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Optima

Miller Optima, JK539176 Owner's manual

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June
1989
FORM:
OM-891
Millerfi
MODEL
OPTIMATM
OWNERS
MANUAL
IMPORTANT
Read
and
understand
the
entire
contents
of
this
manual,
Miller
Electric
Mfg.Co.
with
special
emphasis
on
the
safety
material
throughout
the
manual,
AMOeGroo~LIdC~ny
before
installing,
operating,
or
maintaining
this
equipment.
This
unit
and
P0.
Box
1079
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
Appleton,
WI
54912
USA
the
safe
operation
of
welding
equipment.
Do
not
allow
untrained
persons
Tel.
414-734-9821
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
Effective
With
Serial
No.
JK593176
PRINTED
IN
U.S.A.
LIMITED
WARRANTY
EFFEC11VE:
MARCH
15,
1989
-1
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
fur
nished
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
ac
cessories
and
other
items
are
sold
subject
to
the
warranties
of
their
respective
manufacturers,
if
any.
All
engines
are
war
ranted
by
their
manufacturer
for
one
year
from
date
of
original
purchase,
except
Tecumseh
and
Onan
engines
which
have
a
two
year
warranty.
Except
as
specified
below,
Millers
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,
MILLER
MATIC
parts
that
come
in
contact
with
the
welding
wire
includ
ing
nozzles
and
nozzle
insulators
where
failure
does
not
result
from
defect
in
workmanship
or
material.
Ui:
Miller
shall
be
required
to
honorwarranty
claims
on
warranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
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,
exclusi~
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)
replacement
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
Millarservice
station
or(4)
paymentof
orcredittorthe
purchase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
Customers
risk
and
expense.
MILLERs
option
of
repairor
replacementwill
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
F.O.B.
at
a
MILLER
authorized
serv
ice
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
Upon
receipt
of
notice
of
apparent
detect
or
failure,
Miller
shall
instruct
the
claimant
on
the
war
ranty
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
PRO
VISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHAN
TABILITY
OR
OF
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY AND
ALL
EQUIPMENT
FUR
NISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
ULTI
MATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
FOROPERATION
BY
PERSONS
TRAINED
AND
EXPE
RIENCED
IN
THE USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CON
SUMER
USE.
MILLERS
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
I
ii.
-~
SYNERGIC
INFORMATION
The
manufacturer
makes
no
warranties,
express
or
implied,
that
welds
made
using
the
synergic
parameters
of
this
equip
ment
will
meet
the
requirements
of
the
application.
L
~~1
The
quality
of
any
weld
is
determined
by
many
factors
of
which
the
current,
voltage,
and
power
source
characteristics
are
only
a
small
part.
Each
weld
and
weld
setting
must
be
examined
and
tested
as
to
its
suitability
for
each
application.
The
ultimate
suit
ability
of
any
weld
orweld
procedure
is
the
responsibility
of
com
petent
welding
engineering.
By
providing
the
synergic
parameters
as
convenient,
preset
configurations,
the
manufacturer
does
not
recommend
any
given
setting
as
a
suitable
one
for
the
application.
The
synergic
parameters
contained
in
this
equipment
are
in
tended
only
to
be
a
general
guideline.
The
choice
and
use
of
any
synergic
setting
must
be
tested
as
to
its
suitability
for
the
appli
cation.
L
xwI
I
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
Lt0
data
appearing
later
in
this
manual.
AMENDMENT
TO
SECTION
3
INSTALLATION
Amend
Step
2
of
Section
3-2.
CONNECTION
TO
THE
WELDING
POWER
SOURCE
2.
Place
MODE
switch
on
MAXTRON
300
to
CC
position
and
ARC
CONTROL/INDUCTANCE
control
to
minimum.
The
ARC
PAK
350
does
not
require
any
adjustments.
AMENDMENT
TO
SECTION
5
SEQUENCE
OF
OPERATION
Add
Step
6a
to
Section
5-1.
GAS
METAL
ARC
WELDING
-
PULSED
ARC
(GMAW-P)
WITH
THE
MAXTRON
300
6a.
Rotate
ARC
CONTROL/INDUCTANCE
control
to
minimum
(see
MAXTRON
300
Owners
Manual).
AMENDMENT
TO
SECTION
7
ELECTRICAL
DIAGRAMS
Amend
Diagram
7-1.
Circuit
Diagram
For
Pendant
Control
IMPORTANT:
Use
Serial
Number
of
unit
to
select
appropriate
Diagram
7-1
(see
Pages
1
and2
on
this
Errata
Sheet).
PLG4
M
B
E
H
P
L
S
WORK
(NEG.)
ELECTRODE
(POS.)
0
5L
U
<
5PN
SL
UVBL
/i~
<
RED
<
URN
<
8LK
~T
~EL~
42
:
(<P03-A
<<RC3-B
Z-(
RC3-C
(<P03-0
(<RC3-E
-<(
RC3-F
~<
RC3-G
<<RC
I
-A
<<PC
I
-B
J
PC
I
RC2-A
P02-B
P02
-
C
PC
I
/PLG
I
RC2/PLG2
RC3/PLG3
ARC
LENGTH
4
/
Circuit
Diagram
No.
SA-135
490
Diagram
7-1.
Circuit
Diagram
For
Models
Effective
With
Serial
No.
KA747874
Thru
KA900310
PLG4
Circuit
Diagram
No.
SA-141
214
Diagram
7-1.
Circuit
Diagram
For
Models
Effective
With
Serial
No.
KA900311
Amend
Diagram
7-2.
Wiring
Diagram
For
Pendant
Control
IMPORTANT:
Use
Serial
Number
of
unit
to
select
appropriate
Diagram
7-2
(see
Pages
2
and
3
on
this
Errata
Sheet).
GND.
Wiring
Diagram
No.
SB-i
35
491
Diagram
7-2.
Wiring
Diagram
For
Models
Effective
With
Serial
No.
KA747874
Thru
KA900310
OM-891
Page
2
PC
I
M
B
E
H
P
L
S
WORK
(NEG.)
ELECTRODE
(POS.)
0
((RC3-A
P03-B
(<P03-C
Z
RC3-E
~
P03-F
<<RC3-G
,~
-
YEL
<
8LLVBL/(
<
5L1<
<
BPV
BLU
<
d2
RC2-A
RC2-B
P02-C
ARC
LENGTH
4
RCI/PLGI
~<PC
-
A
I
RC2/PLG2
<<RCI-B
RC3/PLG3
~First
digit
represents
page
no
-
digits
following
dash
represent
item
no.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
GND.
Wiring
Diagram
No.
SB-141
213
Diagram
7-2.
Wiring
Diagram
For
Models
Effective
With
Serial
No.
KA900311
AMENDMENT
TO
SECTION
8
PARTS
LIST
Amend
Parts
List
as
follows:
Part
Replaced
No.
With
Description
Quantity
10-1
121816
134892
CASES
ECTION,
front/ends
10-6
123
531
123
531
STRAIN
RELIEF,
(qty
chg)
10-6
123
531
134
900
STRAIN
RELIEF,
cable
flexible
.270-.480
10-12
090
890
135
304
CABLE,
port
No.
18
8/c
(order
by
ft)
2Oft
OM-891
Page
3
SECTION
1
-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
and
on
various
la
bels,
tags,
and
plates
on
the
unit
pertains
to
equipment
design,
i
nstauation,
operation,
maintenance,
and
troubleshooting
which
should
be
read,
understood,
and
followed
for
the
safe
and
effective
use
of
this
equipment.
B.
Safety
The
installation,
operation,
maintenance,
and
trouble
shooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
in
stalled,
operated,
and
maintained
only
by
qualified
per
Sons
~fl
accordance
with
this
manual
and
all
applicable
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
Safety
Rules
For
Operation
Of
Arc
Weld
ing
Power
Source
in
the
welding
power
source
manual.
1-2.
SAFETY
ALERT
SYMBOL
AND
SIGNAL
WORDS
The
following
safety
alert
symbol
and
signal
words
are
used
throughout
this
manual
to
call
attention
to
and
iden
tify
different
levels
of
hazard
and
special
instructions.
a
a
This
safety
alert
symbol
is
used
with
the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid seri
ous
personal
injury
or
loss
of
life.
a
CAUTION
statements
identify
procedures
or
practiceswhich
must
be
followed
to
avoid
minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
statements
identify
special
instructions
necessary
for
the
most
efficient
operation
of
this
equip
ment.
SECTION
2-
SPECIFICATIONS
Figure
2-1.
Overall
DimensIons
2-1.
DESCRIPTION
The
OPTIMA
is
an
adaptive
synergic
pendant
control
designed
for
the
Gas
Metal
Arc
Welding
-
Pulsed
Arc
(GMAW-P)
process.
This
unit
can
be
configured
to
oper
ate
with
the
MAXTRON
300
or
ARC
PAK
350
welding
power
sources.
The
OPTIMA
automatically
adjusts
theweld
parameters
which
determine
arc
power
(background
amperage,
peak
amperage,
pulse
frequency,
and
pulse
width)
to
match
the
selected
program
and
wire
feed
speed.
It
is
equipped
with
remote
voltage
sensing
leads
for
arc
length
regulation.
To
be
operational,
the
OPTIMA
must
be
used
with
a
wire
feeder
and
a
constant
current
(CC)
welding
power
source
having
the
necessary
interface
circuitry.
The
OP
TIMA
does
not
set
wire
feed
speed,
so
no
feeder
control
connection
is
required.
Wire
feed
speed
is
set
at
the
wire
feeder.
Two
internal
DIP
switches
must
be
repositioned
TA~129
744
depending
on
the
welding
power
source
being
used.
When
used
in
conjunction
with
this
equipment,
the
OP
TIMA
allows
the
operator
to
establish
a
stable
pulsed
spray
metal
transfer
in
the
majority
of
situations
using
various
types
and
sizes
of
welding
wire
and
shielding
gases.
23/16
In.
(55.5
mm)
(178
mm)
OM-891
Page
1
SECTION
3-INSTALLATION
3-1.
SETTING
THE
DIP
SWITCHES
(Figure
3-1)
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shutdown
welding
powersource,
anddiscon
nect
the
Remote
Pendant
Control
before
chang
ing
position
of
dip
switches.
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
circuit
boards.
Put
on
properly
grounded
wrist
strap
BEFORE
handling
circuit
boards.
Perform
work
only
at
a
static-safe
work
area.
The
OPTIMA
can
be
used
with
either
the
MAXTRON
300
or
ARC
PAK
350
welding
power
source.
On
ship
ment,
it
is
configured
for
use
with
the
MAXTRON
300.
In
order
to
operate
this
control
with
an
ARC
PAK
350,
two
internal
DIP
switches
must
be
repositioned
as
follows:
IMPORTANT:
All
directions,
such
as
left
or
right,
are
with
respect
to
the
operator
facing
the
pendant
control
front
panel.
1.
Access
internal
DIP
switch
by
removing
plastic
hole
plug
on
lower
right
side
of
pendant
control.
2.
Ad
just
the
DIP
switches
using
a
nonconductive,
flat
instrument.
Move
both
DIP
switches
fully
down
for
ARC
PAK
350
operation.
Move
both
DIP
switches.
fully
up
for
MAXTRON
300
operation.
3.
Reinstall
the
plastic
plug.
3-2.
CONNECTION
TO
THE
WELDING
POWER
SOURCE
(FIgure
3-1)
4~
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shutdown
welding
powersource,
andbe
sure
it
cannot
be
accidentally
energized
before
mak
ing
connections.
Connect
the
17-pin
Amphenol
plug
on
the
interconnect
ing
cord
to
the
REMOTE
17
receptacle
on
the
welding
power
source
as
follows:
1.
Align
keyways,
insert
plug
fully
into
the
REMOTE
17
receptacle,
and
rotate
threaded
collar
fully
clock
wise.
2.
Place
MODE
switch
on
MAXTRON
300
to
CC
posi
tion.
The
ARC
PAK
350
does
not
require
any
ad
just
ments.
3-3.
VOLTAGE
SENSE
LEAD
CONNECTIONS
4k
WARNING:
ELECTRIC
SHOCK
can
kill.
_____
S
Do
not
touch
live
electrical
parts.
Shut
down
wire
feeder
and
welding
power
source,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
making
volt
age
sensing
connections.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removin9
fuses
fromfuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
Both
dip
switches
fully
down
for
ARC
PAK
350
operatIon.
Both
dip
switches
fully
up
for
MAXTRON
300
operation.
TA
129
744
17-Pin
Amphenol
Hole
Plug
Voltage
Sensing
Lead
With
Ring
Terminal
(Electrode)
Figure
3-1.
Pendant
Control
Connectors
And
Dip
Switch
PosItIons/Locations
OM-891
Page
2
The
OPTIMA
is
equipped
with
a
set
of
remote
Voltage
Sends
Leads
necessary
for
arc
length
regulation.
These
leads
must
be
connected
in
the
correct
polarity
for
prop
er
operation.
Best
results
will
be
obtained
when
the
Volt
age
Sends
Leads
are
placed
as
close
to
the
arc
as
possi
ble.
The
most
convenient
place
to
make
these
connec
tions
is
at
the
wire
feeder.
IMPORTANT:
The
voltage
sensing
leads
are
labeled
ELECTRODE
and
WORK.
These
labels
indicate
the
proper
polarity
fora
DC
Electrode
Positive
(Reverse)
po
larity
application.
A.
Connections
To
Push-Type
WIre
Feeder
(Figure
3-1
And
Figure
3-2)
4~
WARNING:
Read
and
follow
safety
informa
tion
at
beginning
of
entIre
Section
3-3
before
proceeding.
1.
Locate
Voltage
Sense
Lead
labeled
ELECTRODE.
Install
and
secure
the
Voltage
Sense
Lead
ring
ter
minal
to
weld
cable
terminal
on
wire
drive
assembly
of
wire
feeder
(see
wire
feeder
Owners
Manual
for
location).
OPTIMA
-
(Front
View)
To
REMOTE
17~
Receptacle
On
The
Welding
Power
Source
interconnecting
Cord
Figure
3-2.
Power
Source/OPTIMA/Push
Type
Wire
Feeder
Connections
2.
Locate
Voltage
Sense
Lead
labeled
WORK.
Con
nect
the
Voltage
Sense
Lead
to
workpiece.
3.
Place
remote
control
switch
on
wire
feeder
in
STAN
DARD
position,
if
applicable.
B.
Connections
To
XR-15
And
XR-30
(Push-Pull
Type)
WIre
Feeder
Models
Effective
With
Serial
No.
JH247300
Thru
JH308297
(Figure
3-1
And
Figure
3-3)
a
WARNING:
Read
and
follow
safety
Informa
tion
at
beginning
of
entire
Section
3-3
before
proceeding.
IMPORTANT:
A
Voltage
Sensing
Cable
is
supplied
with
the
XR
wire
feeder
when
a
digital
meter
option
is
in
stalled.
Connect
the
voltage
Sensing
Cable
betwen
wire
feeder
terminal
strip
3TA
and
the
workpiece.
To
REMOTE
1,
Receptacle
On
The
Welding
Power
Source
+Supp
lied
only
on
wire
feeders
with
digital
meters.
S~0252
Figure
3-3.
Power
Source/OPTIMA/XR-1
5
Or
XR-30
Wire
Feeder
Connections
(Effective
With
Serial
Nos.
JH247300
Thru
JH308297)
IMPORTANT:
The
OPTIMA
cannot
be
used
with
XR-
15
and
XR-30
wire
feeder
models
prior
to
Serial
No.
JH24
7300.
IMPORTANT:
All
directions,
such
as
left
or
right,
are
with
respect
to
the
operator
facing
the
wire
feeder
front
panel.
1.
Remove
right
side
panel
from
wire
feeder,
and
loos
en
upper
strain
relief
clamp
on
rear
of
wire
feeder.
2.
Cut
3/8
in.
ring
lug
off
voltage
sensing
lead
labeled
ELECTRODE,
and
crimp
or
solder
supplied
1/8
in.
ring
lug
onto
lead.
3.
Route
end
of
Voltage
Sense
Lead
labeled
ELEC
TRODE
through
strain
relief
to
inside
of
wire
feeder,
and
make
connections
as
follows:
a.
Connect
Voltage
Sense
Lead
labeled
ELEC
TRODE
to
terminal
B
on
terminal
strip
3T.
b.
Tighten
strain
relief
clamp,
and
reinstall
right
side
panel
onto
wire
feeder.
4.
Locate
Voltage
Sense
Lead
labeled
WORK.
Con
nect
the
Voltage
Sense
Lead
to
workpiece.
C.
Connections
To
XR-15
And
XR-30
(Push-Pull
Type)
Wire
Feeder
Models
Effective
With
Serial
No.
JH308297
And
Following
(Figure
3-1
And
Figure
3-4)
IMPORTANT:
A
Voltage
Sensing
Cable
is
supplied
with
the
XR
wire
feeder
and
must
be
connected
between
the
wire
feeder
and
the
workpiece
before
welding.
Refer
to
the
XR
Wire
Feeder
Owners
Manual
for
connections.
IMPORTANT:
All
directions,
such
as
left
or
right,
are
with
respect
to
the
operator
facing
the
wire
feeder
front
panel.
1.
Remove
right
side
panel
from
wire
feeder,
and
loos
en
upper
strain
relief
clamp
on
rear
of
wire
feeder.
2.
Cut
3/8
in.
ring
lug
off
Voltage
Sense
Lead
labeled
ELECTRODE
and
crimp
or
solder
supplied
1/8
in.
ring
lug
onto
lead.
Voltage
Sensing
Lead
With
Clamp
(Work)
Voltage
Sensing
Lead
With
Clamp
(Work)
S-0251
OM-891
Page
3
3.
Remove
clamp
from
Voltage
Sense
Lead
labeled
WORK.
4.
Route
ends
of
voltage
sensing
leads
through
strain
relief,
to
inside
of
wire
feeder,
and
make
connection
as
follows:
a.
Connect
Voltage
Sense
Lead
labeled
ELEC
TRODE,
with
1/8
in.
lug,
to
terminal
B
on
termi
nal
strip
31.
b.
Connect
Voltage
Sense
Lead
labeled
WORK
to
terminal
A
on
terminal
strip
3T.
c.
Tighten
strain
relief
clamp,
and
reinstall
right
side
panel
onto
wire
feeder.
5.
Connect
Voltage
Sensing
Cable
from
the
XR
wire
feeder
to
workpiece.
SECTION
4-
OPERATOR
CONTROLS
4-1.
PROGRAM
SELECTOR
SWITCH
(Figure
4-1
And
Table
4-1)
The
PROGRAM
SELECTOR
is
a
rotary
switch
which
al
lows
the
operator
to
choose
between
the
ten
welding
programs
listed
on
the
nameplate
(see
Table
4-1).
The
program
selected
should
match
the
wire
type,
wire
size,
shielding
gas,
and
wire
feed
speed
being
used
for
the
specific
application.
4-2.
ARC
LENGTH
CONTROL
(Figure
4-1)
The
ARC
LENGTH
CONTROL
provides
a
means
to
ad
justing
the
arc
length
between
the
electrode
wire
and
the
work.
Each
program
selects
a
different
calibration
for
this
control
in
order
to
meet
the
arc
length
requirements
for
the
process
to
be
used.
The
scale
of
5
to
+5
on
this
control
indicates
only
longer
and
shorter
arcs,
not
an
ac
tual
length
or
voltage.
Adjustment
of
this
control
is
nor
TA-129
mat
if
a
significant
change
of
wire
feed
speed
or
joint
con
figuration
is
made.
Voltage
Sensing
Lead
With
Clamp
(Work)
S-0253
FIgure
3-4.
Power
Source/OPTIMA/XR-15
Or
XR-30
Wire
Feeder
Connections
(Effective
With
Serial
No.
JH308297)
rogram
Selector
Switch
Figure
4-1.
Operator
Controls
OM-891
Page
4
Table
4-1.
WeldIng
Programs**
PROGRAM
#
WIRE
TYPE
WIRE
SIZE
SHIELDING
GAS
1PM
MIN
1PM
MAX
1
Nickle
.035
in.
Argon
120
350
2
5356AL
.047
in.
Argon
120
300
3
5356AL
.035
in.
Argon
180
600
4
4043AL
.047
in.
Argon
150
300
5
4043AL
.035
in.
Argon
160
500
6
Steel
.045
in.
95Ar15CO2*
90
400
7
Steel
.035
in.
95Ar/5C02
120
475
8
Stainless
.045
in.
95Ar/5C02*
110
350
9
Stainless
.035
in.
95Ar/5C02
120
450
10
Copper/Silicon
Bronze
.035
in.
Argon
150
300
*Alternate
gases
are
95Ar/502
and
98Ar/202
**The
manufacturer
makes
no
warranties,
express
or
implied,
that
welds
made
using
the
synergic
parameters
of
this
equipment
will
meet
the
requirements
of
the
application.
The
quality
of
any
weld
is
determined
by
many
factors
of
which
the
current,
voltage,
and
power
source
characteristics
are
only
a
small
part.
Each
weld
and
weld
setting
must
be
examined
and
tested
as
to
its
suitability
for
each
application.
The
ultimate
suitability
of
any
weld
or
weld
procedure
is
the
responsibility
of
competent
welding
engineering.
By
providing
synergic
parameters
as
convenient,
preset
configurations,
the
manufacturer
does
not
recommend
any
given
setting
as
a
suitable
one
for
the
application.
The
synergic
parameters
contained
in
this
equipment
are
intended
to
be
a
general
guideline.
The
choice
and
use
of
any
synergic
setting
must
be
tested
as
to
its
suitability
for
the
application.
SECTION
5
SEQUENCE
OF
OPERATION
4~
WARNING:
ELECTRIC
SHOCK
can
kill;
MOVING
PARTS
can
cause
serious
injury;
IMPROPER
AIRFLOW
AND
EXPOSURE
TO
ENVIRONMENT
can
damage
Internal
parts.
Do
not
touch
live
electrical
parts.
Keep
away
from
moving
parts.
Keep
all
covers
and
panels
in
place
while
operating.
Warranty
is
void
if
the
welding
equipment
is
op
erated
with
any
portion
of
the
outer
enclosure
re
moved.
ARC
RAYS,
SPARKS,
AND
HOT
SURFACES
can
burn
eyes
and
skin;
NOISE
can
damage
hearIng.
Wear
correct
eye,
ear,
and
body
protection.
FUMES
AND
GASES
can
seriously
harm
your
health.
Keep
your
head
out
of
the
fumes.
Ventilate
to
keep
from
breathing
fumes
and
gases.
If
ventilation
is
inadequate,
use
approved
breathing
device.
WELDING
WIRE
can
cause
puncture
wounds.
Do
not
point
gun
toward
any
part
of
the
body,
any
conductive
surface,
or
other
personnel.
HOT
METAL,
SPATTER,
AND
SLAG
can
cause
fire
and
burns.
Watch
forfire.
Keep
a
fire
extinguisher
nearby,
and
know
how
to
use
it.
Do
not
use
near
flammable
material.
Allow
work
and
equipment
to
cool
before
handling.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
See
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source
in
the
welding
power
source
Owners
Manual
for
basic
welding
safety
information.
5-1.
GAS
METAL
ARC
WELDING
-
PULSED
ARC
(GMAW-P)
WITH
THE
MAXTRON
300
a
WARNING:
Read
and
follow
safety
Informa
tion
at
beginnIng
of
entIre
Section
5
before
proceeding.
1.
Install
and
prepare
welding
power
source
according
to
its
Owners
Manual.
2.
Install
and
connect
OPTIMA
according
to
Section
2.
OM-891
Page
5
3.
Install
and
prepare
wire
feeder
according
to
its
Own-
2.
Install
and
connect
OPTIMA
according
to
Section
2.
ers
Manual.
3.
Install
and
prepare
wire
feederaccording
to
its
Own
4.
Place
the
Remote
Control
switch
on
the
wire
feeder
ers
Manual.
in
the
STANDARD
position,
if
applicable.
5.
Place
the
OUTPUTICONTACTOR
switch
on
the
4.
Place
the
Remote
control
on
the
wire
feeder
in
the
MAXTRON
300
in
the
REMOTE
position
(see
MAX-
STANDARD
position,
if
applicable.
TRON
300
Owners
Manual).
5.
Select
desired
program
with
the
PROGRAM
SE-
6.
Place
the
MODE
switch
on
the
MAXTRON
300
in
LECTOR
switch
(see
Section
4-1).
the
CC
position
(see
MAXTRON
300
Owners
Man
ual).
6.
Set
ARC
LENGTH
control
to
midrange
until
proper
arc
length
is
determined
(see
Section
4-2).
7.
Select
desired
program
with
the
PROGRAM
SE
LECTOR
switch
(see
Section
4-1).
7.
Wear
dry
insulating
gloves
and
clothing,
and
wear
8.
Set
ARC
LENGTH
control
to
mid-range
until
proper
welding
helmet
with
proper
filter
lens
according
to
arc
length
is
determined
(see
Section
4-2).
ANSI
Z49.1.
9.
Wear
dry
insulating
gloves
and
clothing,
and
wear
8.
Prepare
for
welding
as
follows:
welding
helmet
with
proper
filter
lens
according
to
ANSI
Z49.1.
a.
Connect
work
clamp
to
clean,
bare
metal
at
workpiece.
10.
Prepare
for
welding
as
follows:
a.
Connect
work
clamp
to
clean,
bare
metal
at
b.
Select
and
obtain
proper
welding
wire,
and
workpiece.
thread
as
instructed
in
wire
feeder
Owners
Manual.
b.
Select
and
obtain
proper
welding
wire,
and
thread
as
instructed
in
wire
feeder
Owners
9.
Turn
on
shielding
gas
supply.
Manual.
10.
Depress
the
POWER
switch
ON
button
(see
ARC
11.
Turn
on
shielding
gas
supply.
PAK
350
Owners
Manual).
12.
Depress
the
POWER
switch
ON
button
(see
MAX
TRON
300
Owners
Manual).
11.
Begin
welding,
adjusting
the
ARC
LENGTH
control
to
achieve
desired
arc
length
(see
Section
4-2).
13.
Begin
welding,
adjusting
the
ARC
LENGTH
control
to
achieve
desired
arc
length
(see
Section
4-2).
5-3.
SHUTTING
DOWN
5-2.
GAS
METAL
ARC
WELDING
PULSED
ARC
1.
Stop
welding.
(GMAW-P)
WITH
THE
ARC
PAK
350
4~
WARNING:
Read
and
follow
safety
Informa-
2.
Shut
down
welding
power
source
and
wire
feeder.
tion
at
beginning
of
entire
Section
5
before
3.
Turn
off
shielding
gas
at
the
source.
proceedIng.
4A
WARNING:
HIGH
CONCENTRATION
OF
1.
instaliandprepareweldingpowersourceaccording
SHIELDING
GAS
can
harm
health
or
kill.
to
its
Owners
Manual.
The
Arc
Pak
350
defaults
to
Shut
off
gas
supply
when
not
in
use.
the
CC
mode
without
the
RCAP-1
pendant.
OM-Bel
Page
6
SECTION
6-
MAINTENANCE
&
TROUBLESHOOTING
6-1.
ROUTINE
MAINTENANCE
IMPORTANT:
Every
six
months
inspect
the
labels
on
this
unit
for
legibility.
All
precautionary
labels
must
be
maintained
in
a
clearly
readable
state
and
replaced
when
necessary.
See
Parts
List
for
part
number
of
precautionary
labels.
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
welding
po
wersource,
and
discon
nect
OPTIMA
before
inspecting,
maintaining,
or
servicing
unit.
Table
6-1.
Maintenance
Schedule
Frequency*
Maintenance
Every
month.
~
Units
in
heavy
service
environ
ments:
Check
labels
and
interconnecting
cord
and
leads.
Every
6
months.
Check
all
labels
(see
IMPORTANT
block,
Section
6-1)
and
inter
connecting
cord
and
leads.
Every
six
months,
inspect
interconnecting
cord
and
leads
for
damage
to
the
insulation
jacket
particularly
at
the
plug
and
strain
relief.
Repair
or
replace
the
cord
and
leads
as
necessary.
6-2.
CIRCUIT
BOARD
HANDLING
PRECAUTIONS
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shutdown
welding
powersource,
anddiscon
nect
OPTIMA
before
inspecting,
maintaining,
or
servicing
unit.
CAUTION:
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
cIrcuit
boards.
Put
on
properly
grounded
wrist
strap
BEFORE
handling
circuit
boards.
Transport
circuit
boards
in
proper
static
shielding
carriers
or
packages.
Perform
work
only
at
a
static-safe
work
area.
INCORRECT
INSTALLATION
or
mIsalIgned
plugs
can
damage
circuit
board.
Be
sure
that
plugs
are
properly
installed
and
aligned.
EXCESSIVE
PRESSURE
can
break
cIrcuit
board.
Use
only
minima/pressure
and
gentle
move
ment
when
disconnecting
or
connecting
board
plugs
and
removing
or
installing
board.
6-3.
TROUBLESHOOTING
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shutdown
welding
po
wersource,
and
discon
nect
OPTIMA
before
inspecting,
maintaining,
or
servicing
unit.
It
is
assumed
that
the
unit
was
properly
installed
accord
ing
to
Section
3
of
this
manual,
the
operator
is
familiar
with
the
function
of
controls,
the
welding
power
source,
wire
feeder,
and
OPTIMA
were
working
properly,
and
that
the
trouble
is
not
related
to
the
welding
process.
The
following
table
is
designed
to
diagnose
and
provide
remedies
for
some
of
the
troubles
that
may
develop
in
the
OPTIMA.
Use
this
table
in
conjunction
with
the
circuit
diagram
while
performing
troubleshooting
procedures.
If
the
trouble
is
not
remedied
after
performing
these
pro
cedures,
contact
the
nearest
Factory
Authorized
Serv
ice
Station.
In
all
cases
of
equipment
malfunction,
strictly
follow
the
manufacturers
procedures
and
instructions.
Table
6-2.
TroubleshootIng
TROUBLE
PROBABLE
CAUSE
REMEDY
No
weld
output.
Welding
power
source
POWER
switch.
PlaceweldirtgpowersourcePOWERswitch
in
ON
position.
Welding
gun
or
wire
feeder.
See
welding
gun
or
wire
feeder
Owners
Manual.
No
control
of
weld
output.
MAXTRON
300
controls
in
wrong
positions.
Place
AMPSNOLTS
switch
in
REMOTE
p0-
sition
and
MODE
switch
in
CC
position.
Voltagesensingleadsnotconnected
or
connected
improperly.
~
Make
voltage
sensing
connections
accord-
ing
to
Section
3-3.
Be
sure
connection
at
workpiece
is
to
clean,
bare
metal.
a
*Frequency
of
service
is
based
on
units
operated
40
hours
per
week.
Increase
frequency
of
maintenance
it
usage
exceeds
40
hours
per
week.
OM-891
Page
7
Table
6-2.
Troubleshooting
(Contd)
TROUBLE
PROBABLE
CAUSE
REMEDY
No
control
of
weld
output.
interconnecting
Cord.
Checkthat
interconnecting
cord
17-pin
plug
(Contd)
is
secure
in
the
REMOTE
17
receptacle
on
welding
power
source
(see
Section
3-2).
Check
continuity
of
the
interconecting
cord.
Replace
if
necessary.
OPTIMA
not
functional.
Erratic
weld;
incorrect
weld
ARC
LENGTH
control
and/or
PRO-
GRAM
SELECTOR
switch.
Check
and
replace
as
necessary.
Circuit
Board
PCi.
Incorrect
control
settings
on
OPTI-
Replace
the
circuit
board
(see
Section
6-2).
Recheck
program
listing
and
reset
to
proper
characteristics.
MA.
program.
Check
ARC
LENGTH
control
and
adjust
if
necessary.
Wrong
wire
feed
speed.
Correct
the wire
feed
speed
at
the
wire
feeder
for
the
workpiece
and
program
selected.
Voltage
sensing
lead
connections.
Check
voltage
sensing
lead
connections
ac
cording
to
Section
3-3.
Be
sure
connections
are
clean
and
tight.
Be
sure
connection
at
workpiece
is
to
clean,
bare
metal.
SECTION
7-
ELECTRICAL
DIAGRAMS
ZZ
RC3-B
-~(<
RC3-D
~
RC3-E
(Rc3-F
~<<
RC
I
-A
<<RCI-B
Diagram
7-1.
Circuit
Diagram
For
Pendant
Control
(RC3-G
Circuit
Diagram
No.
A-124
171
8LU
-
<
BPN
<
MNT
-
~-
~4EO
PLG4
B
E
H
L
s~
WORK
(NEG.)
ELECTRODE
(POS.)
0
-
-c
<
BLK
CPN
d~
T
rJ7
PC
I
RC2-A
~
RC2-B
LENGTH
~~tLIJ
RC2-C
~
RCI/PLGI
RC2/PLG2
RC3/PLG3
5
1
OM-891
Page
8
GND.
Circuit
Diagram
No.
B-128
304
Diagram
7-2.
Wiring
Diagram
For
Pendant
Control
OM-891
Page
9
Item
Dia.
No.
Mkgs.
Part
No.
SECTION
8
-
PARTS
LIST
Figure
8-1.
Main
Assembly
TA-129
744
Figure
8-1
1
2
3
4
5
6
7
8
9
10
ii
12
13
121
816
126931
019
663
121
815
097922
PCi
123700
073 756
126689
Ri
035897
605339
604645
123531
600399
601
226
601
228
PLG4
097
866
073
296
090890
126932
082
798
079
796
048
104
121
814
057
359
Main
Assembly
1
2
2
1
2
2
2
6Oft
I
1
1
2Oft
I
1
1
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
2
1
.4
.5
8
6
Dscription
Quantity
CASE
SECTION,
front/ends
WRAPPER
MOUNT,
nprn
15/16
OD
x
3/8
BRACKET
mtg
pendant
KNOB,
pointer
CIRCUIT
CARD,
remote
pendant
(Fig
8-2)
STAND-OFF~
No.
6-32
x
.625
ig
STAND-OFF,
No.
6-32
x
1.500
Ig
POTENTIOMETER,
C
sltd
sft
lIT
2W
1000
ohm
WASHER,
lock
sti
intl
tooth
.375
(mounts
Al)
NUT,
sti
hex
.375-32
(mounts
Ri)
STRAIN
RELIEF,
cable
flexible
.231-.394
WIRE,
lead
mot
l4ga
(order
by
ft)
INSULATOR,
vinyl
clamp
univ
25A
CLAMP~
Univ
25A
PLUG,
17
pin
MS-3106A-20-29P
CLAMP,
cable
97-3057-12-6
CABLE,
port
No.
20
8/c
(order
by
It)
GUARD,
front
HOUSING,
term
header
2
pin
HOUSING,
term
header
3
pin
HOUSING,
term
header
7
pin
PANEL,
rear
BLANK,
snap-in
fly,
~
mtg
hole
NAMEPLATE,
(order
by
model
&
se,ial
number)
PLG
1
PLG2
PLG3
OM-891
Page
10
Dia.
Mk~s.
A1,2,5
A3
A4
Ci-4,18
C5,6,14-16
C7
C8,9
Cl
0,12
C11,13
C17
C20,21
C22-25,30,31
,34,36-41
C26-29,32,33,35
C42-46
Dl
D2-4,6-20
01
Ri
,2,40,65
R3,4
R5
R6-9,30,35,56,96
Ri
0,12,20,21,26,31,
36,51,103,107,108
R13,18,73
R14,60,66,67,80
R15,77,102
R16
Ri
7,58,81,82
A
19,24,42,44-46,78,1
06
R22,50
R23,43,48,55,1
04
R25,57,92
R27
R28
R29
R32,39,61
R33
63,87
R34
R37,41
,95
R38
R47
R49,53,75,86,88,94
R52,101
R54,97
R62,64,76,84,90,99
R68,69
R70,91
R71
R72
R74
R79,89
R83,93
R85
R98
Ri
00
Ri
05
RI
09,110
093065
114
176
093
062
119
194
119
197
121
683
121
684
039
482
119
199
119
198
119
195
073
739
122
723
053991
032
210
028
351
000
088
039
325
121
829
119
808
044
789
000885
052
138
039
326
121
716
113
144
000
007
108
437
053 572
093
030
005
653
108
435
082
179
045
869
052
145
039
336
009
173
052
142
035830
108440
093037
003272
084205
095245
117
134
052
139
093
032
109337
072
559
121
715
112
155
072
677
094346
035888
072560
030
038
5
I
2
2
2
1
2
13
7
5
1
18
8
2
5
3
1
1
1
3
3
1
3
1
6
2
2
6
2
2
I
1
1
2
2
1
1
1
1
2
Part
No.
Description
Figure
8-2
PCi
Circuit
Card,
Remote
Pendant
Quantity
3
1
1
5
1
4
2
1
8
11
3
5
3
1
4
IC,
linear
347
IC,linear353
IC,Iinear393
CAPACITOR,
poly
film
.Oluf
bOy
CAPACITOR,
poly
film
.luf
bOy
CAPACITOR,
poly
film
.0022uf
bOy
CAPACITOR,
poly
film
.47uf
bOy
CAPACITOR,
elctlt
lOOuf
35VDC
CAPACITOR,
poly
film
lOut
50V
CAPACITOR,
poly
film
.33uf
boy
CAPACITOR,
poly
film
.022uf
bOy
CAPACITOR,
cer
.buf
5OVDC
CAPACITOR,
cer
mono
.luf
5OVDC
CAPACITOR,
cer
.O5uf
500
VDC
DIODE,
zener
by
1W
DIODE,
sig
.020A
75V
SP
TRANSISTOR,
NPN
800MA
40V
RESISTOR,
CF
.25W
82K
ohm
RESISTOR,
CF
.25W
9.1K
ohm
RESISTOR,
CF
.25W
560K
ohm
RESISTOR,
CF
.25W
lOOK
ohm
RESISTOR,
CF
.25W
10K
ohm
RESISTOR,
CF
.25W
20K
ohm
RESISTOR,
CF
.25W
68K
ohm
RESISTOR,
CF
.25W
30K
ohm.
RESISTOR,
CF
.25W
390
ohm
RESISTOR,
CF
.25W
62K
ohm
RESISTOR,
CF
.25W
4.7K
ohm
RESISTOR,
CF
.25W
12K
ohm
RESISTOR,
CF
.25W
15K
ohm
RESISTOR,
CF
.25W
180K
ohm
RESISTOR,
CF
.25W
3.9K
ohm
POTENTIOMETER,
cermet
25/1.5W
25K
ohm
RESISTOR,
CF
.25W
750K
ohm
RESISTOR,
CF
.25W
470K
ohm
RESISTOR,
CF
.25W
220K
ohm
POTENTIOMETER,
cermet
20/1
.5W
5K
ohm
RESISTOR,
CF
.25W
120K
ohm
RESISTOR,
CF
.25W
6.8K
ohm
RESISTOR,
CF
.25W
13K
ohm
RESISTOR,
CF
.25W
47K
ohm
RESISTOR,
CF
.25W
1
meg
ohm
RESISTOR,
CF
.25W
3.3K
ohm
RESISTOR,
CF
.25W
56K
ohm
RESISTOR,
CF
.25W
24K
ohm
RESISTOR,
CF
.25W
39K
ohm
RESISTOR,
CF
.25W
27K
ohm
RESISTOR,
CF
.25W
16K
ohm
RESISTOR,
CF
.25W
22K
ohm
RESISTOR,
CF
.25W
43K
ohm
RESISTOR,
CF
.25W
91K
ohm
RESISTOR,
CF
.25W
33K
ohm
RESISTOR,
CF
.25W
200K
ohm
RESISTOR,
CF
.25W
2.2K
ohm
RESISTOR,
CF
.25W
1K
ohm
RESISTOR,
C
.5W
220
ohm
OM-891
Page
11
RCI
RC2
RC3
RFC1,2
Si
S2
Ui
U2,3
U4-8
u9
VRI
VR2
121
084
089
702
110
323
095258
092367
123532
008881
094
594
119
066
115
695
095269
046932
AS
I
~
~-RS2~
r,
2
~
c:j
P36
C29
~29~
flU
~
-~J
P103
cls~
P53
:~
~
R3ec~
0?
P19
c~.
so
~
Ei
03
-~J-R6
09
Figure
8-2.
Circuit
Card,
Remote
Pendant
PCi
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
1
1
1
2
1
1
1
2
5
1
1
1
9-123
699-A
Dia.
Part
Mkgs.
No.
Description
Quantity
Figure
8-2
Pci
Circuit
Card,
Remote
Pendant
(Contd)
TERMINAL,
header
2
pin
TERMINAL,
header
3
pin
TERMINAL,
header
7
pin
CHOKE,
l000uh
28MA
SWITCH,
dip
SPST
SWITCH,
rotary
10
posn
SP
350MA
250V
IC,
interface
201A
IC,
digital
4098
IC,
interface
4051
IC,
interface
654
IC,linear3l7T
IC,Iirtear7gl5
RIO?
C26~
-c:i-
C32~
P81
-~J
OM-891
Page
12
/