Miller TC-150 Owner's manual
- Category
- Welding System
- Type
- Owner's manual
This manual is also suitable for
cover 7/93 – ST-800 241 PRINTED IN USA
1993 MILLER Electric Mfg. Co.
Read and follow these instructions and all
safety blocks carefully.
Have only trained and qualified persons
install, operate, or service this unit.
Call
your distributor if you do not understand
the directions.
Give this manual to the operator.
For help, call your distributor
or:
MILLER Electric Mfg. Co., P
.O. Box 1079,
Appleton, WI 54912 414-734-9821
OWNER’S
MANUAL
August 1993 Form: OM-509B
Effective With Style No. JE-38
AC-To-DC
W
eld Output Converter
Used With AC W
elding Power Source Or Generator
For SMA
W Or Scratch Start GTAW Welding
Max. Rated W
elding Current: 150 Amperes At 20% Duty Cycle
W
elding Power Source V
oltage Range: 20-80 V
olts AC
Overload Protection
Interconnecting Cables And Jack Plugs Supplied
TC-150
OM-509B – 8/93
EMF INFORMATION
The
following is a quotation from the
General Conclusions Section
of
the U.S. Congress, Of
fice of T
echnology 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 of
fer 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 among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete
information.
Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields
NOTE
mod10.1 4/93
TABLE OF CONTENTS
SECTION 1 – SAFETY INFORMATION 1.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – SPECIFICATIONS
2-1. Duty Cycle 2.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION
3-1. Selecting A Location And Moving Converter 2.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Preparing And Connecting Weld Cables 3.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Connecting To Weld Output Receptacles 5.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – MAINTENANCE & TROUBLESHOOTING
4-1. Routine Maintenance 5.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Overload Protection 6.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Troubleshooting 6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – ELECTRICAL DIAGRAM 7.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – PARTS LIST
Figure 6-1. Complete Assembly 8.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-509 Page 1
SECTION 1 – SAFETY INFORMATION
mod1.1 2/93
Read
all safety messages throughout this manual.
Obey all safety messages to avoid injury
.
Learn the meaning of W
ARNING and CAUTION.
1
Safety Alert Symbol
2
Signal W
ord
W
ARNING means possible death
or serious injury can happen.
CAUTION means possible minor
injury or equipment damage can
happen.
3
Statement Of Hazard And
Result
4
Safety Instructions T
o A
void
Hazard
5
Hazard Symbol (If A
vailable)
6
Safety Banner
Read safety blocks for each sym-
bol shown.
7 NOTE
Special instructions for best op
-
eration – not related to safety
.
2
NOTE
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Disconnect input power before
installing or servicing.
WARNING
READ SAFETY BLOCKS at start of
Section
3-1 before proceeding.
WARNING
5
4
6
7
1
2
CAUTION
MOVING P
ARTS can injure.
• Keep away from moving parts.
• Keep all panels and covers closed
when operating.
3
T
urn Off switch when using high frequency
.
Figure 1-1. Safety Information
SECTION 2 – SPECIFICATIONS
Table 2-1. AC-To-DC Converter
Specification Description
Type
Of Output
DC W
eld Output
Rated W
eld Output
150 Amperes At 20% Duty Cycle (see Section 2-1)
T
ype Of Input Power
20 T
o 80 V
olts AC From W
elding Power Source/Generator
Welding Processes
Shielded Metal Arc (SMA
W) And Scratch Start Gas T
ungsten Arc W
elding (GT
AW)
Interconnecting Cables
T
wo 4 ft (1.2 m) Cables With Jack Plugs
Overall Dimensions
Height: 7-1/4 in (184 mm); Width: 8-1/2 in (216 mm); Length: 14 in (356 mm)
Weight
Net: 30 lb (14 kg); Ship: 32 lb (15 kg)
OM-509 Page 2
2-1. Duty Cycle
CAUTION
EXCEEDING
DUTY CYCLE RA
TINGS 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 20% duty cycle
allowing welding 2 minutes out of
every 10 minutes at rated load. If
the welding amperes decrease,
the duty cycle increases.
sb1.2 2/92 – SB-088 987-A
Figure 2-1. Duty Cycle Chart
SECTION 3 – INSTALLATION
3-1. Selecting A Location And Moving Converter
WARNING
ELECTRIC SHOCK can kill.
• Do
not touch live electrical parts.
• Disconnect
weld cables from deenergized
welding
power source BEFORE moving unit. Stop engine
on
welding generator
.
FIRE OR EXPLOSION can result from
placing unit on, over, or near combus-
tible surfaces.
• Do
not locate unit on, over
, or near combustible sur
-
faces.
• Do
not install unit near flammables.
BLOCKED AIRFLOW causes overheat-
ing and possible damage to unit.
• Do
not block or filter airflow
.
W
arranty is void if any type of filter is used.
FUMES can be hazardous; LACK OF
FRESH AIR AND PROPER VENTILA-
TION can be harmful.
• Do
not breathe welding fumes.
• Place
unit only where there is a good
fresh air sup
-
ply
and proper ventilation.
FALLING EQUIPMENT can cause seri-
ous personal injury and equipment
damage.
• Lift
and carry unit carefully
.
swarn11.1* 3/93
OM-509 Page 3
ST-800 241
118
in (460 mm) Open Space
On Front And Rear For Good
Airflow
2 Cover Overhang
Use overhang of cover to lift and
move
unit.
Front
Rear
1
2
Figure 3-1. Location and Movement Of Converter
3-2. Preparing And Connecting Weld Cables
WARNING
ELECTRIC SHOCK can kill; ARCING can burn skin or damage electrical equipment.
• Do
not touch live electrical parts.
• T
urn Of
f welding power source before making any weld output connections. Stop engine on welding generator
.
•
Do not change position of welding cable connectors while welding.
•
Be sure connectors are secure in receptacles before welding.
swarn12.2 2/93
A. For
W
elding Power Source/Generator With Weld Output Receptacles
Two
jack plugs are supplied with converter
. T
wo additional jack
plugs are required
to connect work clamp and insulated electrode holder cables to converter (see
Figure 3-2).
NOTE
Ref. S-0829
1 Weld
Output Cable
Select and prepare weld output
cables
according to welding power
source/generator Owner’s Manu-
al.
Use
shortest cables possible.
Do not use damaged cables.
2W
ork Clamp
Install onto work cable.
3
Insulated Electrode Holder
4GTA
W T
orch
Install
according to manufacturer
’s
instructions.
5 Weld
Input Cable
6 Jack Plug
Install onto weld input cables as
shown
in Figure 3-4.
OR
1
2
3
4
5
6
6
Figure 3-2. Preparing And Connecting Weld Cables
OM-509 Page 4
B. For Welding Power Source/Generator With Weld Output Terminals
Two terminal lugs are required to connect converter to welding power
source/generator (see Figure 3-3).
NOTE
Ref. S-0829
1 Weld
Output Cable
Select and prepare weld output
cables
according to welding power
source/generator Owner’s Manu-
al.
Use
shortest cables possible.
Do not use damaged cables.
2W
ork Clamp
Install onto work cable.
3
Insulated Electrode Holder
4GTA
W T
orch
Install
according to manufacturer
’s
instructions.
5 Jack
Plug
If necessary, install supplied jack
plugs onto weld output cables as
shown
in Figure 3-4.
6W
eld Input Cable
7T
erminal Lug
Use lugs of proper amperage ca-
pacity
and hole size for connecting
to
weld output terminals.
OR
6
54
3
2
1
7
Figure 3-3. Preparing And Connecting Weld Cables
C. Jack Plug Assembly
sb6.3
1
1/92 – ST-152 315
1 Weld
Output Cable
Strip
insulation as shown. Clamp in
vise.
2Tie
Wire
3 Vise
4 Screwdriver
Twist
wire
tightly around insulation
as shown. Bend wire along bare
weld
cable and cut of
f loops.
5
Copper Foil
Wrap foil tightly around wire and
bare
weld cable.
6 Jack Plug
7 Setscrew
Push jack plug over weld cable
and copper foil and tighten set-
screws.
Remove
weld cable from vise.
8
Insulating Handle
9 Screw
Slide
handle over jack
plug, line up
holes,
and tighten screw
.
1
3/4 in
2
3
4
5
6
7
8
9
(19 mm)
T
ools Needed:
1/4 in
(7 mm)
Figure 3-4. Jack Plug Assembly
OM-509 Page 5
3-3. Connecting To Weld Output Receptacles
ST-800 241
1 Positive
(+) W
eld Output T
er-
minal
2
Negative (–) W
eld Output
Terminal
For Electrode Positive (DCEP),
connect
work cable to negative (–)
terminal and electrode holder
cable
to positive (+) terminal.
For Electrode Negative (DCEN),
reverse
cable connections.
To connect to receptacle, insert
jack
plug and turn clockwise.
1
NEGATIVEPOSITIVE
2
Figure 3-5.
W
eld Output Connections
SECTION 4 – MAINTENANCE & TROUBLESHOOTING
WARNING
ELECTRIC SHOCK can kill.
• Do
not touch live electrical parts.
• Turn Off welding power source, and disconnect
input power before inspecting, maintaining, or
servicing.
Stop engine on welding generator
.
HOT
P
ARTS can cause severe burns.
• Allow cooling period before maintaining or
servicing.
MOVING
P
ARTS can cause injury.
• Keep
away from moving parts.
Maintenance and troubleshooting to be performed
only
by qualified persons.
swarn8.1* 2/93
4-1. Routine Maintenance
Turn
Off all power before maintaining.
ST-800 241
3 Months
OR
Blow
Out
Or
Vacuum
Inside
Replace
Unreadable
Labels
6 Months
Tape Or
Replace
Cracked
Cables
Clean
And
Tighten
Weld
Connections
3-2
See
Section
6
– –
– –
Figure 4-1. Maintenance Schedule
OM-509 Page 6
4-2. Overload Protection
READ SAFETY BLOCKS at start of
Section 4 before proceeding.
WARNING
ST-800 242
Fuse link F1 protects unit from
overload damage. If weld output
stops, check F1 as follows:
Turn
Of
f welding power source
and
disconnect
weld input cables. Stop
engine
on welding generator
.
1
Fuse Link F1 (See Parts List
For Rating)
Check and replace F1, if neces-
sary.
Be sure to reinstall hardware
and
leads in positions shown.
Reinstall wrapper
.
T
ools Needed:
3/8 in
1
Figure 4-2. Fuse Link F1 Location
4-3. Troubleshooting
READ SAFETY BLOCKS at start of
Section 4 before proceeding.
WARNING
Table 4-1. Welding Trouble
Trouble Remedy Section
No
weld output; unit completely inop
-
erative.
For welding power sources, be sure Power switch is On.
– –
Secure cables connections from welding power source/genera
-
tor
, or replace cables if necessary
.
3-2
Check and replace fuse link F1, if necessary
. 4-2
Erratic weld output.
Secure work and electrode holder cable connections to convert
-
er
, or replace cables if necessary
.
3-2, 3-3
Fan does not run.
Check and replace fan motor FM, if necessary
. 6
OM-509 Page 7
SECTION 5 – ELECTRICAL DIAGRAM
SA-096 722-A
Figure 5-1. Circuit Diagram For Converter
OM-509 Page 8
SECTION 6 – PARTS LIST
Figure 6-1. Complete Assembly
SD-088 548-C
1
2
3
4
5
6
7
8
9
11
12*
13
14
16
18
19
23
20
21
22
25
18
27
1
26
27
28
29
31
27
30
29
28
27
26
25
23
10
17
24
15
*Includes Item 15
OM-509 Page 9
Description
Part
No.
Dia.
Mkgs.
Item
No.
Figure 6-1. Complete Assembly
Quantity
1 039 608 PLUG, jack red (consisting of) 2.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 019 833 STRIP, cop .010 x 2.500 x .750 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 010 521
WIRE, tie
1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 178 SCREW, set stl sch .250-20 x .375 knr cup point 2.
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
4 101 219 PLUG, jack 5/8 x 2-5/8 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 602 814 INSULATOR, jack plug red 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 602 160 SCREW, slftpg type F filh 8-32 x .250 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 171 WRENCH, hex .125 across the flat 1.
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 600 317 CABLE, weld cop strd No. 4 (order by ft) 8ft.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 005 656 BLADE, fan 6 in 4wg 30 deg 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 FM 088 317 MOTOR, 80V 60Hz 3000RPM 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 123 154 LABEL, warning general precautionary 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 +088 779 WRAPPER 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 088 910 RECTIFIER, si diode positive (consisting of) 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 C1,2 031 689 CAPACITOR, rectifier 2.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 D1,2 087 998 DIODE, rect 85A 300V SP 2.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 083 147 GROMMET, scr No. 8/10 2.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 088 924 RECTIFIER, si diode negative (consisting of) 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 R1,VR1 044 482 SUPPRESSOR 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 D3,4 087 999 DIODE, rect 85A 300V RP 2.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 C3,4 031 689 CAPACITOR, rectifier 2.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
083 147 GROMMET, scr No. 8/10 2.
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 F1 *088 568 FUSE, link 100A 250V 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 091 101 STRIP, support lead 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 035 133 ANGLE, mtg panel 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 115 104 CONNECTOR, clamp cable .500 2.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 088 757 CASE SECTION, base/front/rear 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 039 800 RECEPTACLE, jack plug red (consisting of) 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 039 801 RECEPTACLE, jack plug black (consisting of) 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 605 787 WASHER, lock stl intl tooth .500 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 604 668 NUT, stl slflkg hex med fnsh .500-.20 2.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 010 291 WASHER, flat nylafil .625 ID x 1.250 OD x .125thk 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 091 541 RECEPT
ACLE & NUT
, jack plug red 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 091 542 RECEPT
ACLE & NUT
, jack plug black 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 NAMEPLATE, (order by model and style number) 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 Z 088 935 STABILIZER 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
088 607 BUS BAR, rect neg to stud neg 1.
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
BE SURE T
O PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT P
ARTS.
-
1
-
2
-
3
-
4
-
5
-
6
-
7
-
8
-
9
-
10
-
11
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