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

LIMITED

WARRANTY

EFFECTIVE:

AUGUST

6.

1990

u

This

warranty

supersedes

all

warranties

and

5

exclusive

with

no

other

guarantees

or

warranties

expressed

or

implied.

i1

LIMITED

WARRANTY



Subject

to

the

terms

and

conditions

hereof,

MILLER

Electric

Mfg.

Co.,

Appleton,

Wisconsin

war

rants

to

its

Distributor/Dealer

that

all

new

and

unused

Equipment

furnished

by

MILLER

is

free

from

defect

in

workmanship

and

material

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

subject

to

the

warranties

of

their

respective

manufacturers,

if

any.

All

engines

are

warrantied

by

their

manufacturer

for

two

years

from

date

of

original

purchase,

except

Deutz

engines

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

coritactor

points.

MILLERMATIC

parts

that

come

in

contact

with

the

welding

wire

including

nozzles

and

nozzle

insulators

where

failure

does

not

result

from

defect

in

workmanship

or

material.

MILLER

shall

be

required

to

honor

warranty

claims

on

war

ranted

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,

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

FOB..

Factory

at

Appleton,

Wisconsin,

or

FOB.

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

MERCHAN

TABILITY

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

COMMERCIALJINDUSTRIAL

USERS

AND

FOR

OPERATION

BY

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EQUIPMENT

AND

NOT

FOR

CONSUMERS

OR

CONSUMER

USE.

MILLERS

WARRANTIES

DO

NOT

EXTEND

TO.

AND

NO

RESELLER

IS

AUTHORIZED

TO

EXTEND

MILLERS

WARRANTIES

TO,

ANY

CONSUMER.

.1

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

damage

that

may

have

occurred

during

shipment.

File

any

claims

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~iier

8/9i

SUPPLEMENTARY DATA

May 1992 FORM: S155 152

Use above FORM number when ordering extra manuals.

For XMT 400 CC CY50 (50 Hz) Models

The data contained in this supplement is either in addition to or takes exception to data appearing later in this

manual.

CHANGES TO SECTION 2 − SPECIFICATIONS

Replace Table 2-1. Welding Power Source

Table 2-1. Welding Power Source

Specification Description

Type Of Output Constant Current (CC), Direct Current (DC)

Rated Weld Output 400 Amperes, 36 Volts DC At 60% Duty Cycle; 300 Amperes, 32 Volts DC At 100% Duty Cycle

(See Section 2-2)

Type Of Input 380 Or 415 Volts AC; 50 Hz; Three Phase

Input Amperes At Rated Output 32.6 Amperes At 380 Volts, 30.4 Amperes At 415 Volts (60 % Duty Cycle); 23 Amperes At 380

Volts, 21.6 Amperes At 415 Volts (100% Duty Cycle)

KVA Used At Rated Output 21.7 kVA

KW Used At Rated Output 16.6 kW

Amperage Range 5-400 Amperes

Max. Open-Circuit Voltage 80 Volts DC

Welding Processes Scratch Start Gas Tungsten Arc (GTAW), Scratch Start Gas Tungsten Arc - Pulsed (GTAW-P),

Shielded Metal Arc (SMAW) Welding

Input Power Cord 13.1 ft. (4 m)

Overall Dimensions Length: 21-3/4 in. (522 mm); Width: 12 in. (305 mm); Height: 17-3/8 in. (441 mm)

Weight Net: 77 lbs. (35 kg); Ship: 82 lbs. (37 kg)

Options See Rear Cover

Replace Figure 2-1. Volt-Ampere Curves

ssb1.1 10/91 − SB-139 721

The volt-ampere curves show the

minimum and maximum voltage

and amperage output capabilities

of the welding power source.

Curves of other settings fall be-

tween the curves shown.

Figure 2-1. Volt-Ampere Curves

S-0007-B

S155 152 Page 2

Replace Figure 2-2. Duty Cycle Chart

CAUTION

EXCEEDING DUTY CYCLE RATINGS will damage unit.

• Do not exceed indicated duty cycles.

warn7.1 2/92

Duty cycle is how long the unit can

operate within a ten minute period

without causing overheating or

damage.

This unit is rated at 60% duty cycle

when operated at 400 amperes, al-

lowing welding 6 minutes out of ev-

ery 10 minutes. If the welding am-

peres decrease, the duty cycle in-

creases.

This unit is rated at 100% duty

cycle when operated at 300 am-

peres, allowing continuous weld-

ing.

sb1.4 2/92 − SB-132 583

Figure 2-2. Duty Cycle Chart

CHANGES TO SECTION 3 − INSTALLATION

Replace Table 3-1. Weld Cable Size

Table 3-1. Weld Cable Size*

Total Cable (Copper) Length In Weld Circuit Not Exceeding*

100 ft. (30 m) Or Less

150 ft.

(45 m)

200 ft.

(60 m)

250 ft.

(70 m)

300 ft.

(90 m)

350 ft.

(105 m)

400 ft.

(120 m)

Welding

Amperes

10 To 60%

Duty Cycle

60 Thru 100%

Duty Cycle

10 Thru 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

*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.

S155 152 Page 3

Replace entire Section 3-6. Connecting Input Power

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Turn OFF welding power source, and disconnect input power before inspecting or installing.

• Have only qualified persons install unit.

• Installation must meet National Electrical Code and all other codes.

swarn3.1 10/91

A. Positioning Jumper Links

ssb5.1* 2/92 − Ref. ST-155 414 / Ref. S-145 063

Jumper links allow operation on

different input voltages and are

factory set for 380 volts input pow-

er.

Check input voltage available at

site.

Remove top of case according to

Section 5-2.

1 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.

1

Tools Needed:

415 Volts380 Volts

2

Figure 3-6. Input Voltage Jumper Links Location

B. Connecting To Input Power

ssb2.3* 3/92 − Ref. SC-144 221 / ST-152 303-A / Ref. S-0092C

Have only qualified persons make this in-

stallation.

1 Line Disconnect Switch Of Proper

Rating

2 Grounding Conductor − Green Or

Green With Yellow Stripe(s)

3 Input Conductors

Install input conductors and grounding con-

ductor from unit to deenergized line discon-

nect switch.

Be sure grounding conductor goes to an

earth ground.

4 Line Fuses

Select fuses or circuit breakers using Table.

Install into deenergized line disconnect

switch.

2

1

4

3

Input Voltage

Circuit Breaker

Size In Amperes

1

Fuse Size In

Amperes

2

380

49

thru

66

50

415

45

thru

60

45

1

Circuit breaker range is 150% to not more than

200% of rated input amperage of the welding

power source (Article 630-12(a) of NEC).

2

Standard fuse size is that closest to 150% of

rated input amperage of the welding power

source (Article 630-126 of NEC).

Figure 3-6. Location And Input Power Connections

S155 152 Page 4

CHANGES TO SECTION 4 − OPERATION

IMPORTANT: The nameplate for this unit uses different symbols and terminology than what appear in the Owner’s

Manual. Individual front panel controls are covered on this supplement only when their action differs from that de-

scribed in the Owner’s Manual.

Replace Figure 4-5. Amperage Control

1 Amperage Control

Use control to select weld amper-

age. Amperage may be adjusted

while welding.

1

Ref. SD-154 155

Figure 4-5. Amperage Control

Replace Figure 4-10. Power Switch And Pilot Light

1 Pilot Light

2 Power Switch

Use this switch to turn unit and pilot

light ON and OFF.

There is a 5 second time delay be-

fore the unit is ready to weld.

Fan motor is thermostatically con-

trolled and only runs when cooling

is needed.

2

1

Figure 4-10. Power Switch And Pilot Light

S155 152 Page 5

CHANGES TO SECTION 5 − MAINTENANCE & TROUBLESHOOTING

Add the following IMPORTANT block at the beginning of entire section

IMPORTANT: Some components in unit do not match those shown in views in Owner’s Manual. Location of com-

ponents pointed out in views is the same.

Replace Figure 5-1. Measuring Input Capacitor Voltage

ST-155 414

Turn OFF welding power source

and disconnect input power.

1 Top Of Case

2 Handles

3 Outside Handle Screws

4 Side Bolts

To loosen top, remove two outside

handle screws from both handles

and all side bolts.

5 Input Rectifier SR1

6 Voltmeter

Measure the dc voltage across the

positive (+) and negative (−) termi-

nals at 30 second intervals until

voltage drops to 0 (zero) volts.

Proceed with job inside unit. Rein-

stall top of case when finished.

1

2

4

3

Tools Needed:

5/32 in.

3/8 in.,

7/16 in.

65

Figure 5-1. Removing Top Of Case And Measuring Input Capacitor Voltage

CHANGES TO SECTION 6 − ELECTRICAL DIAGRAMS

Replace Figure 6-1. Circuit Diagram For Welding Power Source (see Pages 6 and 7 on this Supplement)

Replace Figure 6-2. Wiring Diagram For Welding Power Source (see Pages 8 and 9 on this Supplement)

S155 152 Page 6

Figure 6-1. Circuit Diagram For Welding Power Source

S155 152 Page 7

SD-154 158

S155 152 Page 8

Figure 6-2. Wiring Diagram For Welding Power Source

S155 152 Page 9

SD-154 160

S155 152 Page 10

CHANGES TO SECTION 8 − PARTS LIST

Change Parts List as follows:

Description

Part

No.

Dia.

Mkgs.** Quantity

Replaced

With

23-6 146 727 +151 853 CASE SECTION, front/bottom/rear (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

137 197 NUT, insert 312-18 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

137 198 NUT, insert No. 10-24 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23-10 PLG17 150 319 131 054 HOUSING RECEPTACLE & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . .

113 746 TERMINAL, female 1skt 24-18 wire 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23-11 RC17 151 490 135 635 HOUSING PLUG & PINS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114 656 TERMINAL, male 1 pin 24-18 wire 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23-15 Z1,2 139 219 154 846 STABILIZER 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23-20 L1-4 145 426 151 399 CHOKE, DVDT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23-24 151 226 151 630 PANEL, mtg stab/transformer/cmpts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23-25 CT1 149 418 140 328 COIL, current transformer 500/1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23-26 T1 146 287 139 576 TRANSFORMER, HF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23-27 PC4 151 154 147 608 CIRCUIT CARD, receptacle bypass 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23- PLG30,31 147 993 130 203 HOUSING PLUG & SOCKETS, (consisting of) 2. . . . . . . . . . . . . . . . . . . . . . .

113 746 TERMINAL, female 1skt 24-18 wire 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23-33 152 196 133 948 FOOT, mtg 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23- Added 097 863 CORE, ferrite E 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23- Added 122 681 INSULATOR, coil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23- Added 109 312 STRIP, clamping transformer current 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23- Added 117 860 BLANK, snap-in nyl .187mtg hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23- Added 057 360 BLANK, snap-in nyl 1.375mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25-4 S5 134 848 134 847 SWITCH, tgl SPDT 15A 125VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25-6 PC5 147 824 ♦154 509 CIRCUIT CARD, meter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25- R5 Added 028 271 RESISTOR, C .5W 100K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27-5 PC1 153 736 150 889 CIRCUIT CARD, control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27- PLG4 148 439 115 094 HOUSING PLUG & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . .

113 746 TERMINAL, female 1skt 24-18 wire 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27- PLG6 148 439 115 093 HOUSING PLUG & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . .

113 746 TERMINAL, female 1skt 24-18 wire 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27- PLG8 148 439 ♦115 092 HOUSING PLUG & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . .

113 746 TERMINAL, female 1skt 24-18 wire 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27- PLG10 148 439 115 091 HOUSING PLUG & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . .

113 746 TERMINAL, female 1skt 24-18 wire 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27- PLG18,28 148 439 115 092 HOUSING PLUG & SOCKETS, (consisting of) 2. . . . . . . . . . . . . . . . . . . . . . .

113 746 TERMINAL, female 1skt 24-18 wire 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27- PLG12 147 993 130 203 HOUSING PLUG & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . .

113 746 TERMINAL, female 1skt 24-18 wire 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27-11 146 673 ++152 301 IGBT, LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27- 146 613 152 300 HEAT SINK, IGBT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27-26 146 674 ++154 157 IGBT, RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27- SR1 149 208 149 217 KIT, rectifier integ 100A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27- VCM1 151 199 Deleted. . . . . . . . . . . . .

27- 145 742 152 298 HEAT SINK, IGBT RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27- C50-52 Added 148 480 CAPACITOR 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27- TP2 Added 155 053 THERMOSTAT, NO 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27-27 CM1,2 151 198 Deleted. . . . . . . . . .

27-28 C1,2 152 101 110 941 CAPACITOR, polyp film .85uf 500VAC/1200VDC 2. . . . . . . . . . . . . . . . . . . . . . .

27-30 000 527 000 527 BLANK, (qty chg) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27-30 000 527 010 493 BUSHING, snap-in nyl .625 ID x .875mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27-36 136 190 136 190 NUT, (qty chg) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27-40 149 917 Deleted. . . . . . . . . . . . . . . . . .

28-45 150 233 ++153 062 RECTIFIER, si diode RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28- 149 801 Deleted. . . . . . . . . . . . . . . . . . . .

28- 149 918 Deleted. . . . . . . . . . . . . . . . . . . .

28- 605 538 Deleted. . . . . . . . . . . . . . . . . . . .

S155 152 Page 11

Parts List continued:

Description

Part

No.

Dia.

Mkgs.** Quantity

Replaced

With

28-46 150 234 ++154 156 RECTIFIER, si diode LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28- SN1 Added 152 776 SUPPRESSOR (part of LH Rectifier) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28- TP3 Added 086 323 THERMOSTAT, NO (part of LH Rectifier) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28- C14-17 Added 093 085 CAPACITOR, polye MF .0047uf 1000V 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28- VR1-3 Added 090 304 VARISTOR, 220 joule 730VDC 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28- Added 006 426 CLAMP, capacitor 2.000dia 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28- Added 133 405 NUT, speed 10-24 flat type rectangular 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28- Added 141 422 INSULATOR, flat pack 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28- Added 010 141 CLAMP, nyl .250 clamp dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

♦ Part of 042 807 Meter Kit Option

++All components remain the same with listed exceptions.

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

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

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