Miller | KG049529 | Owner Manual | Miller XMT 400 CC/CV CE User manual

Miller XMT 400 CC/CV CE User manual
March 1996
Form: OM-139 426K
Effective With Serial No. KG049529
OWNER’S
MANUAL
XMT 400 CC/CV CC/CV DC Welding Power Source For GMAW, GMAW-P, FCAW, GTAW, GTAW-P And SMAW Welding
Amperes Input at Rated Load
Output, 50 Hz, Three-Phase
Rated
Welding
Output
60% Duty
Cycle: 400 A
@ 36 VDC
100% Duty
Cycle: 300 A
@ 32 VDC
Voltage
Range In
CV Mode
Amperage
Range In
CC Mode
Maximum
OpenCircuit
Voltage DC
IP
Rating
380 V
415 V
380 V
415 V
KVA
KW
10-36
5-400
80
23
32.6
(0.9)*
30.4
(0.9)*
23
(0.7)*
21.6
(0.6)*
21.7
(0.52)*
16.6
(0.16)*
60% Duty Cycle
100% Duty
Cycle
* While idling
cover_om 4/95 – ST-146 127-C
 1996 MILLER Electric Mfg. Co.
PRINTED IN USA
Declaration of Conformity For
European Community (CE) Products
Miller Electric Mfg. Co.
Manufacturer’s Name:
1635 W. Spencer Street
Appleton, WI 54914 USA
Manufacturer’s Address:
Declares that the product:
XMT 400 CC/CV
conforms to the following Directives and Standards:
Directives
Electromagnetic Compatibility Directives: 89/336/EEC, 92/31/EEC
Low Voltage Directive: 73/23/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Standards
Electromagnetic compatibility (EMC) Product standard for arc welding equipment:
EN50199: August 1995
Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1989
Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989
Insulation coordination for equipment within low-voltage systems:
Part 1: Principles, requirements and tests: IEC 664-1: 1992
European Contact:
Telephone:
Fax:
dec_con1 10/95
Mr. Danilo Fedolfi, Managing Director
MILLER Europe S.r.l.
Via Privata Iseo
20098 San Giuliano
Milanese, Italy
39(02)98290-1
39(02)98281-552
SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING
safety_som1 4/95
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards with this
procedure! The possible hazards are shown in the adjoining symbols.
Y Marks a special safety message.
. Means NOTE; not safety related.
This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS,
and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to
avoid the hazards.
1-2. Arc Welding Hazards
WARNING
The symbols shown below are used throughout this manual to call attention to and identify possible
hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The
safety information given below is only a summary of the more complete safety information found in the
Safety Standards listed in Section 1-4. Read and follow all Safety Standards.
Only qualified persons should install, operate, maintain, and repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll
housing, and all metal parts touching the welding
wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
4. Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according
to OSHA 29 CFR 1910.147 (see Safety Standards).
5. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
6. Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground terminal
ARC RAYS can burn eyes and skin;
NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Noise from some
processes can damage hearing. Chipping, grinding,
and welds cooling throw off pieces of metal or slag.
NOISE
7. When making input connections, attach proper grounding
conductor first – double-check connections.
8. Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
9. Turn off all equipment when not in use.
10. Do not use worn, damaged, undersized, or poorly spliced cables.
11. Do not drape cables over your body.
12. If earth grounding of the workpiece is required, ground it directly
with a separate cable – do not use work clamp or work cable.
13. Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
14. Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
15. Wear a safety harness if working above floor level.
16. Keep all panels and covers securely in place.
17. Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ARC RAYS
2. Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
3. Wear approved safety glasses with side shields.
4. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
5. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
1. Use approved ear plugs or ear muffs if noise level is high.
FUMES AND GASES can
hazardous to your health.
in disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
be
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings,
cleaners, and degreasers.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained
watchperson nearby. Welding fumes and gases can displace air
and lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
OM-139 426 Page 1
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flames, sparks, and arcs.
2. Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
WELDING
explosion.
can
cause
fire
or
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks,
hot workpiece, and hot equipment can cause fires
and burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating,
or fire. Check and be sure the area is safe before
doing any welding.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
4.
5.
6.
7.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder – explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
8. Turn face away from valve outlet when opening cylinder valve.
9. Keep protective cap in place over valve except when cylinder is in
use or connected for use.
10. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
11. Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
12. Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
1-3. Additional Installation, Operation, And Maintenance Hazards
FIRE OR EXPLOSION can result from
placing unit on, over, or near
combustible surfaces.
1. Do not locate unit on, over, or near combustible
surfaces.
2. Do not install unit near flammables.
FALLING EQUIPMENT can cause
serious personal injury and equipment
damage.
1. Use lifting eye to lift unit only, NOT running gear,
gas cylinders, or any other accessories.
2. Use equipment of adequate capacity to lift unit.
3. If using lift forks to move unit, be sure forks are long
enough to extend beyond opposite side of unit.
HOT PARTS can cause severe burns.
1. Do not touch hot parts bare handed.
2. Allow cooling period before working on gun or
torch.
MOVING PARTS can cause injury.
1. Keep away from moving parts such as fans.
2. Keep all doors, panels, covers, and guards closed
and securely in place.
MAGNETIC
CURRENTS
operation.
FIELDS FROM HIGH
can affect pacemaker
1. Pacemaker wearers keep away.
2. Wearers should consult their doctor before going
near arc welding, gouging, or spot welding
operations.
OM-139 426 Page 2
MOVING PARTS can cause injury.
1. Keep away from moving parts.
2. Keep away from pinch points such as drive rolls.
FLYING PIECES OF METAL or DIRT can
injure eyes.
1. Wear safety glasses with side shields or face
shield.
WELDING WIRE can cause puncture
wounds.
1. Do not press gun trigger until instructed to do so.
2. Do not point gun toward any part of the body, other
people, or any metal when threading welding wire.
HIGH-FREQUENCY RADIATION can
interfere with radio navigation, safety
services,
computers,
and
communications equipment.
1. Have only qualified persons familiar with electronic
equipment perform this installation.
2. The user is responsible for having a qualified
electrician promptly correct any interference
problem resulting from the installation.
3. If notified by the FCC about interference, stop using
the equipment at once.
4. Have the installation regularly checked and
maintained.
5. Keep high-frequency source doors and panels
tightly shut, keep spark gaps at correct setting, and
use grounding and shielding to minimize the
possibility of interference.
OVERUSE can cause OVERHEATED
EQUIPMENT.
SIGNIFICANT DC VOLTAGE exists after
removal of input power on inverters.
1. Allow cooling period.
2. Reduce current or reduce duty cycle before
starting to weld again.
3. Follow rated duty cycle.
1. Turn Off inverter, disconnect input power, and
discharge input capacitors according to
instructions in Maintenance Section before
touching any parts.
STATIC ELECTRICITY can
parts on circuit boards.
damage
1. Put on grounded wrist strap BEFORE handling
boards or parts.
2. Use proper static-proof bags and boxes to store,
move, or ship PC boards.
BUILDUP OF SHIELDING GAS can harm
health or kill.
1. Shut off shielding gas supply when not in use.
1-4. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from
Superintendent 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,
American Welding Society Standard AWS F4.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields – Background
Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing
Office, May 1989): “. . . there is now a very large volume of scientific
findings based on experiments at the cellular level and from studies
with animals and people which clearly establish that low frequency
magnetic fields can interact with, and produce changes in, biological
systems. While most of this work is of very high quality, the results are
complex. Current scientific understanding does not yet allow us to
interpret the evidence in a single coherent framework. Even more
frustrating, it does not yet allow us to draw definite conclusions about
questions of possible risk or to offer clear science-based advice on
strategies to minimize or avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around the body.
4. Keep welding power source and cables as far away as
practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
The above procedures are also recommended for pacemaker
wearers. Consult your doctor for complete information.
OM-139 426 Page 3
SECTION 2 – DEFINITIONS
2-1. Manufacturer’s Warning Label Definitions
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
1.1
1.2
1.3
2
1
1.1
1.2
1.3
2.1
2.2
2.3
2
2.1
2.2
2.3
3
3.1
3
3.1
3.2
3.2
3.3
3.3
4
4
4.1
+
5
+
+
4.1
6
+
5
6
S-179 310
Electric shock from welding
electrode or wiring can kill.
Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
Protect yourself from electric
shock by insulating yourself
from work and ground.
Disconnect input plug or
power before working on
machine.
Breathing welding fumes can
be hazardous to your health.
Keep your head out of the
fumes.
Use forced ventilation or local
exhaust to remove the fumes.
Use ventilating fan to remove
fumes.
Welding sparks can cause
explosion or fire.
Keep flammables away from
welding. Do not weld near
flammables.
Welding sparks can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
Do not weld on drums or any
closed containers.
Arc rays can burn eyes and
injure skin.
Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
Become trained and read the
instructions before working on
the machine or welding.
Do not remove or paint over
(cover) the label.
1/96
OM-139 426 Page 4
1
2
3
1
2
3
4
5
6
4
V=0
V
5
V
> 60 s
S-179 190
6
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from wiring can
kill.
Disconnect input plug or
power before working on
machine.
Hazardous voltage remains
on input capacitors after
power is turned off.
Always wait 60 seconds after
power is turned off before
working on unit.
Check input capacitor voltage,
and be sure it is near 0 before
touching parts.
1/96
1
2
1
2
3
4
5
3
4
5
S-179 304
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
When power is applied failed
parts can explode or cause
other parts to explode.
Flying pieces of parts can
cause injury.
Always wear a face shield
when servicing unit.
Always wear long sleeves and
button your collar when
servicing unit.
1/96
1
1
2
3
4
5
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Falling equipment can cause
injury and damage to unit.
Always lift and support unit
using both handles.
Use a proper cart to move
unit.
Do not use one handle to lift
or support unit.
S-179 309
2
3
4
5
1/96
OM-139 426 Page 5
1
1
2
3
2
3
380 V
4
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from wiring can
kill.
Disconnect input plug or
power before working on
machine.
Look at inside label, and
properly position jumper links
to match available input
voltage.
415 V
4
S-180 163
1/96
2-2. Manufacturer’s Rating Labels For CE Products
Ref. ST-179 379
OM-139 426 Page 6
2-3. Symbols And Definitions
A
Panel
Gas Metal Arc
Welding (GMAW)
Output
Circuit Breaker
Remote
On
Off
High Temperature
Negative
Voltage Input
Direct Current
(DC)
Positive
Shielded Metal Arc
Welding (SMAW)
Protective Earth
(Ground)
Constant Current
Constant Voltage
Wire Feed
Line Connection
Inductance
Alternating
Current (AC)
Three Phase Static
Frequency ConverterTransformerRectifier
Arc Force
U0
I1
V
Amperage
Rated No Load
Voltage (Average)
Primary Current
U1
IP
Primary Voltage
Degree Of
Protection
U2
I2
Voltage
Conventional
Load Voltage
X
Duty Cycle
Rated Welding
Current
%
Percent
OM-139 426 Page 7
SECTION 3 – INSTALLATION
3-1. Selecting A Location
1
Lifting Handles
Use handles to lift unit.
2
1
Movement
Hand Cart
Use cart or similar device to move
unit.
3
4
Plate Label
Rating Label
Use rating label to determine input
power needs. Label is on nameplate.
2
5
Line Disconnect Device
Locate unit near correct input power supply.
Y Special installation may be
required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
Section 20.
Location And Airflow
5
3 in
(78 mm)
3
6 in
(156 mm)
3 in
(78 mm)
4
ST-146 127-C / Ref. ST-151 556
3-2. Dimensions And Weights
Dimensions
Height
17-3/8 in (441 mm)
Width
12 in (305 mm)
Length
21-3/4 in (522 mm)
Weight
ST-146 127-C
OM-139 426 Page 8
Net: 77 lb (35 kg)
Ship: 82 lb (37 kg)
3-3. Tipping
Y Be careful when placing or
moving unit over uneven
surfaces.
3-4. Weld Output Receptacles And Selecting Cable Sizes
Y ARC WELDING can cause Electromagnetic Interference.
To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed
and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving
the welding machine, using shielded cables, using line filters, or shielding the work area.
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft (30 m) Or Less
Weld Output
Receptacles
Positive
(+)
Negative
(–)
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 – 60%
Duty
Cycle
60 – 100%
Duty
Cycle
100
4
4
4
3
2
1
1/0
1/0
150
3
3
2
1
1/0
2/0
3/0
3/0
200
3
2
1
1/0
2/0
3/0
4/0
4/0
250
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
350
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
400
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
500
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-3/0
600
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
10 – 100% Duty Cycle
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
S-0007-D
OM-139 426 Page 9
3-5. Remote 14 Receptacle Information
Socket*
A
B
K
J
I
24 VOLTS AC
C L N
D M
E
Socket Information
H
A
24 volts ac. Protected by circuit breaker CB2.
B
Contact closure to A completes 24 volts ac contactor control circuit.
I
115 volts ac. Protected by circuit breaker CB1.
J
Contact closure to I completes 115 volts ac contactor control circuit.
C
+10 volts dc output to remote control.
E
0 to +10 volts dc input command signal from remote control.
D
Remote control circuit common.
G
Circuit common for 24 and 115 volts ac circuits.
K
Chassis common.
G
F
115 VOLTS AC
REMOTE
OUTPUT
CONTROL
GND
ST-800 827-A
*The remaining sockets are not used.
3-6. Remote 17 Receptacle Information
REMOTE 17
B
C
D
Socket*
D
Contactor on/off signal; +13 to +24 volts dc contactor on, 0 volts dc contactor off.
A
+10 volts dc output to remote control; allows full
control of A/V output from remote control.
B
0 to +10 volts dc input command signal from remote control.
H
+24 volts dc; fused at 1/2 ampere.
K
0 to +10 volts dc set by panel A/V control; remote
control percent of panel A/V control.
L
–24 volts dc; fused at 1/2 ampere.
E
Current feedback; 0 to +10 volts dc, 1 volt per 100
amperes.
M
Voltage feedback; 0 to +10 volts dc, 1 volt per 10
arc volts.
J
Negative weld output; fused at 1/2 ampere.
N
Positive weld output.
F
Circuit common for sockets A, B, D, E, K, and M.
P
Circuit common for sockets H and L.
S
Chassis common.
A
M
L
P NT
K
R S J
E
H
FG
REMOTE
OUTPUT
CONTROL
Socket Information
METER
Voltage Sensing
ST-800 828-A
GND
*The remaining sockets are not used.
OM-139 426 Page 10
3-7. 115 Volt AC Receptacle
1
115 Volt AC Receptacle
(Twistlock Shown)
The receptacle on the rear of this
unit supplies up to 5 amperes of 115
volt ac power. The receptacle is
commonly used to power a cooling
system. The receptacle may be
twistlock or standard.
1
Power output is shared between
this receptacle and the Remote 14
receptacle (see Section 3-5).
115 VOLTS AC
ST-146 127-C
3-8. Electrical Service Guide
Input Voltage
380
415
Input Amperes At Rated Output (Ieff)
26
24
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
40
40
Reference: 1993 National Electrical Code (NEC).
S-0092J
3-9. Placing Jumper Links
380 Volts
415 Volts
Y Significant DC voltage can
remain on capacitors after
unit is Off. Always check capacitors according to Section 5-2 before working on
unit.
1
Check input voltage available at
site.
1
Jumper Link Label
2
Jumper Links
Move jumper links to match input
voltage.
Reinstall top of case.
2
Tools Needed:
ssb5.1* 2/92 – Ref. ST-153 971-D / Ref. S-145 063
OM-139 426 Page 11
3-10. Connecting Input Power
Y Have only qualified persons
make this installation.
1
2
Input And Grounding
Conductors
Line Disconnect Device
Select type and size overcurrent
protection using Section 3-8.
GND/PE
Earth Ground
Y Special installation may be
required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
Section 20.
2
L1 (U)
L2 (V)
Connect
GND/PE
Conductor
First
L3 (W)
1
Tools Needed:
ssb2.3 11/93 – Ref. SC-144 221 / ST-146 127-C / Ref. S-0092C
OM-139 426 Page 12
SECTION 4 – OPERATION
4-1. Front Panel Controls
4
5
6
3
2
7
1
8
9
10
Ref. ST-179 379
1
Output (Contactor) Switch
For weld output, place switch in On position.
To preset weld output, place switch in Preset
position. Value selected on Amperage/Voltage control will be present when the contactor is energized.
For remote control, make connections to correct receptacle, and place switch in Remote
14/17 position.
2
Amperage/Voltage Control Switch
For front panel control, place switch in Panel
position.
Use GMAW position for GMAW and FCAW.
Use SMAW position for SMAW, GMAWPulsed, GTAW, and GTAW-Pulsed.
4
Optional Amperage/Voltage Meter
Meter displays preset value when Output
(Contactor) switch is in Preset position. Meter displays actual values when Output (Contactor) switch is in On or Remote 14/17 position.
5
Meter Switch
6
Power On/Off Switch
There is a 5 second time delay before the unit
is ready to weld.
For remote control, make connections to correct receptacle, and place switch in Remote
14 or Remote 17 position as applicable.
7
Pilot Light
8
Over Temperature Light
3
9
Amperage/Voltage Adjustment Control
Mode Switch
10 Arc/Inductance Control
Adjusts Arc Control with Mode switch in
SMAW position. Adjusts Inductance with
Mode switch in GMAW position.
For Arc Control, when set at 0, short-circuit
amperage at low arc voltage is the same as
normal welding amperage. When set at 100,
short-circuit amperage is increased at low
arc voltage to assist with arc starts and reduce sticking while welding.
Set at 0 for GTAW welding.
For Inductance, use control to change weld
output inductance for GMAW and FCAW. Inductance determines the “wetness” of the
weld output puddle.
Select setting best suited for application.
Numbers around control are for reference
only.
OM-139 426 Page 13
4-2. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If unit overheats, over temperature
light goes On and output stops. Let
fan run for fifteen minutes. Reduce
amperage or duty cycle before
welding.
. Unit is equipped with Fan-On-
Demand. Fan only runs when
cooling is necessary.
Y Exceeding duty cycle can
damage unit and void warranty.
60% Duty Cycle At 400 A
100% Duty Cycle At 300 A
Continuous Welding
6 Minutes Welding
4 Minutes Resting
Overheating
0
A
15
Minutes
OR
Reduce Duty Cycle
duty1 4/95 / ST-132 583
OM-139 426 Page 14
SECTION 5 – MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance
Y Disconnect power before maintaining.
3 Months
Repair Or
Replace
Cracked
Weld
Cable
Replace
Unreadable
Labels
Clean And
Tighten Weld
Connections
Replace
Cracked
Parts
14-Pin Cord
Gas Hose
Torch Cable
6 Months
OR
Blow Out Or Vacuum
Inside,
During Heavy Service,
Clean Monthly
OM-139 426 Page 15
5-2. Removing Top Of Case And Measuring Input Capacitor Voltage
Y Significant DC voltage can remain on
capacitors after unit is Off. Always
check capacitors as shown to be sure
they have discharged before working
on unit.
1
Turn Off welding power source and
disconnect input power.
1
Outside Handle Screws
To loosen top, remove two outside
handle screws from both handles
and all side bolts.
2
Input Rectifier SR1
3
Voltmeter
Measure the dc voltage across the
positive (+) and negative (–) terminals until voltage drops to near 0
(zero) volts.
1
Proceed with job inside unit. Reinstall top of case when finished.
2
3
Tools Needed:
3/8, 7/16 in
5/32 in
ST-153 971-D
OM-139 426 Page 16
5-3. Circuit Breakers And Fuses
Y Turn Off welding power
source, disconnect input
power, and check voltage on
input capacitors according
to Section 5-2 before
proceeding.
1
Circuit Breaker CB1
If CB1 opens, remote devices requiring 115 volts from Remote 14
receptacle RC2 or 115 volts ac receptacle RC3 shut down. Manually
reset CB1.
6
5
2
3
Circuit Breaker CB2
If CB2 opens, remote devices requiring 24 volts shut down. Manually reset CB2.
3
Fuse F1
If F1 opens, the welding power
source shuts down.
4
Fuse F2
Fuse F2 is located in the wiring harness behind the negative weld output receptacle. If F2 opens, the
negative weld output voltage sensing signal on socket J of Remote 17
receptacle RC1 is not present.
5
Fuse F3
6
Fuse F4
If F3 or F4 opens, remote control
devices connected to Remote 17
receptacle RC1 may shut down.
See Parts List for fuse sizes. Use
proper tool when removing fuses.
1
4
2
Tools Needed:
ST-159 312-B / Ref. ST-157 752
OM-139 426 Page 17
5-4. Selecting Meter Hold Function On/Off
With the hold function On, the meter
display stays for 15 seconds after
welding stops. With the hold function Off, the meter display leaves
when welding stops.
Y Turn Off welding power
source, disconnect input
power, and check voltage on
input capacitors according
to Section 5-2 before
proceeding.
2
1
ON
2
OFF
Hold On
Digital Meter Board PC5
OFF
2
DIP Switch S2
2
4
1
1
3
ON
3
Toggle 1
4
Toggle 2
1
Hold Off
Set toggles as desired.
Reinstall top of case.
Tools Needed:
Front Panel
ST-159 050-A
5-5. Troubleshooting
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position (see Section 3-10).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-10).
Check for proper input power connections (see Section 3-10).
Check for proper jumper link position (see Section 3-9).
Check fuse F1, and replace if necessary (see Section 5-3)
No weld output; Power switch pilot light
on, fan On.
If using remote control, place Output (Contactor) switch in Remote 14/17 position, and connect remote control to proper remote receptacle (see Section 3-5 or 3-6). If remote is not being used, place
Output (Contactor) switch in On position.
Unit overheated. Allow unit to cool with fan On (see Section 4-2).
Low weld output with no control.
Check position of Amperage/Voltage Control switch (see Section 4-1).
Have Factory Authorized Service Agent check control board PC1.
Limited output and low open-circuit
voltage.
Check input power for correct voltage. Check and replace line fuse(s), if necessary, or reset circuit
breaker (see Section 3-10).
Check for proper jumper link position (see Section 3-9).
Check for proper input and output connections (see Sections 3-10 and 3-4).
OM-139 426 Page 18
Trouble
Erratic or improper weld output.
Remedy
Clean and tighten all weld connections.
Use proper size and type of weld cable (see Section 3-4).
Check for proper input and output connections (see Sections 3-10 and 3-4).
Replace electrode.
Remote device completely inoperative.
Check remote control connections (see Sections 3-5 and 3-6).
If remote device connected to Remote 14 receptacle, reset circuit breaker CB1 and/or CB2 (see Section 5-3).
If remote device connected to Remote 17 receptacle, check fuses F3 and/or F4 and replace if needed
(see Section 5-3).
Erratic weld or incorrect weld characteristics on a remote device requiring
voltage sense signal.
Check fuse F2, and replace if needed (see Section 5-3).
Fan not operating. NOTE: fan only
runs when cooling is necessary.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check thermostats TP2 and/or TP3 and fan motor.
Wandering arc; poor control of arc
direction.
Reduce gas flow rate.
Select proper size tungsten.
Properly prepare tungsten.
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
Shield weld zone from drafts.
Increase postflow time.
Clean and tighten all gas fittings.
Water in torch. Refer to torch Owner’s Manual for part(s) requiring replacement, and repair torch as
necessary.
No 115 volts ac output at twistlock
receptacle.
Reset circuit breaker CB1 (see Section 5-3).
OM-139 426 Page 19
SECTION 6 – ELECTRICAL DIAGRAM
Figure 6-1. Circuit Diagram For Welding Power Source
OM-139 426 Page 20
SD-179 918-A
OM-139 426 Page 21
OM-139 426 Page 22
1
2
20
19
3
4
5
6
7
8
9
21
17
Figure 7-1. Main Assembly
Fig 7-3
15
10
16
22
11 12
13
23
24
14
25
26
31
30
27
32
12
29
13
Fig 7-2
8
7
ST-159 261-B
33
9
34
28
35
11
10
SECTION 7 – PARTS LIST
18
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . . 126 415
. . . 2 . . . . . . . . . . . . . . . 126 416
. . . 3 . . . . . . . . . . . . . . . 179 309
. . . 4 . . . . . . . . . . . . . . +141 350
. . . 5 . . . . . . . . . . . . . . . 179 308
. . . 6 . . . . L1-4 . . . . . 151 399
. . . 7 . . . C10,11 . . . . 164 812
. . . 8 . . . . . . . . . . . . . . . 141 357
. . . 9 . . . . C8,9 . . . . . 139 151
. . . 10 . . . . . . . . . . . . . . . 108 105
. . . 11 . . . . . . . . . . . . . . . 133 405
. . . 12 . . . R13,14 . . . . 139 203
. . . 13 . . . . . . . . . . . . . . . 141 422
. . . 14 . . . . . . . . . . . . . . . 151 630
. . . 15 . . . . . . . . . . . . . . +151 853
. . . . . . . . . . . . . . . . . . . . . 161 136
. . . . . . . . . . . . . . . . . . . . . 161 135
. . . 16 . . . . . . . . . . . . . . . 179 190
. . . 17 . . . . . T1 . . . . . . 174 432
. . . 18 . . . . CT1 . . . . . 158 555
. . . 19 . . . . . T2 . . . . . . 145 080
. . . . . . . . . . PLG7 . . . . . 135 556
. . . . . . . . . . . . . . . . . . . . . 114 066
. . . . . . . . . . RC7 . . . . . 116 045
. . . . . . . . . . . . . . . . . . . . . 113 633
. . . 20 . . . . . . . . . . . . . . . 020 265
. . . 21 . . . . . . . . . . . . . . . . Fig 7-3
. . . 22 . . . . RC3 . . . . . 134 837
. . . 22 . . . . RC3 . . . ♦135 291
. . . 23 . . . . . . . . . . . . . . . 139 041
. . . 24 . . . . . . . . . . . . . . . 168 579
. . . 25 . . . . Z1,2 . . . . . 154 846
. . . 26 . . . . . . . . . . . . . . . 138 515
. . . 27 . . . . . . . . . . . . . . . 139 658
. . . 28 . . . . . L7 . . . . . . 179 968
. . . 29 . . . . . . . . . . . . . . . . Fig 7-2
. . . 30 . . . . PC4 . . . . . 166 064
. . . . . . . . PLG30,31 . . . 130 203
. . . . . . . . . . . . . . . . . . . . . 113 746
. . . 31 . . . . . . . . . . . . . . . 115 440
. . . 32 . . . . . . . . . . . . . . +141 574
. . . 33 . . . . . . . . . . . . . . . 179 310
. . . 34 . . . . . . . . . . . . . . . 143 915
. . . 35 . . . . . . . . . . . . . . . 133 948
. . CLAMP, saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, caution falling equipment can cause injury . . . . . . . . . . . . . . . . .
. . CASE, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning electric shock can kill . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CHOKE, DVDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, polyp met film 1uf 600VDC . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUS BAR, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, elctlt 2700uf 350VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, capacitor 2.500dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, speed 10-24 flat type rectangular . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR, WW fxd 30W 8K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INSULATOR, flat pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, mtg stab/transformer/cmpts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CASE SECTION, front/bottom/back (consisting of) . . . . . . . . . . . . . . . . .
. . . . NUT, insert .312-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, insert No. 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect pin 20-14ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect pin 20-14ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CABLE TIE, 0-1.750 bundle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CHASSIS, mid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECEPTACLE, str grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECEPTACLE, twlk grd 2P3W 15A 250V . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUSHING, strain relief .455/.629 ID x 1.115mtg hole . . . . . . . . . . . . . . . .
. . CABLE, pwr No. 6mm 4/c x 4M lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPACER, plstc .257 ID x .500 OD x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . .
. . INSULATOR, stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INDUCTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD, receptacle bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF, No. 6-32 x .687 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CASE, bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MOUNT, sgl stud 1.5dia x 1.375 lg .312-18 stud . . . . . . . . . . . . . . . . . . . .
. . FOOT, mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
1
1
2
2
2
2
2
2
2
2
1
1
4
4
1
1
1
1
1
6
1
6
1
1
1
1
1
1
2
9
1
1
1
1
2
12
4
1
2
4
4
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦Part of 043 056 Optional Twistlock Receptacle for Auxiliary 115VAC.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-139 426 Page 23
4
5
6
2
7
3
9
10
8
11
1
16
17
12
18
15
13
14
29
28
19
21
20
27
26
25
1
22
See Fig 7-1
Item 15
23
24
20
ST-159 262-A
Figure 7-2. Panel, Front w/Components
OM-139 426 Page 24
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-2. Panel, Front w/Components (Fig 7-1 Item 29)
. . . 1 . . . . C6,7 . . . . . 138 115 . . CAPACITOR, cer disc .1uf 500VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . R2 . . . . . . 039 462 . . POTENTIOMETER, CP plain rnd 1/T 2W 10K/10K ohm . . . . . . . . . . . . .
. . . 3 . . . . . R3 . . . . . . 035 897 . . POTENTIOMETER, C std slot 1/T 2W 1K ohm . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . S2 . . . . . . 134 848 . . SWITCH, tgl DPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . S4 . . . . . . 134 840 . . SWITCH, tgl SPTT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . S3 . . . . . . 134 849 . . SWITCH, tgl DPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . PC5 . . . . . 159 220 . . CIRCUIT CARD, meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG50 . . . . 089 222 . . CONNECTOR, rect 11skt plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . . . . . 146 684 . . INSULATOR, switch pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . . . . . 148 297 . . NUT, speed U-type 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . S1 . . . . . . 128 756 . . SWITCH, tgl 3PST 40A 600VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . R19 . . . . . 139 200 . . RESISTOR, WW fxd 10W 50 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . CB1 . . . . . 083 431 . . CIRCUIT BREAKER, man reset 1P 5A 250V . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . CB2 . . . . . 083 432 . . CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . RC1,PC10 . . 137 542 . . CIRCUIT CARD, rcpt 17 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 097 866 . . CONNECTOR, circ 17 pin plug Amphenol MS-3106A-20-29P
. . . 15 . . . . . . . . . . . . . . . 053 297 . . HOLDER, fuse crtg in-line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . R17 . . . . . 604 178 . . RESISTOR, C 2W 100 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . R5 . . . . . . 030 044 . . RESISTOR, MF .5W 100K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . C39 . . . . . 035 561 . . CAPACITOR, polye met film 4uf 200V . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . F2 . . . . . *012 652 . . FUSE, mintr gl slo-blo .5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . Pos,Neg . . . 129 525 . . RECEPTACLE, twlk insul fem (Dinse type) 50/70 series . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 042 418 . . CONNECTOR KIT, Dinse male 50 series (consisting of) . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 134 746 . . . . WRENCH, hex 5mm short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . RC2 . . . . . 143 976 . . CONNECTOR w/SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 079 534 . . . . CONNECTOR, circ skt push-in 14-18ga . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . D17 . . . . . 175 815 . . LED, yellow w/leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . . . 039 885 . . CONNECTOR, circ protective cap 9760-20 . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . PL1 . . . . . 161 141 . . LIGHT, ind white lens 28V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG11 . . . . 131 054 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . RC11 . . . . . 135 635 . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 114 656 . . . . CONNECTOR, rect pin 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . . 135 299 . . LOCK, shaft pot .375-32 x .250dia shaft . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . . . 097 924 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . . . 097 922 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . . . 134 843 . . NUT, brs hex .250-40 jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
2
1
1
14
1
1
2
1
1
2
1
2
1
1
1
1
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-139 426 Page 25
28
29
26
27
25
6
24
23
22
21
7
20
8
5
1
19
4
2
9
10
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11
18
31
12
13 16
14 15
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57
56
30
32
17
55
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34
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40
41
42
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35
52
36
37
38 39
39
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ST-159 263-B
Figure 7-3. Chassis, Mid
OM-139 426 Page 26
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-3. Chassis, Mid (Fig 7-1 Item 21)
. . . 1 . . . . HD1 . . . . . 156 313
. . . . . . . . . PLG62 . . . . 130 204
. . . . . . . . . . . . . . . . . . . . . 114 066
. . . 2 . . . . F3,4 . . . . *012 652
. . . 3 . . . . . . . . . . . . . . . 098 376
. . . 4 . . . . . . . . . . . . . . . 010 116
. . . 5 . . . . . . . . . . . . . . . 083 147
. . . 6 . . . . PC1 . . . . . 172 050
. . . . . . . . . . PLG4 . . . . . 115 094
. . . . . . . . . . . . . . . . . . . . . 113 746
. . . . . . . . . . PLG6 . . . . . 115 093
. . . . . . . . . . . . . . . . . . . . . 113 746
. . . . . . . PLG8,18,28 . . 115 092
. . . . . . . . . . . . . . . . . . . . . 113 746
. . . . . . . . . PLG10 . . . . 115 091
. . . . . . . . . . . . . . . . . . . . . 113 746
. . . . . . . . . PLG12 . . . . 130 203
. . . . . . . . . . . . . . . . . . . . . 113 746
. . . 7 . . . . . . . . . . . . . . . 162 096
. . . 8 . . . . . . . . . . . . . . . 137 768
. . . 9 . . . . . . . . . . . . . . . 010 141
. . . 10 . . . . TE1 . . . . . 038 861
. . . . . . . . . . . . . . . . . . . . . 601 219
. . . 11 . . . . . . . . . . . . . . . 605 741
. . . 12 . . . . . R1 . . . . . . 079 781
. . . 13 . . . . . . . . . . . . . . . 095 847
. . . 14 . . . . . F1 . . . . . *162 312
. . . 15 . . . . . . . . . . . . . . . 159 167
. . . . . . . . . C40-43 . . . . 031 689
. . . . . . . . . . D9-12 . . . . 149 209
. . . . . . . . . . TP3 . . . . . 155 053
. . . . . . . . . . . . . . . . . . . . . 072 253
. . . . . . . . . . . . . . . . . . . . . 133 290
. . . 16 . . . . SN1 . . . . . 152 776
. . . 17 . . . CM1,2 . . . . 151 198
. . . 18 . . . . . . . . . . . . . . . 152 301
. . . . . . . . . . PM1 . . . . . 150 913
. . . . . . . . . . . . . . . . . . . . . 169 402
. . . 19 . . . . . . . . . . . . . . . 152 780
. . . 20 . . . . R9-12 . . . . 145 084
. . . 21 . . . . . . . . . . . . . . . 143 797
. . . 22 . . . . . . . . . . . . . . . 154 408
. . . 23 . . . . . . . . . . . . . . +146 581
. . . 24 . . . . . . . . . . . . . . . 180 163
. . . 25 . . . . . . . . . . . . . . . 133 295
. . . 26 . . . . . . . . . . . . . . . 135 661
. . . 27 . . . . . FM . . . . . . 132 232
. . . . . . . . . . PLG9 . . . . . 131 054
. . . . . . . . . . . . . . . . . . . . . 113 746
. . . . . . . . . . RC9 . . . . . 135 635
. . . . . . . . . . . . . . . . . . . . . 114 656
. . . 28 . . . . . . . . . . . . . . . 155 426
. . . 29 . . . . . . . . . . . . . . . 134 209
. . . 30 . . . . VCM1 . . . . 164 849
. . . 31 . . . . . . . . . . . . . . . 010 140
. . . 32 . . . . . . . . . . . . . . . 146 689
. . TRANSDUCER, current 300A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 20-14ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FUSE, mintr gl slo-blo .5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GROMMET, rbr .375 ID x .500mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GROMMET, scr No. 8/10 panel hole .312sq .500 high . . . . . . . . . . . . . . .
. . CIRCUIT CARD, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRAY, mtg PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GROMMET, rbr .750 ID x .875mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, nyl .250 clamp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLOCK, term 20A 3P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINK, jumper term blk 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLIP, mtg resistor .312 ID core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR, WW fxd 25W 50 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOLDER, fuse crtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FUSE, crtg 5A 600V time delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER, si diode LH (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CAPACITOR, cer disc .01uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . KIT, diode fast recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . THERMOSTAT, NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . STUD, connection single 10-32 x .500 x 1.250mtg . . . . . . . . . . . . . . . .
. . . . HEAT SINK, rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MODULE, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . IGBT, LH (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . KIT, transistor IGBT module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HEAT SINK, IGBT LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAFFLE, air wind tunnel LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR, WW fxd 55W 35 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPACER, nylon .312 OD x .194 ID x .437 lg . . . . . . . . . . . . . . . . . . . . . . .
. . BUSHING, snap-in nyl .562 ID x .875mtg hole . . . . . . . . . . . . . . . . . . . . .
. . WIND TUNNEL, 6.500 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning electric shock can kill . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CHAMBER, plenum 6.500 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . EDGE TRIM, style 3100-1/16 (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . .
. . MOTOR, fan 220/230V 50/60Hz 3000RPM . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect pin 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KIT, fan blade (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, speed push-on-type .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MODULE, varistor/capacitor 4 400 joule 1620-1980VDC . . . . . . . . . . . .
. . CLAMP, nyl .187 clamp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAFFLE, air wind tunnel RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
3
2
1
2
6
1
1
4
1
6
3
8
1
10
1
12
1
1
1
1
1
2
1
1
1
1
4
4
1
4
1
1
2
1
1
1
1
4
4
2
1
1
1
2ft
1
1
2
1
2
1
1
1
2
1
OM-139 426 Page 27
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-3. Chassis, Mid (Fig 7-1 Item 21) (Continued)
. . . 33 . . . . . . . . . . . . . . . 166 251
. . . . . . . . . . PM2 . . . . . 150 913
. . . . . . . . . . SR1 . . . . . 149 208
. . . . . . . . . . TP1 . . . . . 006 334
. . . . . . . . . . TP2 . . . . . 155 053
. . . . . . . . . . . . . . . . . . . . . 169 403
. . . 34 . . . . C56 . . . . . 179 967
. . . 35 . . . . . . . . . . . . . . . 133 968
. . . . . . . . . C44-47 . . . . 031 689
. . . . . . . . . D13-16 . . . . 149 209
. . . . . . . . . . . . . . . . . . . . . 072 253
. . . . . . . . . . . . . . . . . . . . . 133 290
. . . 36 . . . . . . . . . . . . . . . 139 743
. . . 37 . . . . . . . . . . . . . . . 000 527
. . . 38 . . . . . . . . . . . . . . . 030 170
. . . 39 . . . . . . . . . . . . . . . 148 297
. . . 40 . . . . . W . . . . . . 132 889
. . . 41 . . . C50-55 . . . . 179 966
. . . 42 . . . . VR4 . . . . . 139 218
. . . 43 . . . . C21 . . . . . 028 294
. . . 44 . . . . . R8 . . . . . . 028 280
. . . 45 . . . . . . . . . . . . . . +148 296
. . . 46 . . . . . . . . . . . . . . . 179 304
. . . 47 . . . . . . . . . . . . . . . 179 190
. . . 48 . . . . . . . . . . . . . . . 145 053
. . . 49 . . . . . . . . . . . . . . . 099 037
. . . 50 . . . . . . . . . . . . . . . 010 493
. . . 51 . . . . . . . . . . . . . . . 006 426
. . . 52 . . . . C1,2 . . . . . 110 941
. . . 53 . . . . . . . . . . . . . . . 158 557
. . . 54 . . . . . . . . . . . . . . . 158 443
. . . 55 . . . . . . . . . . . . . . . 154 702
. . . 56 . . . . . . . . . . . . . . . 158 444
. . . 57 . . . . . . . . . . . . . . . 134 058
. . IGBT, RH (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . KIT, transistor IGBT module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . KIT, diode pwr module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . THERMOSTAT, NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HEAT SINK, IGBT RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER, si diode RH (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CAPACITOR, cer disc .01uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . KIT, diode fast recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . STUD, connection single 10-32 x .500 x 1.250mtg . . . . . . . . . . . . . . . .
. . . . HEAT SINK, rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INSULATOR, heat sink lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLANK, snap-in nyl .875mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUSHING, snap-in nyl .750 ID x 1.000mtg hole . . . . . . . . . . . . . . . . . . . .
. . NUT, speed U type 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTACTOR, def prp 40A 3P 24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . VARISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, polye met film 1uf 250VDC . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR, C .5W 10 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning exploding parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, shldr nyl .298 OD x .203 ID x 1.000 x .062shldr . . . . . . . . . .
. . EDGE TRIM, style 62-1/16 (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUSHING, snap-in nyl .625 ID x .875mtg hole . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, capacitor 2.000dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, polyp film .85uf 500VAC/1200VDC . . . . . . . . . . . . . . . . . . .
. . BUS BAR, interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INSULATOR, heat sink upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INSULATOR, fuse holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STRIP, bus rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF SUPPORT, PC card .156dia . . . . . . . . . . . . . . . . . . . . . . . . .
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-139 426 Page 28
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