Miller KC179876 Owner's manual

Millerﬁ

March

1992

FORM:

OM-146

741

Effective

With

Serial

No.

KC179876

MODEL:

XMTﬁ

300

CC

OWNERS

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

use

only

by

persons

trained

and

experienced

in

the

safe

operation

of

welding

equipment.

Do

not

allow

untrained

persons

to

install,

operate,

ormaintain

this

unit.

Contact

your

distributor

if

you

do

not

fully

understand

these

instructions.

MILLER

ELECTRIC

Mfg.

Co.

A

M~1er

Group

Ltd..

Compeny

P~

Box

1079

Appleton,

WI

54912

USA

T~.

414-734-9821

~ver1

1/92

-

ST-152

303-A

PRINTED

IN

USA

I

\~7

~LI

LIMITED

WARRANTY

EFFECTIVE:

AUGUST

6.

1990

This

warranty

supersedes

all

warranties

and

is

exclusive

with

no

other

guarantees

or

warranties

expressed

or

implied

LIMITED

WARRANTY



Sublect

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

as

of

the

time

and

place

of

delivery

by

MILLER.

No

warranty

iS

made

by

MILLER

with

respect

to

engines,

trade

accessories

or

other

items

manufactured

by

others.

Such

engines,

trade

accessories

and

other

items

are

sold

sublect

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

which

have

a

one

year,

2000

hOur

warranty

Except

as

specified

below.

MILLERs

warranty

does

not

apply

to

components

having

normal

useful

life

of

less

than

one

(1)

year,

such

as

spot

welder

tips,

relay

and

contactor

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,

MILLER

shall

be

required

to

honor

warranty

claims

on

war

ranted

Equipment

in

the

event

of

failure

resulting

from

a

detect

within

the

following

periods

from

the

date

of

delivery

of

Equipment

to

the

original

user:

1.

Arc

welders,

power

sources,

robots.

and

1

year

components

2.

Load

banks

1

year

3.

Original

main

power

rectifiers

3

years

(labor



1

year

only)

4.

All

welding

guns.

feeder/guns

and

torches

.

90

days

5.

All

other

MILLERMATIC

Feeders

1

year

6.

Replacement

or

repair

parts,

exclusive

of

labor

.

60

days

7.

Batteries

6

months

provided

that

MILLER

is

notified

in

writing

within

thirty

(30)

days

of

the

date

of

such

failure.

As

a

matter

of

general

policy

only,

MILLER

may

honor

claims

submitted

by

the

original

user

within

the

foregoing

periods.

In

the

case

of

MILLERS

breach

of

warranty

or

any

other

duty

with

respect

to

the

quality

of

any

goods,

the

exclusive

remedies

therefore

shall

be.

at

MILLERs

option

(1

(repair

or

(2)

replace

ment

or.

where

authorized

in

writing

by

MILLER

in

appropriate

cases.

(3)

the

reasonable

cost

of

repair

or

replacement

at

an

authorized

MILLER

service

station

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.

MILLERs

option

of

repair

or

replacement

will

be

F

O.B..

Factory

at

Appleton,

Wisconsin,

or

F

0

B

at

a

MILLER

authorized

service

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.

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

MERCI-IAN

lABILITY

OR

OF

FITNESS

FOR

PARTICULAR

PURPOSE.

WITH

RESPECT

TO

ANY

AND

ALL

EQUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

EXCEPT

AS

EXPRESSLY

PROVIDED

BY

MILLER

IN

WRITING,

MILLER

PRODUCTS

ARE

INTENDED

FOR

ULTIMATE

PURCHASE

BY

COMMERCIAL/INDUSTRIAL

USERS

AND

FOR

OPERATION

BY

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EQUIPMENT

AND

NOT

FOR

CONSUMERS

OR

CONSUMER

USE.

MILLERS

WARRANTIES

DO NOT

EXTEND

TO.

AND

NO

RESELLER

IS

AUTHORIZED

TO

EXTEND

MILLERS

WARRANTIES

TO.

ANY

CONSUMER.

I

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

damage

that

may

have

occurred

during

shipment.

File

any

cla~rns

for

loss

or

damage

with

the

delivering

carrier.

Assistance

for

filing

or

settling

claims

may

be

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

or

Style

Number.

Use

the

following

spaces

to

record

Model

Designation

and

Serial

or

Style

Number

of

your

unit,

The

information

is

located

on

the

rating

label

or

nameplate.

Model

_________

Serial

or

Style

No.

Date

of

Purchase

m~iiar

8,91

ERRATA

SHEET

June

10,

1992

FORM:

OM-146

741

Use

above

FORM

number

when

ordering

extra

manuals.

147824

042517

153736



.

.138114

149209

138

114

149209

042517

155

520

042

805

+155480

+155

605

031

689

155634

031

689

155634

042

805

I

1

4

1

4

1

~First

digit

represents

page

no



digits

following

dash

represent

item

no.



Part

of

042

805

Meter

Kit

Option

+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.

After

this

manual

was

printed,

refinements

in

equipment

design

occurred.

This

sheet

lists

exceptions

to

data

appearing

later

in

this

manual.

CHANGES

TO

SECTION

8-

PARTS

LIST

Change

Parts

List

as

follows:



--

Dia.

Part

Mkgs.

No.

Replaced

With

Description

Quantity

25-6...

PC5

25-

27-5...

PCi

27-5...

PCi

28-

..

C44-47

28-

..

013-16

28-

..

C40-43

28-

..

D9-12

28-

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)

ARC

WELDING

SAFETY

PRECAUTIONS

A

WARNING

ARC

WELDING

can

be

hazardous.

PROTECT

YOURSELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

OR

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTiNG

YOUR

DOCTOR.

In

welding,

as

in

most

jobs,

exposure

to

certain

hazards

occurs.

Welding

is

safe

when

precautions

are

taken.

The

safety

information

given

below

is

only

a

summary

of

the

more

complete

safety

information

that

will

be

found

in

the

Safety

Standards

listed

on

the

Read

and

follow

all

Safety

Standards.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

BY

QUALIFIED

PEOPLE.

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.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

FLYING

SPARKS

AND

HOT

METAL

can

cause

injury.

Chipping

and

grinding

cause

flying

metal.

As

welds

cool,

they

can

throw

off

slag.

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.

6.

Turn

oft

all

equipment

when

not

in

use.

7.

Do

not

use

worn,

damaged.

undersized,

or

poorly

spliced

cables.

8.

Do

not

wrap

cables

around

your

body.

9.

Ground

the

workpiece

to

a

good

electrical

(earth)

ground.

1

0

Do

not

touch

electrode

while

in

contact

with

the

work

(ground)

circuit.

11

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

12.

Wear

a

safety

harness

to

prevent

falling

if

working

above

floor

level.

13.

Keep

all

panels

and

covers

securely

in

place.

/)

.~.

ARC

RAYS

can

burn

eyes

and

skin;

I.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

(see

NOISE

can

damage

hearing.

ANSI

Z49.1

listed

in

Safety

Standards)

to

protect

your

face

and

eyes

when

welding

or

watching.

Arc

rays

from

the

welding

process

produce

intense

2.

Wear

approved

safety

gfasses.

Side

shields

recommended,

heat

arid

strong

ultraviolet

rays

that

can

burn

eyes

3.

Use

protective

screens

or

barriers

to

protect

others

from

flash

and

skin.

Noise

from

some

processes

can

damage

and

glare.

warn

others

not

to

watch

the

arc.

hearing.

4.

Wear

protective

clothing

made

from

durable,

flame-resistant

material

(wool

and

leather)

and

foot

protection.

5.

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

FUMES

AND

GASES

can

be

hazardous

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

to

your

health.

wearing

an

air-supplied

respirator.

Shielding

gases

used

for

~

Welding

producesfumesandgases.

Breathing

these

welding

can

displace

air

causing

injury

or

death.

Be

sure

the

fumes

and

gases

can

be

hazardous

to

your

health.

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

1.

Keep

your

head

out

of

the

fumes.

Do

not

breath

the

fumes.

form

highly

toxic

and

irritating

gases.

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

remove

welding

fumes

and

gases.

7.

Do

not

weld

on

coated

metals,

Such

as

galvanized,

lead,

or

3.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

4.

Read

the

Material

Safety

Data

Sheets

(MSDSs)

and

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

manufacturers

instruction

for

metals,

consumables,

coatings,

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

and

cleaners,

containing

these

elements

can

give

off

toxic

fumes

if

welded.

WELDING

can

cause

fire

or

explosion.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

Sparks

and

spatter

fly

off

from

the

welding

arc.

The

flying

sparks

and

hot

metal,

weld

spatter,

hot

6.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

of

electrode

or

welding

wire

7.

Do

not

weld

on

closed

containers

such

as

tanks

or

drums.

to

metal

objects

can

cause

sparks,

overheating,

or

fire.

8.

Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long,

possibly

1.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

2.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

9.

unknown

paths

and

causing

electric

shock

and

fire

hazards.

Do

not

use

welder

to

thaw

frozen

pipes.

3.

Removeallflammableswithin35ft(10.7m)oftheweldingarc.lf

this

is

not

possible,

tightly

cover

them

with

approved

covers,

10.

Remove

stick

electrode

from

holder

or

cutoff

welding

wire

at

contact

tip

when

not

in

use.

4.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

11.

Wear

oil.free

protective

garments

such

as

leather

gloves.

heavy

easily

go

through

small

cracks

and

openings

to

adjacent

areas.

shirt.

cuffless

trousers,

high

shoes,

and

a

cap.

1.

Wear

approved

face

shield

or

safety

goggles.

Side

shields

recommended.

2.

Wear

proper

body

protection

to

protect

skin.

Sri

9/91

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

cytinders

from

excessive

heat,

mechanical

shocks,

and

arcs.

2.

Install

and

secure

cylinders

in

an

upright

position

by

chaining

them

to

a

stationary

support

or

equipment

cylinder

rack

to

prevent

falling

or

tipping.

a

WARNING

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.

4.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

5

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

6.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

7.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

in

use

or

connected

for

use.

8.

Read

and

fotlow

instructions

on

compressed

gas

cylinders,

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.1,

from

American

Welding

Society,

550

NW.

LeJeune

Pd,

Miami

FL

33126

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,

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.

Cede

for

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.

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.

ENGINES

can

be

hazardous.

.

~

:

ENGINE

EXHAUST

GASES

can

kill.

1.

Use

equipment

outside

in

open,

well-ventilated

areas.

2.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

Engines

produce

harmful

exhaust

gases.

away

from

any

building

air

intakes.

ENGINE

FUEL

can

cause

fire

or

1.

Stop

engine

before

checking

or

adding

fuel.

explosion.

2.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

.

3.

Allow

engine

to

cool

before

fueling.

If

possible,

check

and

add

Engine

fuel

is

highly

flammable.

fuel

to

cold

engine

before

beginning

job.

4.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

5.

Do

not

spill

fuel.

If

fuel

is

spilled,

clean

up

before

starting

enQine.

MOVING

PARTS

can

cause

injury.

3.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

troubleshooting

as

necessary.

Moving

parts,

such

as

fans,

rotors,

and

belts

can

4.

To

prevent

accidental

starting

during

servicing,

disconnect

cut

fingers

and

hands

and

catch loose

clothing.

negative

()

battery

cable

from

battery.

5.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

I.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

parts.

securely

in

place.

6.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

2.

Stop

engine

before

installing

or

connecting

unit,

finished

and

before

starting

engine.

SPARKS

can

cause

BATTERY

GASES

1.

Always

wear

a

face

shield

when

working

on

a

battery.

TO

EXPLODE;

BATTERY

ACID

can

2.

Stop

engine

before

disconnecting

or

connecting

battery

burn

eyes

and

skin,

cables.

3.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

4.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

Batteries

contain

acid

and

generate

explosive

gases.

5.

Observe

correct

polarity

(+

and

)

on

batteries.

.t

~

~_.

-

~

STEAM

AND

COOLANT

can

skIn.

The

coolant

in

the

PRESSURIZED

burn

face,

eyes,

radiator

can

be

very

h

HOT

and

ot

and

I.

2.

Do

not

remove

radiater

cap

when

engine

is

hot.

Allow

engine

to

cool.

Wear

gloves

and

put

a

rag

over

cap

area

when

removing

cap.

under

pressure.

3.

Allow

pressure

to

escape

before

completely

removing

cap.

srI

9/91

TABLE

OF

CONTENTS

SECTION

1

-

SAFETY

SIGNAL

WORDS

1

SECTION

2

SPECIFICATIONS

2-1.

Volt-Ampere

Curves

2

2-2.

Duty

Cycle

2

SECTION

3INSTALLATION

3-1.

Selecting

A

Location

And

Moving

Welding

Power

Source

3

3-2.

Selecting

And

Preparing

Weld

Output

Cables

4

3-3.

Connecting

To

Weld

Output

Receptacles

5

3-4.

Remote

14

Receptacle

Information

And

Connections

5

3-5.

Connecting

Input

Power

6

SECTION

4

OPERATION

7

SECTION

5

MAINTENANCE

&

TROUBLESHOOTING

5-1.

Routine

Maintenance

.

11

5-2.

Removing

Top

Of

Case

And

Measuring

Input

Capacitor

Voltage

12

5-3.

Overload

Protection

13

5-4.

Changing

AmperageNoltage

Meter

Hold

Function

14

5-5.

Troubleshooting

15

SECTION

6

ELECTRICAL

DIAGRAMS

17

SECTION

7TUNGSTEN

ELECTRODE

7-1.

Selecting

Tungsten

Electrode

20

7-2.

Preparing

Tungsten

21

SECTION

8

PARTS

LIST

Figure

8-1.

Main

Assembly

22

Figure

8-2.

Panel,

Front

w/Components

24

Figure

8-3.

Chassis,

Mid

26

OM.146

741



3/92

SECTION

1



SAFETY

SIGNAL

WORDS

mO~I

9,91

The

following

safety

alert

symbol

and

signal

words

are

used

throughout

this

manual

to

call

attention

to

and

identify

different

levels

of

hazard

and

special

instructions.

a

WARNING

statements

identify

procedures

or

practices

which

must

be

followed

to

avoid

serious

personal

injury

or

loss

of

life.

a

CAUTION

statements

identify

procedures

or

practices

which

must

be

followed

to

avoid

minor

personal

~~jury

or

damage

to

this

equipment.

~

IMPORTANT:

statements

identify

special

instructions

necessary

for

the

most

efficient

operation

of

this

equipment.

SECTION

2

SPECIFICATIONS

Table

2-1.

Welding

Power

Source

Specification

Description

Type

Of

Output

Constant

Current

(CC),

Direct

Current

(DC)

Rated

Weld

Output

300

Amperes,

32

Volts

DC

At

60%

Duty

Cycle

(See

Sectlon

2.2)

Type

01

Input

380

Or

415

Volts

AC;

50

Hz;

Three

Phase

Input

Amperes

At

Rated

Output

25

Amperes

At

380

Volts,

23

Amperes

At

415

Volts

IC/A

Used

At

Rated

Output

16.4

kVA

KW

Used

At

Rated

Output

11.3kW

Amperage

Range

5-375

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.

(305mm);

HeIght:

17.3/8

In.

(441

mm)

Weight

ShIpping:

82

lbs.

(37

kg);

Net:

77

lbs.

(35

kg)

Options

PC-300,

RFC.14,

Foot

Control,

RHC-14,

RMLS-14,

FTC14

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

OM-146

741

Page

1

2-1.

Volt-Ampere

Curves

Figure

2-1.

Volt-Ampere

Curves

2-2.

Duty

Cycle

a

CAUTION

Duty

cycle

is

how

long

the

unit

can

:

operate

within

a

ten

minute

period

without

causing

overheating

or

~.

=

=:

:

=

damage.

Thisunitisratedat6o%dutycycle

~-

=

: :

=

:

allowingwelding6minutesoutof

(



~



:

~



-

:



-

:::

-

=

:



-

s~::

--~3PHASE



-

OPERATION

every

10

minutes

at

rated

load.

If

theweldingamperesdecrease,

the

dutycycleincreases.

900

::

w

3

~-

100



-

--

::

--

-

-.



--

0-



~

-

-





-

10

20

a

30

4050

eo~eoso10o

%

DUTY

CYCLE

sbl.2

2/92



SB.153

910

Figure

2-2.

Duty

Cycle

Chart

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~~~

30

v/1~Mh1W

MIN

20

~-.....

~c

cotrrRot.

10

I

~0X

5~

I

~

I

%50X

%75~~ioox

0



I

II

Ii

I I



0

100

200

300

400

AMPERES

ssbl.I

10/91



S8.146

879-8

EXCEEDING

DUTY

CYCLE

RATINGS

will

damage

unit.

S

Do

not

exceed

indicated

duty

cycles.

warnl,1

2/92

OM-146

741

Page

2

SECTION

3INSTALLATION

3-1.

Selecting

A

Location

And

Moving

Welding

Power

Source

a

WARNING

ELECTRIC

SHOCK

can

kill.

S

Do

not

touch

live

electrical

parts.



Disconnect

input

power

conductors

from

deenergized

supply

line

BEFORE

moving

welding

power

source.

FIRE

OR

EXPLOSION

can

result

from

placing

unit

on,

over,

or

near

combustible

surfaces.



Do

not

locate

unit

on,

over,

or

near

combustible

surfaces.



Do

not

install

unit

near

flammables.

BLOCKED

AIRFLOW

causes

overheating

and

possible

damage

to

Unit.

FALLING

EQUIPMENT

can

cause

serious

personal

injury

and

equipment

damage.



Lift

unit

at

handles.



Have

two

person

of

adequate

physical

strength

lift

unit.



Move

unit

with

hand

cart

or

similar

device

of

adequate

capacity.



If

using

a

fork

lift

vehicle,

secure

unit

on

a

proper

skid

before

transporting.

FUMES

can

be

hazardous;

LACK

OF

FRESH

AIR

AND

PROPER

VENTILATION

can

be

harmful.



Do

not

breathe

welding

fumes.



Place

unit

only

where

there

is

a

good

fresh

supply

and

proper

ventilation.

air



Do

not

block

or

filter

airflow.

Warranty

is

void

1

any

type

of

fitter

is

used.

Swarnhl

2/92

2

1

3

in.

(78

mm)

Open

Space

At

Sides,

6

in.

(156

mm)

At

Rear

For

Good

Airflow

2

Lifting

Handles

Use

handles

to

move

unit.

3

Rating

Label

Locate

unit

near

correct

input

pow

er

supply.

S7-152303-A/Rf.

ST-t51

558

Figure

3-1.

Location

And

Movement

Of

Welding

Power

Source

OM-146

741

Page

3

3-2.

Selecting

And

Preparing

Weld

Output

Cables

Figure

3-2.

Selecting

And

Preparing

Weld

Output

Cables

Table

3-1.

Weld

Cable

Size*

Welding

Amperes

100

150

200

Total

Cable

(Copper)

Length

In

Weld

Circuit

Not

Exceeding*

100

ft.

(30

m)

Or

Less

150

ft.

I

200

ft.

250

ft.

I

300

ft.

I

350

ft.

1

400

ft.

(45

m)

(60

m)

(70

m)

(90

m)

(105

m)

(120

m)

10

To

60%

Duty

Cycle

4

3

60

Thru

100%

Duty

Cycle

4

3

2

10

Thru

100%

Duty

Cycle

4

3

2

1

1/0

2

1

1/0

210

3/0

1

1/0

2/0

3/0

4/0

250

300

350

2

1

1/0

1

1/0

2/0

1/0

2/0

3/0

2/0

3/0

4/0

3/0

4/0

2-2/0

4/0

2-2/0

2-3/0

2.210

2-3/0

2-2/0

2-3/0

2-4/0

S-0001AfT-91

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.

OM-146

741

Page

4

For

Example,

Total

Cable

Length

In

Weld

Circuit

=

20

ft.

(6

m)

1

Weld

Output

Cable

Determine

total

cable

length

in

weld

Circuit

and

maximum

welding

amperes.

Use

Table

3-1

to

select

proper

cable

size.

Use

shortest

cables

possible.

Do

not

use

damaged

cables.

2

Terminal

Lug

Use

lugs

of

proper

amperage

Ca

pacity

and

hole

size

for

connecting

to

work

clamp,

electrode

holder,

or

wire

feeder.

3

Insulated

Electrode

Holder

Install

according

to

manufacturers

instructions.

4

Work

Clamp

Install

onto

work

cable.

5

Dinse-Type

Connector

6

Weld

Output

Cable

7

Insulator

Slide

cable

through

insulator

and

remove

1

in.

(25

mm)

insulation

from

end

of

cable.

8

Sleeve

9

Connector

Insert

cable

with

sleeve

into

con

nector

body

so

cable

is

snug

against

bottom.

10

Setscrew

Tighten

setscrew

and

push

insula

tor

fully

over

connector.

If

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

-

S-0656

/

S-0288-8

3-3.

Connecting

To

Weld

Output

Receptacles

a

WARNING

ELECTRIC

SHOCK

can

kill;

ARCiNG

can

burn

skin

or

damage

electrical

equipment.



Do

not

touch

live

electrical

parts.



Turn

OFF

welding

power

source

before

making

any

weld

output

connections.



Do

not

change

position

of

welding

cable

connectors

while

welding.

e

Be

sure

connectors

are

secure

in

receptacles

before

welding.

swarnl2

2

2/92

2

3

1

Positive

(+)

Weld

Output

Re

ceptacle

2

Negative

()

Weld

Output

Re

ceptacle

3

Connector

For

Electrode

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

key-

way,

insert

connector,

and

turn

clockwise

until

tight.

Ref.

5Q.t34

~62/Ref.

Sr.15222~

Figure

3-3.

Connecting

To

Weld

Output

Receptacles

3-4.

Remote

14

Receptacle

Information

And

Connections

1

Remote

14

Receptacle

RC2

2

Keyway

3

Plug

2

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

ac

contactor

control

circuit.

Protected

by

fuse

F2.

Remote

Amperage/Voltage

Control

C

Command

reference

;+10

volts

dc.

0

Control

circuit

common.

E

Input

command

signal

(potentiometer

wiper

or

0-10

volts

dc

source);

0

to

#10

volts

dc.

K

Chassis

common.

The

remaining

sockets

are

not

used.

ebl.1

1)52



Rel.

S0.134

162-B

/

Ret.

5-0004-A

/

5-0626

Figure

3-4.

Remote

14

ConnectIons

OM-146

741

Page

5

3-5.

Connecting

tnput

Power

a

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

OFF

welding

power

source,

and

disconnect

input

power

before

inspecting

or

instafling.



Have

only

qualified

persons

install

unit.



Installation

must

meet

National

Electrical

Code

and

all

other

codes.

swarr3.1

10/91

A.

Positioning

Jumper

Links

Jumper

links

allow

operation

on

dif

ferent

input

voltages

and

are

facto

ry

set

for

380

volts

input

power.

________

_______

Check

input

voltage

available

at

site.

Remove

top

of

case

according

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.

380

Volts

A

415

Volts

A

L

Tools

Needed:

ssb5.12/92ST-152225/R&

S-145063

Figure

B.

Connecting

To

Input

Power

3-5.

Input

Voltage

Jumper

Links

Location

2

Input

Voltage

380

415

Circuit

Breaker

Size

In

Amperes

t4~i

Fuse

Size

in

Amperes2

35

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).

Have

only

qualified

persons

make

this

instal-

3

Input

Conductors

4

Line

Fuses

lation.

1

Line

Disconnect

Switch

Of

Proper

Rating

Install

input

conductors

and

groufldifl9

con-

Select

fuses

or

Circuit

breakers

using

Table.

ductor

from

unit

to

deenergized

line

discon-

Install

into

deenargized

line

disconnect

nect

switch.

2

Grounding

Conductor



Green

Or

Green

With

Yellow

Stripe(s)

Be

sure

grounding

conductor

goes

to

an

earth

ground.

i$b2.3

3~52

-

Rsf.

SC-I

44221

/

ST-I

52

303-A

/

R&.

5-0092C

4

3

FIgure

3-6.

LocatIon

And

Input

Power

Connections

OM-146

741

Page

6

SECTION

4

OPERATION

WELDING

can

cause

fire

or

explosion.



Do

not

weld

near

flammable

material.



Watch

for

fire;

keep

extinguisher

nearby.



Do

not

locate

unit

over

combustible

surfaces.



Do

not

weld

on

closed

containers.



Allow

work

and

equipment

to

cool

before

handling.

,~

~

:._~..

ARC

RAYS

can

burn

eyes

and

skin;

NOISE

can

damage

hearing.

S

Wear

welding

helmet

with

correct

shade

of

filter.



Wear

correct

eye,

ear,

and

body

protection.



~11

MOVING

PARTS

can

cause

injury.

S

Keep

away

from

moving

parts.



Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

MAGNETIC

FIELDS

FROM

HIGH

CUR

RENTS

can

aftect

pacemaker

operation.



Pacemaker

wearers

keep

away.



Wearers

should

consult

their

doctor

before

going

near

arc

welding,

gouging,

or

spot

welding

opera

tions.

See

Safety

Precautions

at

beginning

of

manual

for

ba

sic

welding

safety

information.

swarn6

110/91

Figure

4-2.

Safety

Equipment

a

WARNING

ELECTRIC

SHOCK

can

kill.



Always

wear

dry

insulating

gloves.



Insulate

yourself

from

work

and

ground.



Do

not

touch

live

electrical

parts.



Keep

all

panels

and

covers

securely

in

place.

FUMES

AND

GASES

can

be

hazardous

to

your

health.



Keep

your

head

out

of

the

fumes.



Ventilate

area,

or

use

breathing

device.



Read

Material

Safety

Data

Sheets

(MSDSs)

and

manufacturers

instructions

for

material

used.

8

Power

Switch

Pilot

Light

2

3

4

5

6

7

8

2

3

Amperage

Control

Arc

Force

(Dig)

Control

Output

(Contactor)

Switch

Amperage

Control

Switch

Process

Selector

Switch

Optional

AmperageNoltage

Meter

And

Switch

FIgure

4-1.

Controls

ST152

224

2

3

1

Insulating

Gloves

/

2

Safety

Glasses

With

Side

Shields

3

Welding

l4elmet

glasses

with

side

shields,

and

a

_______

Wear

dry

insulating

gloves,

safety

welding

helmet

with

a

correct

shade

of

filter

(see

ANSI

Z49.

1).

sb3.1

10/91

OM-146

741

Page

7

I

~

Tools

Needed:

~

I

Work

Clamp

Use

wire

brush

or

sandpaper

to

clean

metal

at

weld

joint

area.

paint-free

location

on

workpiece,

as

Connect

work

clamp

to

a

clean,

close

to

weld

area

as

possible.

sb4

10/91

Figure

4-3.

Work

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)

1

control

(see

Figure

4-6).

Ref

SO-134

162

Figure

4-5.

Amperage

Control

I

Arc

Force

Control

(Dig)

This

control

is

used

for

SMAW

welding

and

only

works

when

Pro.

cess

Selector

switch

(see

Figure

4.4)

is

in

the

SMAW

position.

I

Use

control

to

help

start

an

arc

or

make

vertical

or

overhead

welds

(control

increases

short-circuit

am

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

cation.

Numbers

around

control

are

for

reference

only.

Set

control

at

0

for

GTAW

welding.

Figure

4.4.

Process

Selector

Switch

I

Amperage

Control

Use

control

to

select

wel

d

amper

age.

Amperage

may

be

adjusted

while

welding.

Figure

4-6.

Arc

Control

(Dig)

Control

OM-146

741

Page

8

I

Amperage

Control

Switch

Use

switch

to

select

way

of

control

ling

amperage.

For

front

panel

control.

place

switch

in

the

PANEL

position.

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

energized.



Do

not

touch

electrode

and

work

clamp

at

the

same

time.

swam?

m

1

Output

(Contactor)

Switch

Use

Switch

to

select

way

of

control.

ling

output.

r~~~i

For

front

panel

control,

place

switch

fl

ON

position.

OUTPUT

(CONTACTOR)~,)

For

remote

control,

place

switch

in

REMOTE

14

position

(see

Section

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

displayed

for

AIV

switch

settings.

2

Meter

Switch

Use

switch

to

select

amperage

or

voltage

display.

AN

Switch

Positions

Meter

Display

When

Not

When

Welding

A

Preset

Amps

Actual

Amps

V

Preset

Amps

Actual

Volts

Figure

4-9.

Amperage/Voltage

Meter

And

Switch

(Optional)

OM-146

741

Page

9

Figure

4-11.

Sequence

Of

Gas

Tungsten

Arc

Welding

(GTAW)

Figure

4-12.

Sequence

Of

Gas

Tungsten

Arc

Welding

-

Pulsed

(GTAW-P)

Figure

4-13.

Sequence

Of

Shielded

Metal

Arc

Welding

(SMAW)

Figure

4-10.

Power

Switch

And

Pilot

Light

Install

&

~\

~

Install

&

Connec~\\

Select

Insert

Connect

)

High-Frequency

)

Tungsten

Tunasten

Pe

Put

On

)

Equipment~J

Unit

JJ

(See

Section

Into

Thrch

))

Equipment

rsonal

Safety

Turn

On

Turn

On

))

Turn

On~~~)

Begin

Welding~)

)

Shielding

Gas

I

~1igh-Frequency

Welding

Power

_________________

J

Unit

Source

_________________

ssb8

2192

Install

&

Install

&

Connec))

Install

&

Connec\\

Select

Insert

Connect

1

Pulser

Control

High

)

Equipment

},J

Unit

-Frequency

j

)

Tungsten

I

Tungsten

________________

Unit

~JJ

(See

Section

7)])

Into

iorch

_____

~~pment

~

Turn

On

Turn

On

))

Turn

Qn

)

Set

Controls

Shielding

Gas

I

}

High-Frequency

Welding

Power

1

Begin

WeIdin9~

________________

})

Unit

Source

)

Install

&

Select

Put

On

)

Equipment~}

Equipment

D)

Into

Holder

I

Connect

Electrode

Personal

Safety

Set

Contro

Electrode

_____

~__~e

~

)

Begin

Weldin~

ssb7.1

2/92

OM-146

741

Page

10

SECTION

5

MAINTENANCE

&

TROUBLESHOOTING

a

WARNING

ELECTRIC

SHOCK

can

kill.

SIGNIFICANT

DC

VOLTAGE

exists

after

removal

of

input

power.



Do

not

touch

live

electrical

parts.



Turn

OFF

welding

power

source,

disconnect

input

power,

wait

60

seconds,

measure

voltage

on

input

capacitors

according

to

Section

5-3,

and

wait

for

voltage

to

drop

to

zero

before

touching

any

parts.

,~



Allow

cooling

penod

before

maintaining

or

HOT

PARTS

can

cause

severe

burns.

servicing.



~

MOVING

PARTS

can

cause

iniury.



Keep

away

from

moving

parts.

Maintenance

to

be

performed

persons.

only

by

qualified

swarn8

1

10/91

5-1.

Routine

Maintenance

Table

5-1.

Routine

Maintenance

Time

Maintenance

Every

month

More

than

normal

equipment

use:

Check

all

labels

(see

6

month

entry),

Repair

any

damaged

insulation

or

replace

weld

cables

if

necessary.

Clean

and

tighten

cable

connections.

Clean

internal

parts

(see

6

month

entry).

Every

3

months

Repair

any

damaged

insulation

or

replace

weld

cables

if

necessary.

Clean

and

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.

OM-146

741

Page

11

5-2.

Removing

Top

Of

Case

And

Measuring

Input

Capacitor

Voltage

LA

WARNING

ELECTRIC

SHOCK,

HOT

PARTS,

AND

MOVING

PARTS

HAZARDS.

Read

safety

infor

mation

at

beginning

of

Section

5

before

proceeding.

a

CAUTION

STATIC

ELECTRICITY

can

damage

parts

on

circuit

boards.



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

fwarn5.

I



9/91

Turn

OFF

welding

power

source

and

disconnect

input

power.

I

lop

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

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.

3

4

5

Tools

Needed:

5/32

in.

FIgure

5-1.

RemovIng

Top

Of

Case

And

MeasurIng

Input

Capacitor

Voltage

51-153

512/Pet.

51-153

512

OM-146

741

Page

12

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