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OM-203 860C October 2002 Processes Gas Metal Arc (MIG) Welding Description Arc Welding Power Source Auto Deltaweld 452 Visit our website at www.MillerWelds.com R From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The Miller is the first welding parts list will then help you to decide the equipment manufacturer in exact part you may need to fix the problem. the U.S.A. to be registered to the ISO 9001:2000 Quality Warranty and service information for your System Standard. particular model are also provided. Working as hard as you do – every power source from Miller is backed by the most hassle-free warranty in the business. Miller offers a Technical Manual which provides more detailed service and parts information for your unit. To obtain a Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog orindividual catalog sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web. TABLE OF CONTENTS The following terms are used interchangeably throughout this manual: Mig = GMAW WARNING This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . 1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . 1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6. Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7. 115 VAC Receptacle And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11. Placing Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13. Front Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14. Peripheral Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Upper Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Meter Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Resetting Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 – MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Fuse F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Short Circuit Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Front Panel Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Weld Interface Board PC12 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Diagnostic LED’s On Weld Interface Board PC12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. Customer Interface Board PC14 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9. Diagnostic LED’s On Customer Interface Board PC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10. Motor Board PC13 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11. Diagnostic LED’s On Motor Board PC13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIES WARRANTY 1 1 3 3 4 5 5 5 7 8 8 9 9 9 10 10 11 11 12 12 13 14 15 16 17 18 19 19 19 20 20 20 21 21 21 22 23 24 25 26 28 29 30 31 54 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_7/02 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2. Arc Welding Hazards Y The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-4. Read and follow all Safety Standards. D If earth grounding of the workpiece is required, ground it directly with a separate cable. Y Only qualified persons should install, operate, maintain, and repair this unit. D Wear a safety harness if working above floor level. D Keep all panels and covers securely in place. Y During operation, keep everybody, especially children, away. D Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. 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. D Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. D Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. D Insulate work clamp when not connected to workpiece to prevent contact with any metal object. D Do not connect more than one electrode or work cable to any single weld output terminal. SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters. D Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts. D Do not touch live electrical parts. D Wear dry, hole-free insulating gloves and body protection. D Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. D Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. D Use AC output ONLY if required for the welding process. D If AC output is required, use remote output control if present on unit. D Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). D Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. D Keep your head out of the fumes. Do not breathe the fumes. D Always verify the supply ground – check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. D When making input connections, attach proper grounding conductor first – double-check connections. D Frequently inspect input power cord for damage or bare wiring – replace cord immediately if damaged – bare wiring can kill. D Turn off all equipment when not in use. D Do not use worn, damaged, undersized, or poorly spliced cables. D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. D Do not drape cables over your body. FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. D If ventilation is poor, use an approved air-supplied respirator. D Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers. D Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. D Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. OM-203 860 Page 1 ARC RAYS can burn eyes and skin. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). D Wear approved safety glasses with side shields under your helmet. D Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. D Always ventilate confined spaces or use approved air-supplied respirator. HOT PARTS can cause severe burns. D Do not touch hot parts bare handed. D Allow cooling period before working on gun or torch. MAGNETIC FIELDS can affect pacemakers. WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. D Protect yourself and others from flying sparks and hot metal. D Do not weld where flying sparks can strike flammable material. D Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. D Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. D Watch for fire, and keep a fire extinguisher nearby. D Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. D Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see Safety Standards). D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards. D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. D Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. FLYING METAL can injure eyes. D Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. D Wear approved safety glasses with side shields even under your welding helmet. OM-203 860 Page 2 D Pacemaker wearers keep away. D Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations. NOISE can damage hearing. Noise from some processes or equipment can damage hearing. D Wear approved ear protection if noise level is high. 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. D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs. D Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. D Keep cylinders away from any welding or other electrical circuits. D Never drape a welding torch over a gas cylinder. D Never allow a welding electrode to touch any cylinder. D Never weld on a pressurized cylinder – explosion will result. D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. D Turn face away from valve outlet when opening cylinder valve. D Keep protective cap in place over valve except when cylinder is in use or connected for use. D Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards. 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place. FALLING UNIT can cause injury. H.F. RADIATION can cause interference. D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. D Use equipment of adequate capacity to lift and support unit. D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. D OVERUSE can cause OVERHEATING D D Allow cooling period; follow rated duty cycle. D Reduce current or reduce duty cycle before starting to weld again. D Do not block or filter airflow to unit. D D D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. STATIC (ESD) can damage PC boards. D Put on grounded wrist strap BEFORE handling boards or parts. D Use proper static-proof bags and boxes to store, move, or ship PC boards. ARC WELDING can cause interference. MOVING PARTS can cause injury. D Keep away from moving parts. D Keep away from pinch points such as drive rolls. D D WELDING WIRE can cause injury. D Do not press gun trigger until instructed to do so. D Do not point gun toward any part of the body, other people, or any metal when threading welding wire. D D D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. D Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area. OM-203 860 Page 3 1-4. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www.aws.org). Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800–463–6727 or in Toronto 416–747–4044, website: www.csa–international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org). Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 11 West 42nd Street, New York, NY 10036–8002 (phone: 212–642–4900, website: www.ansi.org). National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269–9101 (phone: 617–770–3000, website: www.nfpa.org and www. sparky.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269–9101 (phone: 617–770–3000, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202–4102 (phone: 703–412–0900, website: www.cganet.com). Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there are 10 Regional Offices––phone for Region 5, Chicago, is 312–353–2220, website: www.osha.gov). 1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting. To reduce magnetic fields in the workplace, use the following procedures: OM-203 860 Page 4 1. Keep cables close together by twisting or taping them. 2. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. 4. Keep welding power source and cables as far away from operator as practical. 5. Connect work clamp to workpiece as close to the weld as possible. About Pacemakers: Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended. SECTION 1 – CONSIGNES DE SÉCURITÉ – À LIRE AVANT UTILISATION som _nd_fre 7/02 1-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Y Identifie un message de sécurité particulier. . Signifie « NOTA » ; n’est pas relatif à la sécurité. Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigilance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger. 1-2. Dangers relatifs au soudage à l’arc Y Les symboles ci-après sont utilisés tout au long du présent manuel pour attirer l’attention sur les dangers potentiels et les identifier. Lorsqu’on voit un symbole, faire preuve de vigilance et suivre les directives mentionnées afin d’éviter tout danger. Les consignes de sécurité énoncées ci-après ne font que résumer le contenu des normes de sécurité mentionnées à la section 1–4. Lire et respecter toutes ces normes. Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées. Y Pendant l’utilisation de l’appareil, tenir à l’écart toute personne, en particulier les enfants. D N’utiliser que du matériel en bon état. Réparer ou remplacer sur–le– champ les pièces endommagées. Entretenir l’appareil conformément au présent manuel. D Porter un harnais de sécurité quand on travaille en hauteur. D Maintenir solidement en place tous les panneaux et capots. D Fixer le câble de retour de façon à obtenir un bon contact métal sur métal avec la pièce à souder ou la table de travail, le plus près possible de la soudure. D Ne pas connecter plus d’une électrode ou plus d’un câble de masse à un même terminal de sortie. LES DÉCHARGES ÉLECTRIQUES peuvent être mortelles. Un simple contact avec des pièces sous tension peut causer une électrocution ou des blessures graves. L’électrode et le circuit de soudage sont sous tension dès que l’appareil est en fonctionnement. Le circuit d’entrée et les circuits internes de l’appareil sont également sous tension. En soudage semi–automatique ou automatique, le fil, le dévidoir, le logement des galets d’entraînement et les pièces métalliques en contact avec le fil de soudage sont sous tension. Tout matériel mal installé ou mal mis à la terre présente un danger. D Ne jamais toucher aux pièces électriques sous tension. D Porter des gants et des vêtements de protection secs et exempts de trous. D S’isoler de la pièce et de la terre au moyen de tapis ou autres dispositifs isolants suffisamment grands pour empêcher tout contact physique avec la pièce ou la terre. D D D Ne pas se servir d’une source de courant alternatif dans les zones humides, les endroits confinés ou là où on risque de tomber. Ne se servir d’une source de courant alternatif QUE si le procédé de soudage l’exige. Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé. D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueter l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de sécurité). D Installer et mettre à la terre correctement l’appareil conformément à son manuel d’utilisation et aux codes nationaux, provinciaux et municipaux. D Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre. D Pour exécuter les branchements d’entrée, fixer d’abord le conducteur de mise à la terre adéquat et contre–vérifier les connexions. D Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’est ni endommagé ni dénudé ; le remplacer immédiatement s’il est endommagé – tout câble dénudé peut causer une électrocution. D Mettre l’appareil hors tension quand on ne l’utilise pas. D Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou mal épissés. D Ne pas s’enrouler les câbles autour du corps. D Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct. D Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode d’une autre machine. Il subsiste un COURANT CONTINU IMPORTANT dans les convertisseurs après la suppression de l’alimentation électrique. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions énoncées à la section Entretien avant de toucher les pièces. LES FUMÉES ET LES GAZ peuvent être dangereux. Le soudage génère des fumées et des gaz dont l’inhalation peut être dangereuse pour la santé. D Se tenir à distance des fumées et ne pas les inhaler. D À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. D Si la ventilation est insuffisante, utiliser un respirateur à adduction d’air agréé. D Lire les fiches techniques de santé–sécurité (FTSS) et les instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs. D Ne travailler dans un espace clos que s’il est bien ventilé ou porter un respirateur à adduction d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent se substituer à l’air, abaisser la teneur en oxygène et causer des lésions ou des accidents mortels. S’assurer que l’air est respirable. D Ne pas souder à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants. D Ne pas souder de métaux munis d’un revêtement, tels que la tôle d’acier galvanisée, plombée ou cadmiée, à moins que le revêtement n’ait été enlevé dans la zone de soudage, que l’endroit soit bien ventilé, et si nécessaire, porter un respirateur à adduction d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques lorsqu’on les soude. OM-203 860 Page 5 LES RAYONS DE L’ARC peuvent causer des brûlures oculaires et cutanées. Le rayonnement de l’arc génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage. D Porter un masque de soudage muni d’un filtre de la nuance adéquate pour se protéger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de sécurité ANSI Z49.1 et Z87.1). D Porter des lunettes de sécurité à écrans latéraux sous le masque. D Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder l’arc. D Porter des vêtements de protection en matière durable et ignifuge (cuir ou laine) et des chaussures de sécurité. LE SOUDAGE peut causer un incendie ou une explosion. Le soudage effectué sur des récipients fermés tels que des réservoirs, des fûts ou des conduites peut causer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, les pièces chaudes et les équipements chauds peuvent causer des incendies et des brûlures. Le contact accidentel de l’électrode avec tout objet métallique peut causer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger. D Se protéger et protéger les tiers de la projection d’étincelles et de métal chaud. D Ne pas souder à un endroit où des étincelles peuvent tomber sur des substances inflammables. D Placer toutes les substances inflammables à une distance de 10,7 m de l’arc de soudage. En cas d’impossibilité, les recouvrir soigneusement avec des protections agréées. D Des étincelles et des matières en fusion peuvent facilement passer même par des fissures et des ouvertures de petites dimensions. D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité. D Le soudage effectué sur un plafond, un plancher, une paroi ou une cloison peut déclencher un incendie de l’autre côté. D Ne pas souder des récipients fermés tels que des réservoirs, des fûts ou des conduites, à moins qu’ils n’aient été préparés conformément à l’AWS F4.1 (voir les normes de sécurité). D Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter que le courant ne circule sur une longue distance, par des chemins inconnus, et ne cause des risques d’électrocution et d’incendie. D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées. D En cas de non utilisation, enlever la baguette d’électrode du porte– électrode ou couper le fil au raz du tube–contact. D Porter des vêtements de protection exempts d’huile tels que des gants en cuir, une chemise en tissu épais, des pantalons sans revers, des chaussures montantes et un masque. D Avant de souder, retirer tout produit combustible de ses poches, tel qu’un briquet au butane ou des allumettes. LES PARTICULES PROJETÉES peuvent blesser les yeux. D Le soudage, le burinage, le passage de la pièce à la brosse métallique et le meulage provoquent l’émission d’étincelles et de particules métalliques. Pendant leur refroidissement, les soudures risquent de projeter du laitier. D Porter des lunettes de sécurité à écrans latéraux agréés, même sous le masque de soudage. OM-203 860 Page 6 LES ACCUMULATIONS DE GAZ peuvent causer des blessures ou même la mort. D D Couper l’alimentation en gaz protecteur en cas de non utilisation. Veiller toujours à bien ventiler les espaces confinés ou porter un respirateur à adduction d’air agréé. LES PIÈCES CHAUDES peuvent causer des brûlures graves. D Ne pas toucher les pièces chaudes à main nue. D Prévoir une période de refroidissement avant d’utiliser le pistolet ou la torche. LES CHAMPS MAGNÉTIQUES peuvent perturber le fonctionnement des stimulateurs cardiaques. D D Les personnes qui portent un stimulateur cardiaque doivent se tenir à distance. Ils doivent consulter leur médecin avant de s’approcher d’un lieu où on exécute des opérations de soudage à l’arc, de gougeage ou de soudage par points. LE BRUIT peut affecter l’ouïe. Le bruit de certains processus et équipements peut affecter l’ouïe. D Porter des protecteurs d’oreille agréés si le niveau sonore est trop élevé. Les BOUTEILLES peuvent exploser. endommagées Les bouteilles de gaz protecteur contiennent du gaz sous haute pression. Toute bouteille endommagée peut exploser. Comme les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution. D Protéger les bouteilles de gaz comprimé de la chaleur excessive, des chocs mécaniques, du laitier, des flammes nues, des étincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte–bouteilles pour les empêcher de tomber ou de se renverser. D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques. D Ne jamais poser une torche de soudage sur une bouteille de gaz. D Ne jamais mettre une électrode de soudage en contact avec une bouteille de gaz. D Ne jamais souder une bouteille contenant du gaz sous pression – elle risquerait d’exploser. D N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et raccords adéquats pour l’application envisagée ; les maintenir en bon état, ainsi que les pièces connexes. D Détourner la tête lorsqu’on ouvre la soupape d’une bouteille. D Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille D Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P–1 de la CGA, mentionnées dans les normes de sécurité. 1-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLOSION LES ORGANES MOBILES peuvent causer des blessures. D Ne pas placer l’appareil sur une surface inflammable, ni au–dessus ou à proximité d’elle. D Se tenir à l’écart des organes mobiles comme les ventilateurs. D Maintenir fermés et bien fixés les portes, panneaux, recouvrements et dispositifs de protection. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l’installation électrique – s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service. LA CHUTE DE L’APPAREIL peut blesser. D N’utiliser que l’anneau de levage pour lever l’appareil. NE PAS utiliser le chariot, les bouteilles de gaz ou tout autre accessoire. D Utiliser un engin de capacité adéquate pour lever l’appareil. D Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil. L’EMPLOI EXCESSIF peut FAIRE SURCHAUFFER L’ÉQUIPEMENT. D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal. D Réduire le courant ou le cycle opératoire avant de reprendre le soudage. D Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste. LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés. D Mettre un bracelet antistatique AVANT de manipuler des cartes ou des pièces. D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimés. LES PIÈCES MOBILES peuvent causer des blessures. D Se tenir à l’écart des pièces mobiles. D Se tenir à l’écart des points de coincement tels que les dévidoirs. LES FILS DE SOUDAGE peuvent causer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, vers d’autres personnes ou vers toute pièce mécanique en engageant le fil de soudage. LE RAYONNEMENT HAUTE FRÉQUENCE (H. F.) risque de causer des interférences. D Le rayonnement haute fréquence peut causer des interférences avec les équipements de radionavigation et de communication, les services de sécurité et les ordinateurs. D Ne demander qu’à des personnes qualifiées familiarisées avec les équipements électroniques de faire fonctionner l’installation. D L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences causées par l’installation. D Si la Federal Communications Commission signale des interférences, arrêter immédiatement l’appareil. D Faire régulièrement contrôler et entretenir l’installation. D Maintenir soigneusement fermés les panneaux et les portes des sources de haute fréquence, maintenir le jeu d’éclatement au réglage adéquat et utiliser une terre et un blindage pour réduire les interférences éventuelles. LE SOUDAGE À L’ARC peut causer des interférences. D L’énergie électromagnétique peut causer des interférences avec l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots. D Veiller à ce que tout l’équipement de la zone de soudage soit compatible au point de vue électromagnétique. D Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (par ex. : à terre). D Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible. D Veiller à ce que le poste de soudage soit posé et mis à la terre conformément au présent manuel. D En cas d’interférences après exécution des directives précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail. LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques. D Porteurs de stimulateur cardiaque, restez à distance. D Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points. OM-203 860 Page 7 1-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (téléphone : (305) 443–9353, site Web : www.aws.org). Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463–6727 ou à Toronto : (416) 747–4044, site Web : www.csa–international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (téléphone : (305) 443–9353, site Web : www.aws.org). Practice For Occupational And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute, 11 West 42nd Street, New York, NY 10036–8002 (téléphone : (212) 642–4900, site Web : www.ansi.org). National Electrical Code, norme NFPA 70, de la National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269–9101 (téléphone : (617) 770–3000, sites Web : www.nfpa.org et www.sparky.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, norme NFPA 51B, de la National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269–9101 (téléphone : (617) 770–3000, site Web : www.nfpa.org et www.sparky.org). Safe Handling of Compressed Gases in Cylinders, brochure CGA P–1, de la Compressed Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202–4102 (téléphone : (703) 412–0900, site Web : www.cganet.com). Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux régionaux – Téléphone pour la Région 5, Chicago : (312) 353–2220, site Web : www.osha.gov). 1-5. Information sur les champs électromagnétiques Données sur le soudage électrique et les effets des champs magnétiques basse fréquence sur l’organisme En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent préoccupants. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité de spécialistes du National Research Council a conclu : « L’accumulation de preuves n’a pas démontré que l’exposition aux champs magnétiques et aux champs électriques à haute fréquence constitue un risque pour la santé humaine ». Toutefois, les études et l’examen des preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs électromagnétiques pendant le soudage ou le coupage. OM-203 860 Page 8 Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes : 1. Garder les câbles ensemble en les torsadant ou en les fixant avec du ruban adhésif. 2. Mettre tous les câbles du côté opposé à l’opérateur. 3. Ne pas s’enrouler les câbles autour du corps. 4. Garder le poste de soudage et les câbles le plus loin possible de soi. 5. Placer la pince de masse le plus près possible de la zone de soudage. Consignes relatives aux stimulateurs cardiaques : Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus. SECTION 2 – INSTALLATION 2-1. Specifications Rated Welding Output Model 450 Amp 450 A @ 38 (36.5) Volts DC, 100% Duty Cycle Voltage Range DC Max OCV DC 10 – 38 48 Amperes Input at Rated Load Output, 50 or 60 Hz, Three-Phase 200 V 230 V 380 V 400 V 440 V 460 V 575 V KVA KW 72 3.2* 63 2.7* 39 2.6* 37 2.2* 33 2.1* 32 1.4* 25 1.1* 25.1 1.09* 21.1 0.26* *While idling 2-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. RATED OUTPUT WELD AMPERES 1000 If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. 800 600 Y Exceeding duty cycle can damage unit and void warranty. 400 300 40 50 60 70 80 90 100 % DUTY CYCLE 100% Duty Cycle Continuous Welding Overheating V 0 15 Minutes OR Reduce Duty Cycle duty1 4/95 / Ref. 168 918 OM-203 860 Page 9 2-3. Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall between curves shown. va_curve1 – 4/95 – 171 224 / 171 225 / 171 226 2-4. Selecting A Location 1 2 Lifting Eye Lifting Forks Use lifting eye or lifting forks to move unit. Movement If using lifting forks, extend forks beyond opposite side of unit. 1 3 Rating Label Use rating label to determine input power needs. Label located under front access door. OR 2 4 Line Disconnect Device Locate unit near correct input power supply. Location And Airflow Y Special installation may be required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 20. 4 3 18 in (460 mm) 18 in (460 mm) OM-203 860 Page 10 802 962 2-5. Dimensions And Weights Dimensions A A C B 30 in (762 mm) Including lift eye B 23 in (584 mm) C 38 in (965 mm) Including strain relief D 35 in (889 mm) E 1-1/4 in (32 mm) F 21-1/8 in (537 mm) G 1-1/8 in (29 mm) H 7/16 in (11 mm) Dia F G H 4 Holes D Weight E 545 lb (247 kg) Front 800 453-A / 801 530 2-6. Tipping Y Be careful when placing or moving unit over uneven surfaces. OM-203 860 Page 11 2-7. 115 VAC Receptacle And Circuit Breakers Y Turn Off power before connecting to receptacle. 1 115 V 15 A AC Receptacle RC9 Power is shared between RC9 and Remote 14 receptacle RC8. 3 2 3 2 Circuit Breaker CB1 Circuit Breaker CB2 CB1 protects the 115 volts ac portion of RC8 and RC9 from overload. CB2 protects the 24 volts ac portion of RC8. 1 Press button to reset breaker. Ref. 800 166-D 2-8. Connection Diagram 5 2 . The proper robot adapter cord must be connected to the interface unit to allow it to be connected to the robot. 3 4 1 1 6 13 11 7 8 12 9 Robot (Will Vary According To Application) 2 Motor/Drive Assembly 3 Gas Cylinder 4 Gas Hose 5 Robot Control 6 Robot Input/Output Cable 7 Remote Program Select Cable (Optional) 8 Gas And Motor Control Cable 9 Welding Power Source/Interface Unit 10 Negative (–) Weld Cable 11 Workpiece 12 Voltage Sensing Lead . Positive (+) voltage sensing lead is contained in the motor cable. 13 Positive (+) Weld Cable 10 802 963 OM-203 860 Page 12 2-9. Weld Output Terminals And Selecting Cable Sizes Total Cable (Copper) Length In Weld Circuit Not Exceeding Y Turn off power before connecting to weld output terminals. Y Do not use worn, damaged, undersized, or poorly spliced cables. Negative Positive High Inductance Positive Low Inductance 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 – 60% Duty Cycle 60 – 100% Duty Cycle 100 4 4 4 3 2 1 1/0 1/0 150 3 3 2 1 1/0 2/0 3/0 3/0 200 3 2 1 1/0 2/0 3/0 4/0 4/0 250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0 300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0 400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0 500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0 600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0 700 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0 4-4/0 10 – 100% Duty Cycle *Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your distributor for the mm2 equivalent weld cable sizes. S-0007-E OM-203 860 Page 13 2-10. Electrical Service Guide 60 Hertz Models 450 Amp Model Input Voltage 200 230 460 575 Input Amperes At Rated Output 72 63 32 25 90 70 40 30 110 90 45 40 4 6 8 10 163 (50) 142 (43) 366 (112) 379 (115) 6 8 10 10 Max Recommended Standard Fuse Rating In Amperes 1 Time-Delay 2 Normal Operating 3 Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil Reference: 1999 National Electrical Code (NEC) 1 Consult factory for circuit breaker applications. 2 “Time-Delay” fuses are UL class “RK5” . 3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and above). 50 Hertz Models 450 Amp Model Input Voltage 380 400 440 Input Amperes At Rated Output 39 37 33 Time-Delay 2 45 45 40 Normal Operating 3 60 50 50 8 8 8 250 (76) 277 (84) 335 (102) 10 10 10 Max Recommended Standard Fuse Rating In Amperes 1 Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil Reference: 1999 National Electrical Code (NEC) 1 Consult factory for circuit breaker applications. 2 “Time-Delay” fuses are UL class “RK5” . 3 “Normal Operating” (general purpose – no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and above). OM-203 860 Page 14 2-11. Placing Jumper Links Y Disconnect and lockout/tagout input power before installing or moving jumper links. Check input voltage available at site. 1 Jumper Link Label Check label – only one is on unit. 2 Jumper Links Move jumper links to match input voltage. Close access door, or go on to Section 2-12. 200 VOLTS 230 VOLTS 460 VOLTS Ref. S-174 976-A 230 VOLTS 460 VOLTS 575 VOLTS 1 Ref. S-174 973-A 220 VOLTS 380 VOLTS 400 VOLTS 440 VOLTS (FACTORY OPTION) Ref. S-174 975-A 2 Tools Needed: 3/8 in Do not overtighten jumper link nuts. 3/8 in Ref. ST-800 103-A OM-203 860 Page 15 2-12. Connecting Input Power Y Disconnect and lockout/tagout input power before connecting input conductors from unit. Y Have only qualified persons make this installation. = GND/PE Earth Ground See rating label on unit and check input voltage available at site. 1 1 2 3 9 Select size and length using Section 2-10. Conductors must comply with national, state, and local electrical codes. If applicable, use lugs of proper amperage capacity and correct hole size. 8 4 Strain Relief Route conductors through strain relief. 4 7 5 6 3 When making connections in the line disconnect device, connect the Green Or Green/Yellow conductor first. Machine Grounding Terminal Line Terminals Y Make input power connections to the welding power source before making connections into a deenergized line disconnect device. Connect green or green/yellow grounding conductor to machine grounding terminal first. Then connect input conductors to line terminals. Install conductors into a deenergized line disconnect device. IMPORTANT 6 Make connections to machine first and supply last. 3 Input Contactor Close access door. 7 8 Disconnect Device (Supply) Grounding Terminal Disconnect Device Line Terminals Y In the deenergized line disconnect device, connect green or green/yellow grounding conductor to supply grounding terminal first, never to a line terminal. Be sure grounding conductor goes to an earth ground. L1 (U) 2 L2 (V) L3 (W) 3 10 Line Disconnect Device Input Conductors Grounding Conductor Connect input conductors to line terminals. 3 9 5 GND/ PE Connect Green Or Green/Yellow GND/PE Conductor First. Overcurrent Protection Select type and size using Section 2-10 (fused disconnect switch shown). Close door on line disconnect device. 10 Reed Switch (Ground Current Sensor) (Optional) If unit is equipped with optional ground current sensor, route grounding conductor through reed switch two times and connect to ground terminal. Tools Needed: 3/8 in Close access door. 3/8 in ST-800 103-B / Ref. ST-801 116 OM-203 860 Page 16 2-13. Front Panel Connections 1 2 B C A M L K J P NT R S D E FG H Example Receptacle 5 6 3 4 Ref. S-0003-A / Ref. 203 394 1 Receptacle cord to work. 2 Keyway 4 3 4-Pin Receptacle (Optional External Voltage Sensing Connection) To connect interconnecting cord to receptacle, align keyway, insert plug, and tighten threaded collar. Secure ring terminal on remaining end of Peripheral Receptacle Receptacle provides connection to water flow switch, jog +/–, and shielding gas purge circuitry. 5 Robot Control Receptacle (Remote Program Select Connection To Robot Control) To connect matching interconnecting cord to one of the above receptacles, align keyway, insert plug, and tighten threaded collar. Connect remaining end of cord to matching receptacle on applicable equipment (see Section 2-8). 6 10-Socket Receptacle (Wire Feed/Shielding Gas Control Connection To Motor Drive Assembly) OM-203 860 Page 17 2-14. Peripheral Receptacle Functions Function A Circuit common. D Contact closure to C completes 24 volts dc solenoid circuit to purge shielding gas line. E Contact closure to F indicates coolant flow switch is closed and recirculating coolant system is operational. F* Circuit common. Jog + H** Contact closure to circuit common advances welding wire at wire drive assembly. Jog – J** Contact closure to circuit common retracts welding wire at wire drive assembly. Coolant Flow Switch Input Signal K J M C L D H E F Rer. 203 394 *Circuit common is same electrical reference point. **Speed of Jog + and Jog – defaults to 200 ipm. Note: A matching amphenol plug is supplied with a flow switch jumper. OM-203 860 Page 18 Socket Information C* Purge B Socket SECTION 3 – OPERATION 3-1. Upper Front Panel Controls 7 8 9 1 1 Jog Forward Push Button Advances wire out of the gun. 2 Wirefeed Indicator LED LED lights when wire feed motor is energized. 3 Jog Reverse Push Button Retracts wire up into the gun. 4 2 Gas Indicator LED LED lights when gas solenoid is energized. 5 Purge Push Button Momentarily energizes gas solenoid to purge air from gun shielding gas line, or to adjust shielding gas regulator. 6 Contactor Indicator LED 3 4 5 6 LED lights when welding power source contactor is energized. 7 Main Display Shows system state, error messages, commands at idle and actual feedback during welding. 8 Motor Circuit Breaker 9 High Temperature Shutdown Light Ref. 203 394 3-2. Meter Functions Mode Meter Reading At Idle V MIG 24.5V Command Volts Meter Reading While Welding IPM 0I Command WFS V 24.5V Actual Volts A 0A Actual Amps IPM 0I Actual WFS OM-203 860 Page 19 3-3. Resetting Memory 2 1 Front Panel Control Buttons Power Switch On Front Panel . All three buttons must be held Jog Reverse Button Jog Forward Button 1 2 down for 3 seconds after unit is energized. Purge Button Press and hold down all three buttons while turning On unit. SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Replace damaged or unreadable label. Repair or replace cracked cables. Replace cracked torch body. Repair or replace cracked cables and cords. 6 Months Clean and tighten weld terminals. OM-203 860 Page 20 Blow out inside. 4-2. Blowing Out Inside Of Unit Y Do not remove case when blowing out inside of unit. To blow out unit, direct airflow through front and back louvers as shown. Ref. 800 453-A 4-3. Fuse F1 Y Turn Off power before opening rear access door. 1 2 Fuse Holder Cover Fuse F1 (See Parts List For Rating) Fuse F1 protects control transformer from overload. If F1 opens, weld output and fan motor stops. Replace F1. 2 1 Tools Needed: 3/8 in Turn Pull Out And Replace Fuse (Install Flat End Of Fuse Into Cover) Turn Ref. 800 101-C 4-4. Short Circuit Shutdown When contact tip is shorted and sticks to workpiece, the unit output falls to a safe operating level. To resume operation, release gun trigger, turn Off unit, and remove contact tip from workpiece. Check contact tip and replace if damaged. Turn On unit to continue operation. OM-203 860 Page 21 4-5. Front Panel Error Displays 7 1 Mem CRC S t o p E r r o r 2 Mem R a n g e E r r N o V o l t S e n s e d E r r o r 1 D e t e c t e d C u r r e n t D e t e c t 10 T a c h S e n s e d E r r o r W i r e S t i c k E r r o r 11 S t o p E r r o r A r c 6 A r c F l o w G r d 5 A r c E r r 9 4 N o C y c l e 8 3 N o We l d F a i l T i me O u t E r r 12 S t a r t E r r o r Memory CRC Error Display Corrupted program data has been detected or loaded. The “X” value indicates the program number. N o I n p u t The motor tachometer feedback is not reaching the control. May be caused by obstructions in the wire feed system or a faulty wire drive system. Ground Current Detect Error Display Weld current has been detected in the earth ground connection. May be caused by a conductor making connection to the unit chassis. May be caused by incompatible information on the data card or bad memory. 5 2 May be caused by obstructions in the wire feed system or a faulty wire drive system or torch is touching part at end of weld. The welding wire has stuck to the workpiece at the end of the weld. 6 May be caused by poor weld conditions. Memory Range Error Display Improper welding power source range is selected. The “X” value indicates the program number. May be caused by improper range settings or improper data loaded into the interface unit. 3 No Volt Sensed Error Display The arc voltage sense circuit did not receive feedback within the required time after an arc was established. May be caused by an inability to establish an arc in the pulse schedule, or a lack of voltage feedback. 4 No Tach Sensed Error Display OM-203 860 Page 22 Arc Stop Error Display 9 I PM Trouble is occurring at arc end. Arc Start Error Display 10 Wire Stick Error Display Trouble is occurring at arc start. 11 Arc Fail Time Out Error Display May be caused by obstructions in the wire feed system or a faulty wire drive system. An arc was not established within the allotted time. 7 May be caused by an inoperable wire drive, absence of shield gas, or improperly operating welding power source. Stop Weld Cycle Error Display An error has been detected and the robot hasn’t stopped the weld cycle, causing the interface unit to stop the weld cycle and wait for the robot to stop. 8 No Flow Detected No coolant is detected after preflow in the weld cycle. Check coolant system and flow switch for proper operation. 12 No Input IPM Display Analog IPM (inches per minute) from robot is not being received. May be caused by having no wire feed speed programmed at the robot. 4-6. Weld Interface Board PC12 Diagnostic LED’s 1 Weld Interface Board PC12 Diagnostic LED’s are visible inside unit, located on PC12 (see illustration for board location). LED2 LED8 LED4 LED6 LED1 LED3 LED5 LED7 Refer to Section 4-7 for information on diagnostic LED’s. LED10 LED9 LED11 Reinstall cover and left side panel after checking diagnostic LED’s. LED12 1 LED13 Front Top View 191 842 / 802 996 OM-203 860 Page 23 4-7. Diagnostic LED’s On Weld Interface Board PC12 LED Status 1 On Indicates auxiliary output relay is not energized. Off Indicates auxiliary output relay is energized. On Indicates gas valve is not energized. Off Indicates gas valve is energized. 3 On Indicates +24 volts dc is present for gas valve. Off Indicates +24 volts dc is not present for gas valve. 4 On Indicates +15 volts dc is present on weld interface board PC12. Off Indicates +15 volts dc is not present on weld interface board PC12. On Indicates –15 volts dc is present on weld interface board PC12. Off Indicates –15 volts dc is not present on weld interface board PC12. 6 On Indicates +15 volts dc power source supply is present on weld interface board PC12. Off Indicates +15 volts dc power source supply is not present on weld interface board PC12. 7 On Indicates –15 volts dc power source supply is present on weld interface board PC12. Off Indicates –15 volts dc power source supply is not present on weld interface board PC12. On Indicates +5 volts dc is present on weld interface board PC12. Off Indicates +5 volts dc is not present on weld interface board PC12. 9 On Input signal for no Jog retract. Off Input signal for Jog retract. 10 On Input signal for no Jog advance. Off Input signal for Jog advance. On Indicates CV mode is selected. Off Indicates CC mode is selected. On Input signal for no welding power source contactor. Off Input signal for welding power source contactor. On Indicates an Emergency Stop condition is not present. Off Indicates an Emergency Stop condition is present. 2 5 8 11 12 13 OM-203 860 Page 24 Diagnosis 4-8. Customer Interface Board PC14 Diagnostic LED’s 1 Customer Interface Board PC14 Diagnostic LED’s are visible inside unit, located on PC14 (see illustration for board location). Refer to Section 4-9 for information on diagnostic LED’s. Reinstall front control panel after checking diagnostic LED’s. LED8 LED6 LED7 1 LED12 LED16 LED14 LED23 LED10 LED9 LED15 LED25 LED22 LED11 LED13 LED24 LED5 LED4 LED21 LED20 LED19 LED18 LED3 LED17 LED2 LED1 Front Control Panel Removed Front View 802 995 OM-203 860 Page 25 4-9. Diagnostic LED’s On Customer Interface Board PC14 LED 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Status Diagnosis On Indicates –15 volts dc RA supply is present on customer interface board PC14. Off Indicates –15 volts dc RA supply is not present on customer interface board PC14. On Indicates +15 volts dc RA supply is present on customer interface board PC14. Off Indicates +15 volts dc RA supply is not present on customer interface board PC14. On Input signal On from robot for no Emergency Stop. Off Input signal Off from robot for Emergency Stop. On Indicates +24 volts dc RD supply is present on customer interface board PC14. Off Indicates +24 volts dc RD supply is not present on customer interface board PC14. On Input signal On from robot for shielding gas. Off Input signal Off from robot for no shielding gas. On Input signal On from robot to energize contactor. Off Input signal Off from robot to not energize contactor. On Input signal On from robot for jog retract. Off Input signal Off from robot for no jog retract. On Input signal On from robot for jog advance. Off Input signal Off from robot for no jog advance. On Indicates automatic configuration Bit D is set. Off Indicates automatic configuration Bit D is not set. On Input signal On for RPS-C. Off Input signal Off for RPS-C. On Input signal On for RPS-B. Off Input signal Off for RPS-B. On Indicates remote program A selected. Off Indicates remote program A not selected. On Input signal On from peripheral for touch sensor. Off Input signal Off from peripheral for no touch sensor. On Indicates automatic configuration Bit B is set. Off Indicates automatic configuration Bit B is not set. On Indicates automatic configuration Bit A is set. Off Indicates automatic configuration Bit A is not set. On Indicates automatic configuration Bit C is set. Off Indicates automatic configuration Bit C is not set. On Input signal On from relay CR4 for wire stuck in weld joint. Off Input signal Off from relay CR4 for wire not stuck in weld joint. On Input signal On from relay CR6 for flow (shielding gas or coolant) present. Off Input signal Off from relay CR6 for flow (shielding gas or coolant) not present. On Input signal On from relay CR5 for arc detect. Off Input signal Off from relay CR5 for no arc detect. On Input signal On from relay CR2. Off Input signal Off from relay CR2. On Input signal On from relay CR1 for welding power source ready and no detected errors present. 21 Off Input signal Off from relay CR1 for welding power source not ready, detected errors are present, or unit is in Setup or Control mode. 22 On Input signal On from peripheral for flow switch. Off Input signal Off from peripheral for no flow switch. 20 OM-203 860 Page 26 LED Status 23 On Input signal On from peripheral for jog advance. Off Input signal Off from peripheral for no jog advance. On Input signal On from peripheral for jog retract. 24 25 26 Diagnosis Off Input signal Off from peripheral for no jog retract. On Input signal On from peripheral for shielding gas purge. Off Input signal Off from peripheral for no shielding gas purge. On Input signal On for touch sensor. Off Input signal Off for no touch sensor. OM-203 860 Page 27 4-10. Motor Board PC13 Diagnostic LED’s 1 LED2 LED1 Motor Board PC13 Diagnostic LED’s are visible inside unit, located on PC13 (see illustration for board location). 1 Refer to Section 4-11 for information on diagnostic LED’s. Reinstall front control panel after checking diagnostic LED’s. LED4 LED3 LED6 LED7 LED8 LED5 Front Control Panel Removed Front View 177 288 / 802 995 OM-203 860 Page 28 4-11. Diagnostic LED’s On Motor Board PC13 LED Status 1 On Indicates motor reverse relay is energized. Off Indicates motor reverse relay is not energized. On Indicates bus voltage is present. Off Indicates bus voltage is not present. On Indicates microprocessor is operational. Off Indicates microprocessor is not operational. On Indicates tachometer feedback signal is present. Off Indicates tachometer feedback signal is not present. On Indicates +5 volts dc is present on motor board PC13. Off Indicates +5 volts dc is not present on motor board PC13. On Indicates +15 volts dc is present on motor board PC13. Off Indicates +15 volts dc is not present on motor board PC13. On Indicates auxiliary forward signal is present. Off Indicates auxiliary forward signal is not present. On Indicates auxiliary output signal is present. Off Indicates auxiliary output signal is not present. 2 3 4 5 6 7 8 Diagnosis OM-203 860 Page 29 4-12. Troubleshooting Trouble No weld output; unit completely inoperative. Remedy Place line disconnect switch in On position (see Section 2-11). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 2-11)). Check for proper input power connections (see Section 2-11). Check fuse F1, and replace if necessary (see Section 4-3). Check for proper jumper link position (see Section 2-11). No weld output; Power switch pilot light on; fan on; meter display On. Check, repair, or replace remote control. Unit overheated. Allow unit to cool with fan On (see Section 2-2). Check voltmeter/ammeter Help displays. Unit overheated. Allow unit to cool with fan On (see Section 2-2). Have Factory Authorized Service Agent check control board PC1. Unit provides only maximum or minimum weld output. Have Factory Authorized Service Agent check control board PC1. Erratic or improper weld output. Use proper size and type of weld cable (see Section 2-9). Clean and tighten all weld connections. Have Factory Authorized Service Agent check control board PC1 and/or SCR in main rectifier. Fan not operating. Note: fan runs only when cooling is necessary. Check for and remove anything blocking fan movement. Have Factory Authorized Service Agent check fan motor. OM-203 860 Page 30 SECTION 5 – ELECTRICAL DIAGRAM . For Primary Circuit Diagram Portion, refer to Circuit Diagram located inside wrapper of welding power source. 207 810-B Figure 5-1. Circuit Diagram For Welding Power Source OM-203 860 Page 31 Figure 5-2. Circuit Diagram For Interface Module OM-203 860 Page 32 207 811-A OM-203 860 Page 33 Figure 5-3. Circuit Diagram For Control Board PC1 (Part 1 Of 2) OM-203 860 Page 34 208 198-1 (1 0f 2) OM-203 860 Page 35 208 198-2 (2 of 2) Figure 5-4. Circuit Diagram For Control Board PC1 (Part 2 Of 2) OM-203 860 Page 36 Notes OM-203 860 Page 37 Figure 5-5. Circuit Diagram For Microprocessor Board PC11 OM-203 860 Page 38 191 838 OM-203 860 Page 39 Figure 5-6. Circuit Diagram For Motor Board PC13 OM-203 860 Page 40 209 749 OM-203 860 Page 41 Figure 5-7. Circuit Diagram For Interface Board PC12 (Part 1 of 2) OM-203 860 Page 42 191 843-A (Part 1 of 2) OM-203 860 Page 43 Figure 5-8. Circuit Diagram For Interface Board PC12 (Part 2 of 2) OM-203 860 Page 44 191 843-A (Part 2 of 2) OM-203 860 Page 45 1 +35V L2 R6 470 +22VDC WBC 1W 5% MF 1 1 1 D1 C16 22uF 35V + C6 470uF + 1N4746A 18V C64 50V 330pF 100V 2 2 TP8 1 2 C12 .033uF 400V 2 2 2 1 + 1 C14 1uF 50V CER 1 1 2 2 R69 1 FB 2 1 Q1 IRF640 10 6 OUTPUT 1 RT/CT 2 1 .2 Ohms rds–on 3 5 GND D3 1 4 UC3813D–5 \ UC TP2 PRLL5819 3845D TP3 2 C5 330pF 100V + C11 1uF 50V CER R65 1 TP1 R3 2 7 VCC I_SENSE .1uF 50V 8 VREF C8 2 1 2 COMP Z3 HEATSINK1 1 .1uF 50V U1 1 3 1 5% 1/4W 2 2 SMT 22K SMT 47 2 22K 2 R5 1 R68 2 TP4 TP5 22 C7 2 1 44.2K 1% + 2 R4 SMT 2 C10 1uF 50V CER 1 C9 100pF 1 1 +22VDC C4 2 1uF 50V CER Figure 5-9. Circuit Diagram For Customer Interface Board PC14 (Part 1 of 3) OM-203 860 Page 46 1 1 + R1 0.06 2 1 1 R66 100K 1% 2 C63 330pF 100V 1 1K 1% 2 2 R2 2 NON–INDUCTIVE MF 1W +20V_UNREG U3 LM340T–15 50V C67 .1uF 50V 2 2 C65 .1uF 50V 1 R71 2.21K R72 2.21K 2 + 100uF 2 C19 TP7 470uF 50V BEAD 2 IN 3 OUT C68 .1uF 50V RA–15V 1 2 LED2 YELLOW SMT 1 1 50V C2 2 + + 1 1 1 2 L3 100uF 2 1 BYJ20J 1.5A 600V C18 U2 GND 2 7 C66 .1uF 50V 2 1 2 D8 3 TP6 2 RAGND 1 RA–15V 1 RA+15V 1 GND C3 470uF 50V BEAD 2 9 8 2 2 BYJ20J 1.5A 600V + 1 1 1 RA+15V 1 10 L4 2 2 D4 2 3 OUT 1 T1 XFRMR – MULTI–OUTPUT IN 1 1 RAGND LED1 YELLOW SMT RAGND LM7915CT 6 –20V_UNREG +24RD L5 1 1 + 50V 2 RD_GND 2 2 1 PRELOAD TL431 TP39 LED4 YELLOW SMT 1 RD_GND R89 Z1 2.21K FUSE CLIP Z2 FUSE CLIP 4 RD_GND 3 2 1 PC817 TL431AI TP29 1 8 R14 44.2K 1% 2 R20 162K 1% D2 2 1 1 TP30 1 2 C29 .01uF 6 R10 4.99K C26 2 2 +22VDC C34 100uF R999 330 U4 C73 .1uF 50V 2 1A 2 R74 2.21K + 1 1 1 C33 470uF 50V 2 BEAD 2 1 1 BYJ20J 600V 1.5A 1 1 RD_GND 2 2 F1 2 D7 1 220pF RD_GND 1kV C15 2 1 RAGND 220pF 1kV Pensar 86147 (Part 1 of 3) OM-203 860 Page 47 RAGND RA+15V 2 2 C75 .1uF 50V 3 4 6 4 4 3 + 2 – R79 44.2K 1% RAGND AGND 1 1 C25 2 .1uF 50V 2 +15V AGND TP41 TP51 2 5 + 6 U13B LM358 7 1 R91 100 1% 1 – 3 C28 .1uF 50V + 9 – R17 44.2K 1% 8 U7C LM324A 4 RAGND 1 R28 44.2K 1% AGND AGND C39 2 .1uF 50V 1 RN3 100K–ADJ 3 2 1 2 R19 12.1K 1% RA+15V 2 2 6 4 1 1 1 2 R30 44.2K 1% 10 2 +15V C79 .01uF 100V U12 TIL–300 5 2 1 R93 221K 1% 2 1 1 AGND AGND 8 2 C41 100uF 50V 2 1 + 1 1 2 1 2 .1uF 50V C32 C83 .1uF 50V RA+15V AGND +15V 1 2 1 +15V U14A LM324A AGND C84 .1uF 50V 2 +15V 2 1 +15V C86 .1uF 50V 2 TP64 1 AGND C46 .1uF 50V 2 1 – C44 .1uF 50V 6 + 3 – 2 2 AGND AGND –15V TP57 RN5 1 3 R31 12.1K 1% RAGND 2 C45 .1uF 50V R39 44.2K 1% 11 1 U9 5 8 4 1 3 6 1 – RA+15V 4 7 1 2 2 R96 100 1% U8A LM358 + 3 4 TIL–300 RAGND +15V C35 1 2 AGND .1uF 50V 1 AGND 1 2 C50 .1uF 50V 2 1 R32 100K 1% RA+15V –15V 2 1 2 2 1 R36 100K 1% 2 – 2 1 4 3 1 8 1 WFS_CMD + U14B LM324A + 5 100K–ADJ 2 1 C48 .1uF 50V C47 .1uF 50V 1 TP49 C51 .1uF 50V C82 AGND AGND – 8 – 13 RA+15V 9 R35 44.2K 1% 5 U10 RN6 1 3 R34 12.1K 1% 100K–ADJ 2 1 3 6 7 TIL–300 AGND – 6 RA+15V 4 +15V U8B LM358 5 RAGND 2 C43 .1uF 50V + 8 U14C LM324A 10 1 14 + 1 2 U14D LM324A + 12 4 1 1 TP48 2 .1uF 50V 2 R97 100 1% 1 AGND 1 2 6 2 1 – 1 R33 100K 1% 2 7 5 4 TRI M_CMD + R37 100K 1% 2 TP65 TP58 2 +15V U15B LM358 2 2 RAGND 2 C37 1 .1uF 50V 1 C49 .1uF 50V Figure 5-10. Circuit Diagram For Customer Interface Board PC14 (Part 2 of 3) OM-203 860 Page 48 C74 .1uF 50V RAGND TP61 TP50 U15A LM358 8 2 1 GND RN4 100K–ADJ 3 2 2 .1uF 50V C42 +15V –15V C40 100uF 50V 1 U7A LM324A 2 RA+15V 1 DGND + GND + RA–15V RA–15V R13 12.1K 1% +5V C53 C89 100uF 50V .1uF 50V C23 .1uF 50V 1 R27 44.2K 1% 2 2 2 2 2 R29 44.2K 1% AGND +5V 1 5 – 1 1 C80 .01uF 100V 2 GND 1 RAGND U11 TIL–300 1 R92 100 1% +15V 1 AGND –15V U13A LM358 + 11 3 +5V CON\2X5\MILLER VCC AGND TP45 2 1 R94 221K 1% 1 RA+15V C72 .1uF 50V 2 DGND TP40 1 +15V +15V C77 .1uF 50V AGND 8 1 6 2 7 3 8 4 9 5 10 2 2 RC97 +5V 1 1 1 +15V 2 TP35 RA+15V Q3 MMBT4401L 3 2 R70 100 1% D12 1 1 2 1 2 – 7 R83 1K 1% RAGND 2 TP28 + C13 680uF 25V TP37 U7B LM324A 2 6 RLS4148 1 + 1 5 TP15 RA+15V TP18 Q2 MMBT4401L 3 2 R67 100 1% D5 1 1 2 1 2 14 + C1 680uF 25V TP19 U7D LM324A 2 – 1 + 13 RLS4148 1 12 R75 1K 1% 2 RAGND K1 6 4 8 RELAY DPDT (MDX24–02) 11 K1_COMMON 13 9 RD_GND 1 16 2 +24RD 1 2 D13 DL4001 R12 10K 1% 2 TP23 2 D10 RLS4148 LF347D 1 R18 R87 221K 1 1% LF347D 2 2 3 RAGND RA+15V 5.11K 2 1 RA–15V RLS4148 TP26 7 1 D9 RLS4148 4 1 R84 R24 221K 1 1% 2 2 5 U6C 8 LF347D 9 10 1 1 R78 100K 1% LF347D RAGND 2 R81 100K 1% C70 .1uF 50V RAGND RAGND RAGND RAGND RD_GND RAGND 2 5.11K 2 RAGND RA–15V RN2 100K–ADJ 2 RA+15V 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 RA+15V RAGND 2 CON\2X10\MILLER R76 100K 1% U6D 12 + 13 – R73 14 2 1 TP17 LF347D 1 2 100K 1% + C17 .47uF 50V 1 R80 100K 1% 1 TP31 6 3 TP27 2 RA+15V 2 R77 100K 1% R82 100K 1% TP9 2 3 2 2 TP22 1 1 RC93 2 U6B 1 2 TP14 R16 100K 1% Pensar 86147 (Part 2 of 3) RAGND 1 U6A 11 RA–15V 1 2 2 C31 .1uF 50V 2 1 2 1 + RAGND TP12 2 C30 .001uF 100V 2 1 – 1 2 LF347D R22 44.2K 1% 1 D6 + 1 R86 221K 1% R8 10K 1% R9 10K 1% 1 2 TP16 C22 .1uF 50V – TP36 C38 .01uF 100V TP32 RAGND + 2 C71 .1uF 50V 1 TP38 2 C24 .1uF 50V RAGND RAGND R26 44.2K 1% 2 R85 100K 1% 2 TP25 1 2 RAGND 1 RAGND RA–15V R88 100K 1% 1 R11 100K 1% C20 .1uF 50V 2 – LF347D RA+15V 1 + 12 1 – 14 13 1 1 TP20 RN1 100K–ADJ U5D TP11 C69 .1uF 50V 11 1 3 RAGND 5 1 1 6 4 1 1 10 7 2 2 C36 .01uF 100V 9 2 RAGND RA–15V U5A LF347D U5B 8 + 2 R23 44.2K 1% U5C 2 – R25 44.2K 1% 1 R21 221K 1% + 1 R7 100K 1% 1 – TP34 RAGND 2 C27 .001uF 100V 2 1 TP33 RA+15V TP13 TP10 2 2 2 RLS4148 1 1 1 D11 R15 10K 1% 1 C21 .1uF 50V 2 1 TP24 2 1 + TP21 – 1 LED3 GREEN SMT RAGND OM-203 860 Page 49 TP101 12 1 1 1 1 1 1 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 2 2 2 2 2 2 1% 1 2 3 4 5 6 9 8 11 10 13 12 74HC1 4 1 2 3 4 +5V 5 6 1 OC12 TP119 A4 4 9 2 1 3 OC11 GND A5 4 TP112 C5 7 .1uF 50V C5 2 .1uF 50V 8 2 1 1 TP120 +5V 1 +5V C5 5 .1uF 50V AB_SEL 10 !AB_SEL 11 13 12 2 AIN4 B0 B1 B2 B3 B4 B5 B6 B7 TP83 TP76 TP70 TP66 TP59 TP53 TP46 TP42 R4 4 R4 3 R4 5 R4 7 R4 2 R4 0 R3 8 R4 1 10K 1% 1% 1% 1% 1% 1% 1% 2 C9 5 .1uF 50V TP122 1 GND 10 U1 6 LED16 SMT RED 2 1 R116 1 2 2.21K 1% 8 U1 8 2 3 TP124 1 C9 6 .1uF 50V AIN3 6 9 74HC1 4 2 2 1 1 A3 4 5 13 +5V 4 1 2 TP126 +24RD TP128 2 3 11 2 1 2.21K 1% A2 1% 1 GND 3 2 1 LED22 RED SMT R119 +24RD GND 4 OC13 1 TP131 2 TP130 OC14 2 TP129 1 C9 7 .1uF 50V AIN2 R120 1 2 2.21K 1% +24RD 1 LED23 RED SMT 2 A1 3 1 A0 A1 A2 A3 A4 A5 A6 A7 GND 4 2 2 AIN1 TP133 OC15 TP134 R5 8 R5 5 R5 2 R5 1 R5 4 R5 7 R4 8 R4 6 10K 1% 1% 1% 1% 1% 1% 1% 2 2 3 1 1 1 2.21K 1% +24RD TP132 A0 4 2 LED24 SMT RED 2 1 C9 8 .1uF 50V R121 OC16 1 2 TP136 U2 2 +5V 1 +24RD TP135 LED25 SMT RED 2 1 C9 9 .1uF 50V AIN0 R6 3 1 2 2.21K 1% 2 2 GND 3 1 C9 4 .1uF 50V TP117 2 1 OC9 GND 74HC1 4 4 A6 3 GND 4 A7 TP85 TP91 2 AIN5 OC10 GND GND TP113 1 1 R113 1 2 2.21K 1% +24RD LED15 RED SMT C9 3 .1uF 50V TP107 3 2 GND 2 AIN6 TP103 1 1 +24RD LED14 SMT RED 2 1 R109 2.21K 1% 2 R106 2.21K 1 1% TP96 LED13 SMT RED 2 1 2 C9 2 .1uF 50V AIN7 2 RC100 TP92 1 BIN_SINK1 BIN_SINK4 BIN_SINK2 RD_GND BIN_SINK3 BIN_SINK5 AIN4 BIN_SINK6 AIN5 TP84 TP86 1 R102 2.21K 1% BIN_SINK1 B0 3 OC7 4 GND B1 1 2 1 3 OC6 4 GND B2 BIN_SRC3 BIN_SRC5 AIN4 BIN_SRC6 AIN5 RD_GN D AIN6 BIN_SRC7 RD_GN D BIN_SRC0 RD_GN D 1 2.21K 1% +24RD 2 LED10 RED SMT 2 3 2 1 TP71 1 C8 8 .1uF 50V TP74 2 4 GND B3 3 GND 2 BIN_SINK2 OC5 1 R101 LED9 RED 2 BIN_SINK3 +24RD U1 9 2 R103 2 R118 2 R115 2 R114 2 R117 2 R112 2 R110 TP125 TP118 TP80 1 2 3 4 5 6 7 8 I1 I2 I3 I4 I5 I6 I7 GND RD_GND O1 O2 O3 O4 O5 O6 O7 V+ 16 15 14 13 12 11 10 9 R9 9 1 2 2.21K 1% TP63 1 LED8 RED SMT 2 1 C8 5 .1uF 50V BIN_SINK4 C8 1 .1uF 50V ULN2003 B4 OC3 4 GND B5 TP60 2 1 3 OC2 1 4 GND B6 3 OC1 4 GND B7 TP54 SMT 2 3 1 2 BIN_SINK5 4 3 2 LED7 RED 2 R9 8 1 2 2.21K 1% TP56 +24RD OC4 2 1 10K 1% 1 2 TP87 TP127 TP123 TP121 1 C8 7 .1uF 50V TP68 RD_GN D TP67 SMT 1 R100 1 2 2.21K 1% +24RD CON\2X8\MILLER 1 1 1 1 1 1 1 1 4 TP77 C9 0 .1uF 50V TP79 OC8 2 2 BIN_SRC1 BIN_SRC4 BIN_SRC2 LED11 SMT RED 2 2 +24RD RD_GN D 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16 1 BIN_SINK0 2 RD_GND RC110 1 2 RD_GND BIN_SINK0 CON\2X8\MILLER BIN_SRC0 BIN_SRC1 BIN_SRC2 BIN_SRC3 BIN_SRC4 BIN_SRC5 BIN_SRC6 1 R105 2.21K 1% +24RD RD_GN D AIN6 BIN_SINK7 LED12 SMT RED 2 1 C9 1 .1uF 50V 1 RD_GND 1 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16 2 +24RD TP52 3 2 +24RD R9 0 1 2 2.21K 1% 2 R107 2.21K 1% BIN_SINK6 Q4 MMBT4401L 1 RD_GN D RD_GND TP47 1 1 C7 8 .1uF 50V SMT 2 R108 12.1K 1% 2 LED6 RED 2 BIN_SINK7 TP44 LED5 RED 2 C7 6 .1uF 50V TP43 SMT 1 1 1 1 BIN_SRC7 +24RD R9 5 1 2 2.21K 1% 2 TP97 Figure 5-11. Circuit Diagram For Customer Interface Board PC14 (Part 3 of 3) OM-203 860 Page 50 GND TP111 TP106 TP102 TP100 TP94 TP89 !AB_SEL 2 1 +5V A1 A2 A3 A4 A5 A6 A7 A8 19 1 1 2 3 4 5 6 7 8 9 10 AB_SEL G DIR 10K TP116 1% R111 18 17 16 15 14 13 12 11 B1 B2 B3 B4 B5 B6 B7 B8 WFS_CMD TRIM_CMD 11 12 13 14 15 16 17 18 19 20 ARC_DET WLDR_RDY SPARE FLOW_ERR STK_ERR TOUCH_SENSOR 20 PIN AMP–LATCH 74H C245 TP82 TP110 +5V TP78 TP72 TP62 TP69 TP55 +5V R104 1 A1 A2 A3 A4 A5 A6 A7 A8 19 1 2 +5V 1 U1 7 2 3 4 5 6 7 8 9 18 17 16 15 14 13 12 11 B1 B2 B3 B4 B5 B6 B7 B8 C5 6 .1uF 50V 2 TP75 1 TP73 C5 4 .1uF 50V 2 TP90 RC98 U2 0 2 3 4 5 6 7 8 9 TP95 GND GND RC94 G DIR 10K 1% !AB_SEL AIN0 AIN1 TP81 C5 8 .001uF 100V 1 LED26 GREEN 1SMT 2 2 R6 1 2.67M 1 R6 0 150 U2 3 4N 32 R R6 2 6 10K 1% 5 2 CON\3X3\MILLE 1 1 1 AIN3 AIN7 AIN2 +24RD 4 TP138 2 TP137 2 RD_GN D 1 R6 4 1K 1% Q5 2 3 2 RD_GN D +5V 4 1 7 5 2 8 6 3 9 RD_GN D RD_GN D 74H C245 MMBT4401L 1 K1_COMMON 1 2 10K 2 R122 RD_GND RC96 K5 RELAY_COM 6 NCA_SPARE 8 NOA_SPARE 11 NCB_SPARE 4 RD_GN D L1 13 +35V TP93 R4 9 392 1% 2 1 DL4001 1 1 2 TP88 +35V 2 1 WBC 1 16 RELAY DPDT (MDX24–02) 2 LED20 NOB_SPARE 9 D1 5 1 8 2 7 3 6 4 5 CON\2X4\MILLER GREEN SMT K6 6 RELAY_COM RC91 NCA_READY 4 8 NOA_READY 11 NCB_READY 9 NOB_READY RELAY_COM +24RD RD_GN D 13 TP98 D1 4 +35V 2 R5 0 392 1% 1 1 1 16 2 DL4001 2 LED21 GREEN SMT 1 TP99 RELAY DPDT (MDX24–02) NCA_SPARE NOA_SPARE NCB_SPARE COMM_SPARE NOA_READY NOB_SPARE NCA_READY COM_READY NOB_READY NCB_READY K2 RELAY_COM 6 NCA_STUCK 8 NOA_STUCK 1 8 2 9 3 10 4 11 5 12 6 13 7 14 CON\2X7\MILLE R 4 11 NCB_STUCK 9 NOB_STUCK 13 U2 1 TOUCH_SENSOR SPARE WLDR_RDY STK_ERR FLOW_ERR ARC_DET 1 2 3 4 5 6 7 8 I1 I2 I3 I4 I5 I6 I7 GND O1 O2 O3 O4 O5 O6 O7 V+ 16 15 14 13 12 11 10 9 +35V 2 R5 3 392 1 1 2 D1 8 DL4001 2 LED17 GREEN SMT 1 1% TP104 1 16 RELAY DPDT (MDX24–02) TP105 K3 ULN2003 NCA_FLOW 6 RELAY_COM 4 GND NOA_FLOW 8 11 CON\3X5\MILLE NOB_FLOW 9 2 R5 6 392 1% 1 2 1 16 D1 7 DL4001 6 1 11 7 2 12 8 3 13 9 4 14 10 5 15 NCB_FLOW 13 +35V RC92 NCA_STUCK NOA_STUCK COMM_STUCK NOB_STUCK COMM_FLOW NCB_STUCK NCB_FLOW NCA_FLOW NOB_FLOW COMM_ARC NCB_ARC NOA_FLOW NCA_ARC NOA_ARC NOB_ARC RELAY DPDT (MDX24–02) 1 1 TP109 2 LED18 GREEN SMT K4 TP108 RELAY_COM 6 NCA_ARC 8 NOA_ARC 4 11 NCB_ARC 13 9 +35V TP114 2 R5 9 392 1% TP115 1 2 1 16 D1 6 DL4001 NOB_ARC Pensar 86147 (Part 3 of 3) RELAY DPDT (MDX24–02) 1 1 2 LED19 GREEN SMT OM-203 860 Page 51 R 174 578-B Figure 5-12. Circuit Diagram For Touch Sensor Board PC18 OM-203 860 Page 52 191 531 Figure 5-13. Circuit Diagram For Power Distribution Board PC20 OM-203 860 Page 53 SECTION 6 – PARTS LIST 13 14 27 25 40 35 37 36 33 38 32 (Fig.6–3) 34 23 26 31 (Fig.6–2) 1 30 3 2 4 39 29 28 5 24 6 7 8 9 4 10 11 12 15 16 17 18 3 20 21 19 (Fig.6–4) available unless listed. 23 . Hardware is common and not 802 994-B Figure 6-1. Main Assembly OM-203 860 Page 54 Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-1 Main Assembly . . . 1 . . . . . . . . . . . . +179 432 . . . 2 . . . . . . . . . . . . . 179 431 . . . 3 . . . . . . . . . . . . . 164 699 . . . 4 . . . . . . . . . . . . . 162 816 . . . 5 . . . . . . . . . . . . . 162 820 . . . 6 . . . . . . . . . . . . . 162 830 . . . 7 . . . . . . . . . . . . . 177 279 . . . 8 . . . . . . . . . . . . . 604 536 . . . 9 . . . . . Z1 . . . . 166 364 . . . 10 . . . . HD1 . . . . 168 829 . . . 11 . . . . CR6 . . . . 160 966 . . . 12 . . . . . . . . . . . . . 173 605 . . . 13 . . . C21-23 . . 163 906 . . . 14 . . . . . T2 . . . . 159 042 . . . 14 . . . . . T2 . . . . 159 041 . . . 14 . . . . . T2 . . . . 159 043 . . . 15 . . . . TE1 . . . . 159 244 . . . 16 . . . . . . . . . . . . . 601 835 . . . 17 . . . . . . . . . . . . . 038 887 . . . . . . . . . . . . . . . . . . . 010 913 . . . . . . . . . . . . . . . . . . . 601 835 . . . . . . . . . . . . . . . . . . . 038 618 . . . 18 . . . . . . . . . . . . . 159 034 . . . 19 . . . . . . . . . . . . . . Fig 6-5 . . . 20 . . . . . F1 . . . *156 065 . . . 21 . . . . . W . . . . . 160 793 . . . 23 . . . . . . . . . . . . . 134 464 . . . 24 . . . . . . . . . . . . . 163 359 . . . 25 . . . . . C1 . . . . 182 661 . . . . . . . . . . . . . . . . . . . 163 535 . . . . . . . . . . . R6 . . . . 140 002 . . . . . . . . . . . . . . . . . . . 162 817 . . . 26 . . . . . . . . . . . . . 182 660 . . . 27 . . . . . T1 . . . . 189 835 . . . 28 . . . . . . . . . . . . . 166 442 . . . 29 . . . . . . . . . . . . . 166 441 . . . 27 . . . . . T1 . . . . 189 836 . . . 28 . . . . . . . . . . . . . 172 309 . . . 29 . . . . . . . . . . . . . 172 308 . . . 27 . . . . . T1 . . . . 189 837 . . . 28 . . . . . . . . . . . . . 172 427 . . . 29 . . . . . . . . . . . . . 172 426 . . . . . . . . . TP1,2 . . . 175 405 . . . . . . . . . TP4,5 . . . 168 891 . . . . . . . . . PLG13 . . 189 873 . . . . . . . . . RC13 . . . 189 874 . . . . . . . . . PLG6 . . . 168 847 . . . . . . . . . . RC6 . . . . 168 845 . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHANNEL, upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BAR, mtg lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKET, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREW, .312-18 x 1.75 hexhd-pln gr 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSDUCER, current 1000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTACTOR, def prp 25A 2P 24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR, 50 and 60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSFORMER, control 50VA 24V 230/460/575 (60Hz) . . . . . . . . . . . . . . . . TRANSFORMER, control 50VA 24V 200/230/460 (60Hz) . . . . . . . . . . . . . . . . TRANSFORMER, control 50A 24V (50Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRIMARY BOX, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, flat .218 ID brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LINK, jumper term bd pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE, crtg .5A 600V time delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTACTOR, def prp 60A 3P 24VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR, elctlt 16000uf 60VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, WW fxd 10W 500 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUS BAR, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUS BAR, mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSFORMER, pwr main 200/230/460 (consisting of) . . . . . . . . . . . . . . . . . . . COIL, pri/sec 200/230/460 (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COIL, pri/sec 200/230/460 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSFORMER, pwr main 230/460/575 (consisting of) . . . . . . . . . . . . . . . . . . . COIL, pri/sec 230/460/575 (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COIL, pri/sec 230/460/575 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSFORMER, pwr main 380/400/440 (consisting of) . . . . . . . . . . . . . . . . . . . COIL, pri/sec (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COIL, pri/sec (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTAT, NC (Included w/T1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTAT, NC (Included w/T1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 2 4 2 1 1 2 1 1 1 1 3 1 1 1 1 24 24 24 24 8 1 1 1 1 2 1 1 6 1 2 4 1 2 1 1 2 1 1 2 1 2 2 1 1 1 1 OM-203 860 Page 55 Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-1 Main Assembly (Continued) . . . 30 . . . . . . . . . . . . . 161 294 . . . 31 . . . . . . . . . . . . . . Fig 6-2 . . . 32 . . . . SR1 . . . . 192 672 . . . . . . . . . PLG14 . . 115 094 . . . . . . . . . PLG7 . . . 152 249 . . . . . . . . . . RC7 . . . . 168 846 . . . . . . . . . . . . . . . . . . . 010 467 . . . . . . . . . . . R7 . . . ♦114 808 . . . 33 . . . . . . . . . . . . . 204 069 . . . 34 . . . PC18 . . . 174 573 . . . 35 . . . PC12 . . . 191 841 . . . 36 . . . PC11 . . . 210 361 . . . 37 . . . . PC1 . . . . 208 197 . . . 38 . . . . CR3 . . . . 052 964 . . . 39 . . . . T11 . . . . 204 979 . . . 40 . . . . CR5 . . . . 006 393 . . BRACKET, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECTIFIER, SCR main (Fig 6-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR, clamp cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, WW fxd 375W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRONICS BOX (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD ASSY, touch sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD ASSY, weld interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD ASSY, processor w/prom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD ASSY, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY, encl 24VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSFORMER, control 200VA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ♦Part of Option 043 286 Additional Resistor +When ordering a component originally displaying a precautionary label, the label should also be ordered. *Recommended Spare Parts. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-203 860 Page 56 7 8 available unless listed. 21 20 19 23 27 25 24 26 28 29 30 22 31 32 18 1 17 16 15 2 14 3 13 4 12 11 6 7 10 6 7 . Hardware is common and not 802 997-A Figure 6-2. Panel, Front w/Components OM-203 860 Page 57 Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-2 Panel, Front w/Components (Fig 6-1 Item 31) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 6 7 8 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 . . . . . . . . . . . . . 203 630 . . . CB1,2 . . . 093 995 . . . . RC9 . . . . 604 176 . . . . . . . . . . . . . . 204143 . . . . POS . . . 181 245 . . . C2,4,5 . . . 128 750 . . . . . . . . . . . . . 161 303 . . . . NEG . . . 181 246 . . . . . . . . . . . . . 162 891 . . . . . . . . . . . . +172 587 . . . . . . . . . . . . . 160 935 . . . . . . . . . . . . . 038 887 . . . . . . . . . . . . . 204 067 . . . PC13 . . . 209 249 . . . PC20 . . . 191 533 . . . PC22 . . . 200 073 . . . PC17 . . . 177 290 . . . PC15 . . . 182 998 . . . . . . . . . . . . . 091 772 . . . . . . . . . . . . . 203 628 . . . . . . . . . . . . . 144 842 . . . RC70 . . . 201 058 . . . . . S2 . . . . 159 039 . . . RC21 . . . 200 082 . . . CB11 . . . 011 991 . . . PC19 . . . 134 560 . . . . RC8 . . . . 200 589 . . . PC21 . . . 200 077 . . . RC25 . . . 200 591 . . . PC14 . . . 203 665 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ELECTRONICS BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . . . . . . RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR, cer disc .1uf 500VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPRING, cprsn .600 OD x .072 wire x 1.500 lg . . . . . . . . . . . . . . . . . . . . . . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COVER, stud output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLIP, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH, reed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD ASSY, 115V motor board . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD ASSY, power distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD ASSY, filter hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISPLAY, LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD ASSY, switch board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STAND-OFF, NO 6-32 x .625 LG .250 hex . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACTUATOR, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONN, rect 72 pin assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH, rocker SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONN, circ 97/met 4 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT BREAKER, man reset 1P 1.5A 250V . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD ASSY, filter hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONN, circ 97/met 10 skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD ASSY, robot interface filter hf . . . . . . . . . . . . . . . . . . . . . . . . CONN, circ 97/met 11 skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD ASSY, customer interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 1 1 2 3 3 1 1 1 3 1 1 1 1 1 1 1 4 1 3 1 1 1 1 1 1 1 1 1 +When ordering a component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-203 860 Page 58 . Hardware is common and not available unless listed. 3 2 1 4 5 6 Figure 6-3. Rectifier, SCR Main SR1 Item No. Dia. Mkgs. SR1 Part No. Description Figure 6-3 Rectifier, SCR Main (Fig 6-1 Item 32) 802 351 Quantity 192 672 . . . 1 . . . . C7-12 . . . . 048 420 . . CAPACITOR, cer disc .01uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . 2 . . . . . . . . . . . . . . . 191 989 . . BAR, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 3 . . . . . . . . . . . . . . . 188 691 . . CLAMP, thyristor rectifier 5.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . 4 . . . . . . . . . . . . . . . 188 839 . . HEAT SINK, rectifier snowflake .800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . 5 . . . SCR1-6 . . . 161 668 . . THYRISTOR, SCR 300A 300V hockey puck . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . 6 . . . . . . . . . . . . . . . 166 667 . . CLAMP, spring thyristor rectifier 5.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . PLG1 . . . . 158 720 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . TP3 . . . . . 192 673 . . THERMOSTAT, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . TP6 . . . . . 192 674 . . THERMOSTAT, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-203 860 Page 59 Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-4 Panel, Rear w/Components (Fig 6-1 Item 19) ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 . . . . . . . . . . . . . . . 173 283 . . . . . . . . . . . . . . . 180 165 . . . . . . . . . . . . . . . 162 807 . . . . . . . . . . . . . . . 168 343 . . . . . . . . . . . . . . +162 818 . . . . . . . . . . . . . . . 168 384 . . . . . . . . . . . . . . . 602 177 . . . . . . . . . . . . . . . 124 274 . . . . . R3 . . . . . . 114 808 . . . . . FM . . . . . 116 190 . . . . . . . . . . . . . . . 194 745 . . . . . . . . . . . . . . . 010 467 .. .. .. .. .. .. .. .. .. .. .. .. CHAMBER, plenum 14 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLADE, fan 14 in 3wg 28deg .375 bore CCW . . . . . . . . . . . . . . . . . . . . . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HINGE, door primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DOOR, access primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREW, set .250-20 x .250knrlpt sch stl . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, WW fxd 375W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOTOR, 1/12HP 230V 1550RPM 50/60Hz 1.5A . . . . . . . . . . . . . . . . . . . BLOCKING DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR, clamp cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . Hardware is common and not 1 1 1 2 1 1 2 1 1 1 1 1 4 available unless listed. 5 6 2 1 (Fig.6-5)11 7 12 8 10 9 Ref. 802 798 / 800 707-B Figure 6-4. Panel, Rear w/Components +When ordering a component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-203 860 Page 60 802 686-A Figure 6-5. Blocking Diode Item No. Part No. Description Quantity Figure 6-5. Blocking Diode (Fig 6-4 Item 11) ... 1 ............... ... 2 ............... ... 3 ............... ... 4 ............... ... 5 ............... ... 6 ............... ... 7 ............... ..................... ..................... 200 355 191 248 086 353 048 775 166 667 201 059 048 420 168 894 192 731 .. .. .. .. .. .. .. .. .. Bracket, Mtg Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heat Sink, rectifier snowflake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diode, Rect 800A 300V R7S Hockey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bus Bar, Tab Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clamp, spring thyristor rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clamp, thyristor rectifier 4.75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacitor, cer disc .01 uf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat, Nc Open 125F Close 105F No Flangew/leads . . . . . . . . . . . Thermostat, Nc Open 203F Close 173F No Flangew/leads . . . . . . . . . . . 1 2 1 2 1 1 1 1 1 To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-203 860 Page 61 Effective January 1, 2002 (Equipment with a serial number preface of “LC” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way. * LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS. Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor. 1. 5 Years Parts — 3 Years Labor * * 2. 3 Years — Parts and Labor * * * * * * 3. Original main power rectifiers Inverters (input and output rectifiers only) Transformer/Rectifier Power Sources Plasma Arc Cutting Power Sources Semi-Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) 1 Year — Parts and Labor Unless Specified * * * * * * * * * * * * * * * * * * DS-2 Wire Feeder Motor Driven Guns (w/exception of Spoolmate Spoolguns) Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems Flowgauge and Flowmeter Regulators (No Labor) HF Units Grids Maxstar 85, 140 Spot Welders Load Banks Racks Running Gear/Trailers Plasma Cutting Torches (except APT & SAF Models) Field Options (NOTE: Field options are covered under True Blue for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.) 4. 6 Months — Batteries 5. 90 Days — Parts * * MIG Guns/TIG Torches Induction Heating Coils and Blankets * * * * * APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts (No labor) Spoolmate Spoolguns Canvas Covers Miller’s True Blue Limited Warranty shall not apply to: 1. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. (Exception: brushes, slip rings, and relays are covered on Bobcat, Trailblazer, and Legend models.) 2. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any. 3. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment. MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. In the event of a warranty claim covered by this warranty, the exclusive remedies 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 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 customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province. miller_warr 6/02 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA Replacement Parts Training (Schools, Videos, Books) International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 Technical Manuals (Servicing Information and Parts) Circuit Diagrams European Headquarters – United Kingdom Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066 Welding Process Handbooks www.MillerWelds.com Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. PRINTED IN USA 2002 Miller Electric Mfg. Co. 8/02
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