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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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