439
.
.
.
147995
145 084
143 797
010 493
.
.
149 452
13
.
.
.
7
12
.
.
.
.
.
.
.
.
.
.
010 116
PM1
.
.
6
ii
.
.
.
9
.
TRANSDUCER,
.
10
.
GROMMET,
.
.
8
.
.
.
.
.
.
147993
.
39
40
41
42
.
..
CM1,2
C1,2.
..
...
..
..
...
RM1
.
VR4
C21
RB
.
.
.
.
.
.
.
.
.
.
.
.
of)
.
RESISTOR, WW fxd 25W 50 ohm
IGBT, LH (consisting of)
KIT, transistor IGBT module
HEAT SINK, IGBT LH
BAFFLE, air wind tunnel LH
RESISTOR, WW fxd 55W 35 ohm
SPACER, nyl .312 00 x .194 ID x .437 Ig
BUSHING, snap-in nyl .625 ID x .875mtg hole
WIND TUNNEL, 6.500 in
LABEL, warning electric shock can kill
CHAMBER, plenum 6.500 in
MOTOR, fan 220/230V 50/60 Hz 3000RPM .25Odia shaft
BLADE, fan 6.5 in 6wg .250 bore CW
NUT, speed push-on-type .250
HOUSING RECEPTACLE & SOCKETS, (consisting of)
TERMINAL, female iskt 24-18 wire
HOUSING PLUG & PINS, (consisting of)
TERMINAL, male 1 pin 24-18 wire
BLOCK, term 20A 3P
LINK, jumper term blk 20A
BAFFLE, air wind tunnel
IGBT, RH (consisting of)
KIT, transistor IGBT module
KIT, diode pwr module
THERMOSTAT, NC open 1 80F close 1 50F
MODULE, varistor/capacitor 3 220 joule 73OVDC
HEATSINK,IGBTRH
MODULE, capacitor 2 polye MF .0047uf 1000V
CAPACITOR, polyp film .34uf700VAC
MODULE, resistor
BLANK, snap-in nyl .875mtg hole
BUSHING, snap-in nyl .750 ID x 1.000mtg hole
CONTACTOR, del prp 40A 3P 24V
VARISTOR, 10 joule 68VDC
CAPACITOR, polye MF luf 25OVDC
RESISTOR, C .5W 10 ohm
6
10
.
.
.
.
.
.
.
...
.
.
.
..
..
1
12
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
..
.
.
.
.
.
...
.
3
1
2
2
1
1
1
4
4
2
1
.
.
.
.
.
134 209
.
.
131 054
.
.
113 746
.
.
.
.
.
.
.
.
.
.
146 689
.
.
146 674
.
.
150 913
.
..
.
..
.
..
1
.
..
1
135 635
114 656
038 861
601 219
149 208
006 334
151 199
.
.
145742
...
.
152 101
.
.
.
.
.
1
1
.
.
..
1
3
.
.
..
1
.
.
.
6
.
151 198
.
high
.
.
.
No. 8/10 panel hole .312sq .500
current 300A module supply
HOUSiNG, term plug nyl 12 cont
TERMINAL, female 1 skt 22-18 wire
GROMMET, rbr .375 ID x .500mtg hole
TRAY, mtg PC card
RESISTOR, WW fxd 30W 8K ohm
CLIP, mtg resistor .312 ID core
..
.
12)
HOUS1NG PLUG & SOCKETS, (consisting
TERMINAL, female 1 skt 22-18 wire
.
.
.
8-1 Item
(Fig
FUSE, mintr gI 2A
CIRCUIT CARD, control
.
.
scr
Mid
HOUSING PLUG & SOCKETS, (consisting of)
TERMINAL, female lskt 20-14 wire
HOLDER, fuse mintr .250x 1.250 clip
.
.
.
W...
Chassis,
.
147 995
.
8-3.
Quantity
151 705
000 527
030 170
132 889
087 156
028 294
030 937
136190
+148 296
126 026
605 538
149 917
145 053
099 037
.
.
.
.
.
.
.
.
.
.
.
.
.
..
.
.
.
.
.
.
.
.
.
.
.
.
1
1
1
1
1
2
1
2
1
1
1
1
1
1
I
2
2
1
2
1
1
1
1
NUT,speedUtypelO-32
2
PANEL, center
1
LABEL, warning electric shock
CABLE TIE, 0-4.500 bundle
BRACKET, mtg capacitor
1
can
kill
2
2
lower
1
WASHER, shldr nyl .298 00 x .203 ID x 1.000
EDGE TRIM, style 62-1/16 black wfclips (order by ft)
4
ift
OM-146 741
Page
27
Part
Nc.
Dia.
Item
No.
Mkgs.
Quantity
Description
Figure 8-3. Chassis, Mid (Fig 8-1 Item 12) (Continued)
.
.
43
139 743
..
44
150 233
..
C44-47
.
D13-16
.
138 114
.
.
.
149 209
.
.
.
149 872
.
.
.
072 253
.
.
.
.
149801
..
.
149 918
.
.
.
605 538
.
.
.
150 234
45
C40-43
D9-12
.
.
..
.
138 114
.
.
.
.
149 209
.
.
.
149872
...
072 253
.
.
010 913
.
.
.
.
601 835
*099 398
..
47
149 873
..
.48
095847
..
49
149 871
..
50
134 058
..
.
.
.
.
46
.
..
Fl
..
010 141
*Recommended
INSULATOR, heat sink lower
RECTIFIER, Si diode RH (consisting of)
Spare
.
.
.
CAPACITOR
KIT, diode fast recovery
HEAT SINK, rect
STUD, connection single 10-32
1
4
4
1
x
.500
x
1 .250
.
.
.
.
SPACER,nyl.5000Dx.l94lDx.4371g
BRACKET, mtg capacitor upper
CABLE TIE, 0-4.500 bundle
RECTIFIER, si diode LH (consisting of)
2
I
1
4
KIT,diode
4
fast recovery
HEATSINK,rect
STUD, connection single 10-32 x .500 x 1.250
WASHER, flat brs .218 ID x .460 OD x .O3lthk
4
NUT, brs hex 10-32
8
FUSE, crtg 3A 500V time delay
INSULATOR, heat sink upper
1
HOLDER,fusecrtg3OA600Vl3/32x1-1/21g
1
STRIP, buss rectifier
STAND-OFF SUPPORT, PC card .l56dia
CLAMP, nyl .250 clamp dia
2
Option.
component originally displaying
+When
ordering
a
precautionary label,
1
8
1
1
3
Parts.
is part of 042 517 Meter Kit
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-146 741 Page 28
4
CAPACITOR
PLG8
a
1

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