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/1 Miller November 1995 Form: OM-2204F Effective With Serial No. KGO1 7632 OWNERS MANUAL .1 XMTfi 300 CC/hG CC/DC Welding Power Source For GTAW, GTAW.P, And SMAW Amperes, 300 Uses Welding 32 Volts DC At 60% Single-Phase Duty Cycle Or Three-Phase Input Power Protection For Control Circuit, 24 VAC, And Overheating AUTO.LINKTM Circuitry And Built-In High Frequency 14-Pin Remote Control For Options Receptacle And Accessories, See Rear Cover Give this manual to the operator. Read and follow these instructions and all safety blocks Have only carefully. and qualified persons service this unit. trained install, operate, or For Call your distributor if you do not understand the directions. cover 5/94 - ST-146 123-A ' 1995 MILLER Electric or: help, call your distributor MILLER Electric Mfg. Co., RO. Box 1079, WI 54912 414-734-9821 Appleton, Mtg. Co. PRINTED IN USA 1. l TRUE BLUETM LIMITED WARRANTY MILLERS Effective (Equipment with This limited warranty supersedes all LIMITED WARRANTY previous a January 1,1995 preface of KD serial number MILLER warranties and is exclusive with Subject to the terms and conditions below, MILLER Electric warrants to its original retail purchaser that new 6. 90 no other guarantees warranties expressed or implied. Torches MIG Guns/flG MILLER equipment sold after the effective date of this limited warranty is free of de fects in material and workmanship at the time it is shipped by MILLER. THIS WAR RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANT1ES, EXPRESS OR IMPLJED, INCLUDING THE WARRAN11ES OF MERCHANTABILITY AND FIT or Parts and Labor Days Mfg. Co., Appleton, Wisconsin, newer) or APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches Remote Controls * Accessory Kits Replacement Parts NESS. Within the warranty periods listed below, MILLER will repair or replace any war ranted parts or components thaI fail due to such defects in material or workmanship. MILLERS 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. 1. True BIue~ Items furnished Umited Warranty shall not apply to: by MILLER, but manufaclured by others, such as engines or are covered by the manufacturers warranty, if trade accessories. These items any. MILLER shall honor warranty claims on warranted equipment listed below in the warranty time periods. All warranty time peflods start on the date that the equipment was delivered tome original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen event of such a failure within the 2. months after the 3. equipment is sent to an International distributor. Consumable components; such as contact tips, and relays or parts that fail due to normal wear. Equipment 5 Years Parts 3 Original * 2. (input and output rectifiers only) MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER CIALI1NDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. Parts and Labor 3 Years Transforrner/Roctffier Power Sources Plasma Arc Cutting Power Sources by this warranty, the exclusive remedies option: (1) repair, or (2) replacement; or, where authorized in appropriate cases, (3) the reasonable coat of mpairor replace ment at an authorized MILLER service station; or (4) payment of orcredit torthe pur chase price (less reasonable depreciation based upon actual use) upon return of the goods at customers risk and expense. MILLERS option of repair or replacement will be FOB., Factoryat Appleton, Wisconsin, or FOB. at a MILLER authorized ser vice facility as determined by MILLER. Therefore no compensation or reimburse ment for transportation costs of any kind will be allowed. In the event of a warranty claim covered Semi-Automatic and Automatic Wire Feeders Inverter Power shall be, at MILLERS writing by MILLER in Supplies Intellitigs Robots 3. 2 Years Parts and Labor Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) Air Compressors 1 YearPartsand 4. * by any party other than MILLER, or equip 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. Years Labor main power rectifiers Inverters contactora that has been modified ment that has been 1. cutting nozzles, TO ThE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE UABLE FOR DIRECT, INDtRECT, SPECIAL INCIDENTALOR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT). WHETHER BASED ON CON TRACT, TORT OR ANY OTHER LEGAL THEORY. Labor Motor Driven Guns Process Controllers IHPS Power Sources Water Coolant ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPUED WAR RANTY, 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, Systems HFUnits Grids OPERA11ON OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WiTH RESPECTTO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. Spot Welders Load Banks SDX Transformere Running Gear/Trailers Cutting Torches (except APT, ZIPCUT Tecumseh Engines Deutz Engines (outside North America) Plasma * Field & PLAZCUT 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 10 you. This warranty provides ape cific legal rights, and other rights may be available, but may vary from state to state. Models) Options Field options are covered under True BIueTM for the remaining wsrrsnty period of the product they are installed in, or for a minimum of In (NOTE: one 5. 6 Months year whichever is Canada, legislation in greeter.) 1_________ provinces provides for certain additional warranties remedies other man ,~,,vary Batteries some 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 ngtrts, and other rights may be available, but may or from province to province. r. RECEIVING-HANDLING unpacking equipment, check carton for any damage that may have occurred during shipment. File any claims for loss or damage delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment manufacturers Transportation Department. Before with the When requesting information following nameplate. Use the or about this equipment, always provide spaces to record Model Designation and Serial or Model Style Designation and Serial or Style Number. Numberof your unit. The information is located on the rating label Model __________ Serial or Style No, Date of Purchase miller 6/95 ARC WELDING SAFETY PRECAUTIONS WARNING A~ ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. In welding, as in most jobs, exposure to cerLain hazards occurs. Welding is safe when precautions are taken. The safety information given below is only a summary of the more complete safety information that will be found in the Safety Standards listed on the next page. Read and follow all Safety Standards. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE. ELECTRIC SHOCK can terminal in disconnect box kill. live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electncally live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. 1. Do not touch live electrical parts. 2. Wear 3. 4. 5. dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. 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). Properly install and ground this equipment according to its Owners 6. Manual and national, state, and local codes. Always verify the supply ground power cord check and be sure ground wire is properly connected that input to ~ 7. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can bum eyes and skin. Noise from some processes can damage hearing. Chipping, grinding, and welds cooling throw oft pieces of metal or slag. approved I ear plugs or ear muffs if noise level is FUMES AND GASES can welding fumes ventilation is poor, Read the Material manufacturers area 11. Do not 12. If earth with and/or exhaust at the use an Safety and the coatings, a safety 15. Wear a 16. Keep all 17. Clamp or J~~~ Protect 2. Wear with worktable as a welding 4. 5. a proper shade of filter to or watching (see ANSI Safety Standards). 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 breathing air is safe. Do not weld in locations near Do not weld Never weld compressed gas cylinders from excessive heat, slag, open flames, sparks, and arcs. 8. 9. spraying react with vapors to on drape a a can give off toxic fumes if welded. welding torch over a gas cylinder. welding electrode to touch any cylinder. on a pressurized cylinder explosion will result. onlycorrectshielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. Turn face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is Use in use 10. or sure plated steel, 6. Install death. Be coated metals, such as galvanized, lead, or 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 cadmium 7. or degreasing, cleaning, operations. The heat and rays of the arc can form highly toxic and irritating gases. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since welding gas cylind:rs are cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Keep cylinders away from any welding or other electrical to approved safety glasses with side shields. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection. Never allow ~ ~ef~Iyfhe place. in good metal-to-metal contact near the weld as practical. Wear Never damaged. securely helmet fitted with Z49.1 and Z87.1 listed in 3. 5. if above floor level. protect your face and eyes when welding 4. explode mechanical shocks, circuits. working covers cable , ~ and containing these elements can body. ARC RAYS cleaners, and degreasers. CYLINDERS harness if panels work workpiece 7. (MSDSs) your grounding of the workpiece is required, ground it directly separate cable do not use work clamp or work cable. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. approved air-supplied respirator. Data Sheets over poorly spliced 14. arc to instruction for metals, consumables, drape cables or Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. the use damaged, undersized, 13. be hazardous to your and gases. grounding not in use. equipment when Do not use worn, cables. head out of the fumes. Do not breathe the fumes. inside, ventilate the remove attach proper double-check connections. Turn off all 6. Keep your a 9. Welding produces fumes and gases. Breathing can making input connections, 10. to your health. these fumes and gases health. is connected to plug outlet. Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill. high. be hazardous that cord 8. 5. Use When conductor first ground ARC RAYS can burn eyes and skin; NOISE can damage hearing; FLYING SLAG OR SPARKS can injure eyes. or properly grounded receptacle Touching or connected for use. Read and follow instructions on compressed gas cylinders, associatedequipment,andCGApublicationP-1 listedinSafety Standards. srl.1.1 2/94 WELDING fire can cause explosion. or 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 bums. 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. Be 6. aware that fire can cause welding ceiling, floor, bulkhead, on a or partition the hidden side. on closed containers such tanks, drums, 7. Do not weld 8. pipes, unless they are properly prepared according to AWS F4.1 (see Safety Standards). 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 on as or hazards. 1. 2. 3. 4. 5. Protect yourself and others from flying sparks and hot metal. Do not weld where flying sparks can strike flammable material. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Watch for fire, and keep a fire extinguisher nearby. ENGINE EXHAUST GASES Engines produce ENGINE can kill. can fire cause or explosion. Engine fuel is 1. Stop engine 2. Do not add fuel while open flames. highly 11. Wear oil-free heavy shirt, smoking or MOVING PARTS or cut off protective garments such high shoes, cuffless trousers, as welding wire at leather gloves, and a cap. Remove any combustibles, such as a butane lighter matches, from your person before doing any welding. 12. or j be hazardous. can in open, well-ventilated areas. equipment outside 1. Use 2. closed area, vent engine exhaust outside and away from any building air intakes. 3. Do not overfill tank 4. Do not If used in a allow spill fuel. If fuel for fuel to room spilled, clean is expand. up before starting engine. flammable. and let it cool off before pipes. Remove stick electrode from holder contact tip when not in use. ENGINES harmful exhaust gases. FUEL welder to thaw frozen use 10. WARNING 4~ A Do not 9. checking or adding fuel. sparks or if unit is near any can cause injury. 3. only qualified people remove guards or troubleshooting as necessary. Have covers for maintenance and Moving parts, such as fans, rotors, and belts can fingers and hands and catch loose clothing. 4. cut negative () battery 5. 1. Keep all doors, panels, securely in place. 2. Stoo ena~ne before covers, installing and guards closed and connecting Keep hands, hair, loose SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin. Reinstall clothing, and tools disconnect awayfrom moving panels or guards and close doors starting engine. 1. 2. when servicing is wear a face shield when working on a battery. Stop engine before disconnecting or connecting battery Always cables. 3. Do not allow tools to 4. Do not gases. 5. Observe correct STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin. 1. It is best to check coolant level when to avoid scalding. during servicing, battery. finished and before unit. Batteries contain acid and generate cable from parts. 6. or To prevent accidental starting explosive engine is cold If the use cause welder to engine is sparks when working on charge polarity (+ warm and batteries and ) checking on or jump a battery. start vehicles. batteries. is needed, follow steps 2 and 3. 2. 3. safety glasses and gloves and put a rag over cap. Turn cap slightly and let pressure escape slowly before Wear completely removing cap. PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting, ANSI Standard Z49. 1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 Safety and Health Standards, OSHA dent of 29 CFR 1910, from Superinten Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, Ameri can Welding Society Standard AWS F4.1 from American Welding So ciety, 550 N.W. Le.Jeune Rd, Miami, FL 33126 National Electrical Code, NFPA Standard 70, from National Fire Pro Association, Batterymarch Park, Quincy, MA 02269. tection srl.1.1 2/94 Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-i, from Compressed Gas Association, 1235 Jefferson Davis High way, Suite 501, Arlington, VA 22202. Code for Safety in Welding and Cutting, CSA Standard Wi 17.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Bou levard, Rexdale, Ontario, Canada M9W 1 R3. SafePracticesForOccupationAndEducationalEyeAndFaceProtec tion, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018. Cutting And Welding Processes, NFPA Standard 51 B, from National Batterymarch Park, Quincy, MA 02269. Fire Protection Association, 1 EMF INFORMATION Considerations About Magnetic Fields NOTE ~ Welding And The Effects Of Low Frequency Electric And ____________________ The is a quotation from the General Conclusions Section Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields Background Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing Office, May 1989): . there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields can interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks. following of the U.S. . To magnetic fields reduce the in workplace, use the following procedures: Keep 1. together by twisting cables close cables to Arrange 3. Do not coil 4. Keep welding power practical. 5. Connect work clamp to one or taping side and away from the 2. them. operator. . or drape cables around the source body. and cables as far away as workpiece as close to the weld as possible. AbOUt Pacemakers; The above procedures are recommended for pacemaker complete information. among wearers. those also normally Consult your doctor for modlO.1 4/93 TABLE OF CONTENTS SECTION 1 - SECTION 2 2-1. 2-2. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. SPECIFICATIONS 1 Volt-Ampere Curves Duty Cycle SECTION 3 3-1. SAFETY INFORMATION 2 2 INSTALLATION 3 Process Connections Typical Selecting A Location And Moving Welding Power Source Selecting And Preparing Weld Output Cables Connecting To Weld Output Receptacles Remote 14 Receptacle RC2 Information And Connections Installing Gas Supply Connecting Input Power SECTION 4 OPERATION SECTION 5 MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Removing 5-3. Overload Protection 5-4. Changing AmperageNoltage Troubleshooting 5-5. 4 5 6 6 7 8 9 5-2. Case And 3 15 15 Measuring Input Capacitor Voltage 16 17 Meter Hold Function 18 18 SECTION 6- ELECTRICAL DIAGRAMS 20 SECTION 7- HIGH FREQUENCY 24 SECTION 8- TUNGSTEN ELECTRODE 26 8-1. 8-2. Selecting Tungsten Electrode Preparing Tungsten SECTION 9 Figure Figure Figure PARTS LIST 9-1. Main Assembly (208-230/460V Model Illustrated) Chassis, Mid (208-230/460V Model Illustrated) 9-3. Panel, Front w/Components 9-2. 26 27 28 28 30 33 OM.2204F- 11195 SECTION 1 SAFETY INFORMATION - modl.1 2/93 Read all all Obey safety messages throughout safety messages Leam the 1 meaning to avoid this manual. injury. of WARNING and CAUTION. 2 1 Safety Alert 2 Signal Word 2 \ ~r~!i!t~ AA CAUTION 3 ELECTRIC SHOC K can kill L~ Do not touch live elect scat parts. Disconnect installing or input power servicing. serious or I ;1~II~eU WARN ING beforeJj_ 4 means injury possible death happen. can CAUTION MOVING PARTS Keep sway Symbol from can moving parts. Keep all panels end when operating. I means possible minor injury or equipment damage can happen. I 3 Statement Of Hazard And Result 4 Safety injure. covers closed I / 5 Instructions To Avoid Hazard READ SAFETY BLOCKS at start of Section 3-1 before proceeding. __!. 6 5 Hazard 6 Safety Read ~ Turn Off switch when using high frequency. 1-1. Safety blocks for each sym NOTE Special ation Figure safety bol shown. 7 NOTE Symbol (If Available) Banner instructions for best oper not related to safety. Information SECTION 2- SPECIFICATIONS Table 2-1. Welding Power Source Specification Type Of Welding Description Output Constant CurrentiDirect Current Processes Gas Tungsten Arc (GTAW), Gas Tungsten Arc (SMAW) Input Power Cord 12 ft Overall Dimensions Length: Weight Net: 84 lb (38 kg); Output (522 mm); 21-3/4 in 300 Ship: Amperes, 32 Volts (See Section 2-2) Type Of Input Input Amperes At Rated Output - Pulsed (GTAW-P), Shielded Width: 12 in 89 lb (305 mm); Height: 17-3/8 in With Input (441 mm) DC At 60% Duty Cycle Single-Phase Input Amperes, 29 Volts DC (See Section 2-2) 225 At 60% Duty Cycle 230, 460, Or 575 Volts AC; 50/60 Hz 230, 460, Or 575 Volts AC; 50/60 Hz 42 A At 230 50.8 A At 230 V, 29 A At 460 V, 23.6 A At 575 V V, 21 A At 460 V, 16.4 A At 575 V 1.2 A At 230 V, 0.6 A At 460 V, 0.6 A At 575 V 1.1 A At 230 KVA/KW Used At Rated 16.1 kVA/1 1.3 kW 12.8 kVA/7.8 kW Amperage Range 5-375 A 5-225 A Max. 80 Volts DC 80 Volts DC Open-Circuit Voltage Welding (40 kg) Input Amperes While Idling (Fan Not Running) Output Metal Arc (3.7 m) With Three-Phase Rated Weld (CC/DC) V, 0.6 A At 460 V, 0.6 A At 575 V OM-2204 Page 1 SECTION 3-INSTALLATION 4~ WARNING HIGH-FREQUENCY RADIATION can interfere with radio and communications equipment. Have only qualified person famitiar with electronic equipment perform this installation. Read and follow entire Section 7 for proper location and installation unit. 3-1. Typical navigation, safety services, computers, requirements for high-frequency equipment before swaml3.1 4/93 Process Connections Work + GTAW Pulse Control Scratch Start Pulsed GTAW Or GTAW + + Figure 3-1. Typical Process Connections OM-2204 Page 3 3-2. Selecting A Location And Moving Welding Power Source WARNING £~ ELECTRIC SHOCK can kill. FUMES can be hazardous; LACK OF FRESH AIR AND PROPER VEN TILATION can be harmful. Do not touch live electncal parts. Disconnect input power conductors from de line BEFORE moving welding power source. Place unit supply FIRE OR EXPLOSION can result from unit on, over, or near com bustible surfaces. welding Do not breathe energized supply only fumes. where there is a good fresh air and proper ventilation. placing Do not locate unit on, over, surfaces. Do not install unit near or near combustible FALLING EQUIPMENT can cause serious personal injury and equipment damage. flammables, Lift unit at handles. Have two persons of unit. BLOCKED AIRFLOW causes over heating and possible damage to unit. Move unit with hand cart If only factory-approved filter. using a fork lift vehicle, skid before Warranty is void if any or similar device of ade quate capacity. Do not block airflow. Use adequate physical strength lift secure unit on a proper transporting. unapproved filter is used. swamll.1 1 Movement Lifting 12/94 Handles Use handles to lift unit. Hand Cart 2 Use cart unit. or 3 Rating Use rating similar device to Label label to determine power needs. 4 input Line Disconnect Device Locate unit er move near correct input pow supply. Location And Airflow 3 in (78 mm) 6 in (156 mm) 3 Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20. 3 in mm) ssb9.15194 -ST-146 123-A/Ref. ST.151 556 Figure OM-2204 Page 4 3-2. Location And Movement Of Welding Power Source 3-3. Selecting And Preparing Weld Output Cables Weld 1 Output Cable Determine total cable length In weld circuit and maximum welding amperes. Use Table 3-1 to select proper cable size. Use shortest cables Do not Terminal 2 possible. damaged use cables. Lug Use lugs of proper amperage capacity and hole size for connect ing to work clamp or electrode holder. 3 Insulated Electrode I-folder 4 GTAW Torch Install according to manufacturers instructions. For Example, Total Cable Length In Weld Circuit 20 ft (6 m) 5 Work Clamp = Install onto work cable. Tools Needed: ~ 6 -r lOft (3 m) Dinse-Type Connector Install onto weld cable Figure 3-4. as sb62 3-3. Figure Selecting And Preparing Output Weld - S~O656 Cables 3~ 2 shown in 5/94 1 Weld 2 Handle 3 Sleeve Output Cable Slide handle onto cable; strip cable and install sleeve. 1 in (26 mm) 5~ 4~ 4 Connector 5 Setscrew Body Insert cable with sleeve connector body, tighten and slide handle over fully into setscrew, connector. If job requires cable larger than 3/0 use 2 ft(610 mm) or shorter piece of 3/0 AWG cable for Dinse Type connector installation. Con AWG, nect other end of short cable to the Tools Needed: 4/0 or larger weld cable. ST.156 496 Figure 3-4. Dinse-Type Connector Assembly Table 3-1. Weld Cable Size* Total Cable 100 ft (30 m) (Copper) Length I 150 ft Or Less (45 m) Welding Amperes 10 To 60% 60 Thru 100% Duty Cycle Duty Cycle In Weld Circuit Not 200 ft I (60_m) 250ft I (70_m) 10 Thru 100% Exceeding 300ft I (90_m) 3~o~ 400ft (105_m) (120_m) 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 1/0 210 3/0 4/0 2-2/0 2-2/0 2-3/0 300 1 1/0 210 3/0 4/0 2-2/0 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 WeId 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. S-0007-D OM-22O4 Page 5 3-4. Connecting To Weld Output Receptacles WARNING 4~ ELECTRIC SHOCK can kill; ARCING burn skin can or damage electrical equipment. Do not touch live electrical parts. Turn Off Do not Be welding power source before making any weld output connections. change position of welding cable connectors while welding. sure connectors are secure in receptacles before welding. swarnl2.2 2/93 1 Positive (+) Weld Output 2 Receptacle Negative () Weld Output Receptacle 3 Connector DC For (DCEP), Electrode Positive connect work cable con negative () nector to receptacle and electrode holder cable DC For (DCEN), 2 con positive (+) receptacle. nector to Electrode cable reverse Negative connec tions. See Figure 3-1 for typical polarity choices. To connect to receptacle, align keyway, insert connector, and turn clockwise until tight. Ref. ST-i 55 091 / Ref. ST-i 53 625 Figure 3-5. Remote 14 ReceptacJe 3-5. Connecting To Weld Output Receptacles RC2 Information And Connections 3 1 Remote 14 Receptacle RC2 (See Table 3-2) 2 Keyway 3 Plug 4 Threaded Collar To connect keyway, to insert receptacle, align plug, and tighten threaded collar. 9 sb7.1 5)94 Figure ST-BOO 829 / Ref. S-0004-A / S-0750 3-6. Remote 14 Connections Table 3-2. Remote 14 Socket Information REMOTE OUTPUT (3~ (CONTACTOR) A The Page Socket Information A 24 volts B Contact closure to A C +10 volts dc D Remote control circuit common. E 0 to +10 volts dc command K Chassis ac. Protected output by fuse F2. completes 24 volts ac contactor control circuit. to remote control. AMPERAGE remaining OM-2204 Socket* 14 sockets 6 are not used. input common. signal from remote control. 3-6. Installing Gas Supply 4~ WARNING CYLINDERS can explode Keep cylinders away from if BUILDUP OF SHIELDING GAS health or kill. damaged. welding and other electrical circuits. Never touch Shutoff harm when not in use. ~ cylinder with welding electrode. Always secure cylinder to running gear, wall, other stationary support. shielding gas supply can or wam4.1 9/Si Obtain gas cylinder and chain to running gear, wall, or other station ary support so cylinder cannot fall and break off valve. 1 Cap 2 Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve. 3 Cylinder 4 Regulator/Flowmeter Install 5 so face is vertical. Gas Hose Connection Fitting has 5/8-18 threads. Obtain and right-hand install gas hose. 2 6 Flow Adjust Typical flow rate feet per hour). Make is 15 cfh (cubic flow adjust is closed opening cylinder to avoid damage to the flowmeter. sure when 3 7 GaslnFitting 8 Gas Out Fithng The Gas In and Gas Out have 5/8-18 Obtain right proper fittings hand threads. size, type, and length hose and make connections as follows: Connect hose from shielding gas supply regulator/flowmeter to Gas In fitting. Connect shielding gas hose from torch to Gas Out fitting. Tools Needed: ~r 5/8, 1-1/8 in ssb3.3 Figure 3-7. 5/94 Ref. ST-i 58 697-A/ Ref. S-0004-A / Ref. ST-i 53 625 / Ref. S-0621 -c Typical Regulator/Flowmeter Installation OM-2204 Page 7 3-7. Connecting Input A~ 1~ Power WARNING ELECTRIC SHOCK HIGH-FREQUENCY RADIATION can interfere with radio navigation, safety services, computers, and communica tions equipment. Have only qualified person familiar with equipment perform this installation. welding power source, and disconnect input power before inspecting or installing. Have only qualified persons install unit. electronic Installation must meet National Electrical Code and all other codes. swam Have System kill. Tum Off Read and follow entire Section 7 for proper location and installation requirements for high-frequency equipment before installing unit. Three-Phase can Do not touch live electrical parts. Single-Phase System 13.2 4/93 only qualified persons make this installation. 1 Rating Label Use single or three-phase, 50/60 input power which matches one of the voltages shown. The AUTO-LINK circuitry senses the input voltage and automatically links the unit for operation. Hz, ac 2 Line Disconnect Device Of Proper Rating 3 Input Power Cord 4 Grounding Conductor Green Or Green With Yellow Stripe(s) Install 9 grounding conductor and input conductors from unit to deen ergized line disconnect device. Connect grounding conductorfirst, input conductors. then line Be sure grounding conductor goes ground. to an earth 5 Black And White Input Con ductor 6 Insulation 7 Electrical 8 Red Sleeving Tape Input Conductor Red conductor not used in singlephase system. Insulate and isolate conductor by sliding insulation sleeving over end of lead, bending lead back, and taping to power cord. 9 Overcurrent Protection Select size using deenergized line disconnect device (fused dis connect switch shown). type and Table 3-3. Install into ssb2.3 Figure OM-2204Page8 3-8. 11/93 Ref. ST-144 221 / Ref. ST-070 399-C / Ref. ST-146 123-A / S-0657 / Ref. S-0092-A Input Power Connections Table 3-3. Electrical Service Guide Three-Phase Input Voltage Input Amperes At Rated 230 460 575 230 460 575 42 21 16.4 50.8 29 23.6 60 30 25 80 40 35 Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Reference: 1993 National Electncal Code (NEC). S-0092J SECTION 4 - OPERATION WARNING AA ELECTRIC SHOCK Always wear Insulate . kill. can yourself from work and Wear ground. ~_~- panels and covers FUMES AND GASES to your health. Keep your securely in place. be hazardous can head out of the fumes. Ventilate area, or use breathing (MSDSs) Safety manufacturers instructions for material used. can cause Do not weld near fire helmet with correct shade of filter. body protection. ~ MOVING PARTS can cause injury. Keep away from moving parts. Keep all doors, panels, securely in place. covers, and guards closed and device. Data Sheets Read Material WELDING welding Wear correct eye, ear, and ~ all ARC RAYS can burn eyes and skin; NOISE can damage hearing. dry insulating gloves. Do not touch live electrical parts. Keep Single-Phase or and I explosion. MAGNETIC FIELDS FROM HIGH CUR RENTS can affect pacemaker operation. Pacemaker wearers keep away. flammable material. Wearers should consult their doctor before Watch for fire; keep extinguisher nearby. Do not locate unit Do not weld on Allow work and over ,~ near arc welding, gouging, or going spot welding opera- tions. combustible surfaces. closed containers. equipment to cool before See Safety Precautions at beginning of manual for ba sic welding safety information. swam6.1 10/91 handling, 10 9 8 2 7. 3 4 6 5 10 Optional AmperageNoltage Meter And Switch ST-146 125~A Figure 4-1. Controls OM-2204 Page 9 1 2 3 / ~ ~ Wear the following 1 Dry, Insulating 2 Safety 3 Welding while welding: Gloves Glasses With Side Shields Helmet With Correct Shade Of Alter (See ANSI Z49.1) s03.i 1/94 Figure 4-2. Safety Equipment Work 1 1 Tools Needed: ~=~==~ Clamp Connect work clamp to a clean, paint-free location on workpiece, . as close to weld area as possible. Use wire brush or sandpaper to clean metal at weld joint area. Use chipping hammer to remove slag after welding. sM.1 2/93 Figure 4-3. Work Clamp 1 Process Selector Switch Use switch to select type of weld output. Use left position for SMAW Welding. Use right position for GTAW Welding with High Frequen cy for arc starting, and center posi tion for GTAW Welding without High Frequency. Switch position determines the op eration of the Arc Force (Dig), Pre flow, and Postf low controls (see Figure 4-6 and Figure 4-9). Ref. ST-i 53 625-A Figure 4-4. Process Selector Switch 1 Amperage Control Use control to select weld amper age. Amperage may be adjusted while welding. Figure OM-2204 Page 10 4-5. Amperage Control Arc Force Control 1 (Dig) This control is used for SMAW welding and only works when Pro (see posi Selector switch is in the SMAW cess Figure 4-4) tion. Use control to make vertical help or start an arc or overhead welds. Control increases amperage at low arc voltage (see Figure 2-1). When set at 0, short-circuit amper age is the same as normal welding amperage. When set at 100, short-circuit amperage increases to help arc starting. Select setting best suited for appli cation. Numbers around control are for reference only. Set control at 0 for GTAW Figure AA 4-6. Arc Force Control welding. (Dig) WARNING ELECTRIC SHOCK can kill. Do not touch live electrical parts. Do not touch weld output terminals when contactor is Do not touch electrode and work clamp energized. at the same time. swaml.1 10191 1 Output (Contactor) Switch Use switch to select way ot control ling output. For front panel control, position. place switch in On For remote output control and to preset amperage using optional digital meter, place switch in Re mote 14 position (see Section 3-5). Weld output terminals are energized when switch Is On and Power is On. Figure 4-7. Output (Contactor) Switch OM-2204 Page 11 Amperage Control Switch 1 Use switch to select way of control ling amperage adjustment. For front panel control, switch in Panel position. For remote control, place switch in Remote 14 position (see Section a 3-5). PANEL Remote control at Remote 14 is percent of front panel ting. A Example: Combinatien Remote 2 Fingertip control set Control 3 Remote Hand Control 4 Remote Foot Control See example below. Amperage Control 175 Z143 place 200 0 PANEL 100~ A 75 ~4~) 4 Unit Mimimum ION (3~ OUTPUT (CONTACTOR) 5 Set Switches A Set Desired Maximum ~ Control c:IiIIII~:~T Setting (200 A) Adjust Remote Control Amperage ST-i 59 059/ S-0769 / S-0774 Figure 4-8. Amperage Control Switch The scale around each control is marked in seconds. 1 Preflow Time Control Use control to adjust the time that gas flows before the welding arc is started. 2 Postf low Time Control Use control to adjust the time that gas flows after the welding arc stops. These controls are for GTAW weld ing and only work when Process Selector switch (see Figure 4-4) is in one of the GTAW positions. 2 Figure OM-2204 Page 12 4-9. Preflow/Postf low Time Controls 1 AmperageNoltage Meter Use meter to read amperage and voltage output. The preset value is displayed when not welding. The actual value is displayed while welding and is held for 15 seconds after welding stops (see Section 5-4). See table for the values for AN switch settings. 2 displayed Meter Switch Use switch to select amperage or voltage display. Meter AN Switch Positions Display When Not When Welding Welding A Preset Amps Actual V Preset Amps Actual Volts Figure 4-10. Amps Amperage/Voltage Meter And Switch (Optional) 1 Power Switch Use switch to turn unit and light On and Off. pilot There is aS second time delay be fore the unit is ready to weld. Fan motor is trolled and is needed. 2 Figure 4-11. Power Switch And Pilot Pilot thermostatically con only runs when cooling Light Light OM-2204 Page 13 WARNING £~ r~J BUILDUP OF SHIELDING GAS Shutoff shielding gas supply harm health can when not in or kill. use. waml.1 9/91 1 Shielding 2 Valve 3 Torch 4 Foot Control Gas Output Open valve welding. Cylinder Control cylinder just before on Torch output control or foot control turns weld output and gas flow on OR and off. Close valve ished on sb5.2 Figure ~S\) )) ) Gas)) Weldin~) Install& Connect ) 4-12. Equipment Shielding Insert Tungsten ) ~ Into Torch }) when f in 5/94 S-0621 -Cf S-0769 Gas ~\ ~\ PutOn Personal Safety Select Tungsten (See Section 8) cylinder welding. Equipment )) Power)) Turn On ) Welding Source etControls~ Turn On Shielding Begin ssb8.1 Figure Install & Connect , ) Equipment ) }} ) Figure ) Sequence Of Connec~ ~\ Install & Pulser Control Unit Set Controls 4-14. )) ) Welding Install & Connect 4-13. Equipment Tungsten ~)) )) Control)) Select Turn On Gas Sequence )) Arc Insert Tunasten ) Tungsten (Se Section8) ~,/) i Shielding Select Electrode Gas lntolbrch Of Gas Tungsten Put On Personal Safety Equipment Arc I )y Begin Put On Personal Safety Equipment WeId~~ Welding Set Controls }) Welding (GTAW) J Turn On Pulsing 12/92 )) Pulsed (GTAW-P) Insert Electrode Into Holder Turn On Source~ ________________ Begin ssb7.1 9/92 Figure OM-2204 Page 14 4-15. Sequence Of Shielded Metal Arc Welding (SMAW) Replace SECTION 5- MAINTENANCE & TROUBLESHOOTING £~ WARNING ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE exists after removal of input power. Do not touch live electrical parts. ~ l~IPi~.~ MOVING PARTS Keep away from can cause Injury. moving parts. Turn Off welding power source, disconnect input power, wait 60 seconds, measure voltage on input capacitors according to Section 5-2, and be sure voltage is near zero before touching any parts. ~pI~ STATIC ELECTRICITY circuit boards. Put on boards HOT PARTS can cause severe Allow cooling servicing. period before burns. maintaining can damage parts on grounded or wrist strap BEFORE handling parts. Use proper static-proof bags and boxes. or Maintenance persons. to be performed only by qualified swam8.3 2/94 Routine Maintenance 5-1. 3 Months ~ Turn Off all power before Section 3 Months ~Replace WARN~ See -~ maintaining. ~j Unreadable Labels Cracked Parts 14/17-Pin Cord Clean ~r 3-4 And ~iii!~~ Tighten Weld Connections ~ Gas Hose -~ Torch Cable 6 Months Blow Out Or Vacuum Inside During Heavy Service, Clean Monthly ST-148 123~A Figure 5-1. Maintenance Schedule OM-2204 Page 15 5-2. Removing Case And Measuring Input Capacitor Voltage ~I_A~aI~~ ~ Significant DC voltage can remain on READ SAFETY BLOCKS at start of Section 5 before proceeding. capacitors is Off. Always check capacitors as shown to be have discharged before working on unit. Turn Off welding power source and disconnect input power. after unit sure 1 they Top Of Case 2 Handles 3 Outside Handle Screws 4 Side Bolts To loosen top, remove two outside handle screws from both handles and all side bolts. 5 Bottom Of Case 6 Mounts To loosen bottom, remove all side bolts, carefully place unit on its side 3 the four mounts. and remove 7 Input Capacitors C12, C13 8 Input Capacitors C8, Locate 9 on C9 lower left side. Voltmeter Check both sets of input capacitors. Measure dc voltage across posi (+) and negative () terminals until voltage drops to near 0 (zero) tive volts. After task is completed, reinstall case. 9 Front Panel (Controls Vary According To 7 Model) Tools Needed: 5/32 in ~ 3/8,7/l6in Ref. ST-I 52 11 4-E Figure OM-2204 Page 16 5-2. Removing Case And Measuring Input Capacitor Voltage 5-3. Overload Protection I~L~W~4~ A. Overheating Figure B. READ SAFETY BLOCKS at start of Section 5 before proceeding. 5-3. Overheating Fuses Turn Off welding power source, disconnect input power, and check voltage on input capacitors ac cording to Section 5-2 before proceeding. 1 Fuse F2 F2 protects the 24 volts ac winding of control transformer T2. If F2 opens, remote control devices connected to Remote 14 recep tacle RC2 shut down. Remove 5-2) top (see Section replace fuse. cover to check and See Parts List for fuse size. Use proper tool when 2 removing fuse. Fuse Holder Tools Needed: ST-146 126-F/Ref. ST-146 122-D Figure 5-4. Overload Protection OM-2204 Page 17 5-4. Changing AmperageNoltage Meter Hold Function READ SAFETY BLOCKS at start of Section 5 before proceeding. AmperageNoltage meter is able to hold the displayed weld out put value for 15 seconds after welding stops. If the hold function is not used, the displayed value The leaves when This welding stops. procedure allows the function to be turned On Turn Off welding or hold Off. power source, input power, and check voltage on input capacitors ac disconnect Section cording to proceeding. before 5-2 1 NV Meter Board PC5 2 DIP Switch S2 S2 is accessible from the left side of the unit. Front Panel (Controls Vary According To Model) Tools Needed: 3 Toggle 1 4 Toggle 2 Set toggles Reinstall in desired position. case. Non-Conductive ST-i 59050-B Figure 5-5. 5-5. Changing Amperage/Voltage Meter Hold Function Troubleshooting WARNING a MOVING PARTS ELECTRIC SHOCK kill. can SIGNIFICANT DC VOLTAGE exists after removal of input power. S can cause injury. Keep away from moving parts. Do not touch live electrical parts. Turn Off welding power source, disconnect input power, wait 60 seconds, measure voltage on input capacitors according to Section 5-2, and be sure voltage is near zero before touching any parts. STATIC ELECTRICITY circuit boards. Put on boards HOT PARTS Allow can cause severe cooling period before can damage parts on burns. grounded or wrist strap BEFORE handling parts. Use proper static-proof bags and boxes. servicing. Troubleshooting to be performed only by qualified persons. swam9.3 2194 Table 5-1. Welding Trouble No weld output; unit completely mop- i -~ Be sure Power switch is On. -~ Be sure line disconnect switch is On. -~ Check line breakers. fuse(s) Check for proper Page Section Remedy Figure 4-11 I erative. OM-2204 Trouble 18 and input replace connections. if necessary. Reset circuit 3-7 3-7 -~ -~ 3-7 Trouble No weld output; fan motor FM and pilot light Section Remedy running on. I I -~ Check position of Output (Contactor) switch. -~ Thermostat TP1 open (overheating). Allow fan to run; thermostat closes when unit has cooled. Low weld output with no Check position of control. Amperage 4-7 5-3A J ]_. Control switch. Factory Authorized Service Station/Service Distributor Have -~ Figure -~ i. Figure 4-8 -~ check control board PCi. Limited output and low open-circuit ~ -~ I voltage. Check open incoming or power for correct voltage. Replace line fuse if -~ 3-7 j reset circuit breaker. _____________ Check for proper ~fatic or improper weld output. Tighten all input and output connections. -~ welding cable connections. Check for proper size and type of cable. Check for proper input Remote device completely inoperative. -~ -~ 3-3,3-4 -~ 3-3 and output connections. -~ Replace electrode. receptacle RC2. 3-5 -~ Check fuse F2 and replace if necessary. Fan motor FM does not I---1 run. Have Factory 3-3, 3-4, 3-7 8-1,8-2 -~ Connect remote control to Remote 14 3-3, 3-4, 3-7 5-3D Authorized Service Station/Service Distributor check thermostats TP2 and/or TP3 and fan motor. ~ -~ I ____________ Wandering arc; poor control ot arc di- rection. i. -~ Reduce flow rate. I Select proper size tungsten. Properly prepare tungsten. Tungsten electrode remaining bright oxidizing and not after conclusion ~. -~ Shield weld zone from drafts. --~ of weld. Increase postflow time. Check and tighten all gas fittings. Water in torch. Refer to torch Owners replacement, Lack of high frequency; difficulty establishing an arc. in 1-.. Be sure and repair torch torch cable is not as near Manual for part(s) requiring any grounded metal. Check work and torch cable for damaged insulation nections, and repair as necessary. No high frequency. or bad con Check position of Process Selector switch. Have check --~ necessary. Factory Authorized Service Station/Service Distributor high frequency board PC2. -~ --~ Figure4-4 -- OM-2204 Page 19 SECTION 6- ELECTRICAL DIAGRAMS 12 U I~7 R~7 ~fP~G18 RC~2-4 RC31-3 ~12-3 I~O-I2 ~~r > CUT ~-< ~314 84 ~. I~ < ~31-2 FC4 FL1~R O/R~G3J ~3V~31 Q~O 42 < ~31-12 ~4AwfG#S ~F I~3O-11 I I Figure OM-2204 Page 20 6-1. Circuit Diagram For 230/460 Volt Models i~1Y 7 ? gp ft~7 3 ~11-e ti ~ ) _3>~- ~11-7 ~11-1t Pc3 ~rt/Ptc1i ~/PLC13 ~-2 ) 9AAW/GAS >0-~O 0 W t7V cTF/G~S cN RC11-~ I ~) ~ ~-1 RC~1~ ~1t~t PGATNE SD-178 777 OM-2204 Page 21 WI LI L2 ClO L3 RC7 PLG7 12 PLOT RC7 R C~) to to a to a to a 4 a to to a a tO a RCA-a PC2/PLO2 RC4/PLO4 RC6/PLOo RCG-2 PCI RC2 B>> PtA ~C<c A>~~fc RC8/PLO8 fl > REF. CON. RCIO-4 PC30/PLO3Q RC3 I /PL133 I IC > c > QCI E ) ~ IN RC 10-2 E 42 cc RC3I-12 RCSO-I0 OUT Rt28/PLO2B 42 CCRC3I-3 Rt4T >>56 PC 12-3 ~ CC 64 1< z a a RC3I-4 RC3O-B>> Ct a ? to tO 0 a a C) C) > RNT. CONTACTOR a 0 0 o to to a UI a a RCI2-9 RC3I-2 60 C RC3I-5 Figure OM-2204 Page 22 a a RC3O-I I>> B PCI 0/PLO 10 PCI 2/PLO 12 PCI 8/PLO I B PC3O-9>> 0 BOARD F 6-2. Circuit Diagram For 460/575 Volt Models PC7/ PLG7 PC2O/ U Gd ~O C4 Ca ca (.1 L Gd U ~ PLG2O U PCI 1-6 PC 11-7 PCI 1/PIGII P~3 SMAW/GAS ~F PCI9-2 RCI3/PL013 PC I 9/PLO 19 I o ~c ~F/GAS £~4 i-c ~VGAS ~ PCI~-I PC 18-6 PCI 8-3 PCI 8-8 PC 10-I PC 12-10 PC 12-Il J SD-hO 4-40 OM-2204 Page 23 SECTION 7- HIGH FREQUENCY mod6.1 5/94 WARNING a HIGH-FREQUENCY RADIATION can interfere with radio and communications equipment. Have only qualified person familiar with electronic The user is installation. responsible If notified the FCC about interference, stop by Have the installation for regularly Keep high-frequency source shown in Figure shielding as having a qualified equipment perform electrician using the promptly equipment navigation, safety services, computers, this installation. correct any interference problem resulting from the at once. checked and maintained. doors and panels tightly shut, keep spark gaps 7-3 to minimize the possibility at correct setting, and use grounding and of interference. 1 Gas 2 High-Frequency Voltage Used to Tungsten help arc between torch and or stabilize the Arc Torch jump air gap workpiece and/ arc. 3 Submerged Arc Welding 4 Flux 5 High-Frequency Voltage Gun Used to Gas Submerged Arc Welding (SAW) Tungsten Arc Welding (GTAW) Figure 7-1. Weldi ng Processes help arc reach workpiece through flux granules. 5-0693 Requiring High Frequency 1 Weld Zone Sources Of Direct High-Frequency Radiation High-frequency source (welding with built-in HF or separate HF unit), weld cables, torch, work clamp, workpiece, and work table. power 2 source Sources Of Conduction Of High Frequency power cable, line disconnect device, and input supply wiring. Input 3 Sources Of Reradiation Of High Frequency Ungrounded metal objects, light ing, wiring, water pipe and fixtures, extemal phone and power lines. S-0694 Figure OM-2204 Page 24 7-2. Sources Of High-Frequency Radiation From Incorrect Installation / / / / Nonmetal \~uilding Metal Building 10 S-0695 1 High-Frequency Built-In HF Or Source Separate (Welder Unit) With HF Ground metal machine case, work output terminal, line disconnect device, input supply, and worktable. 2 Center Point Of Welding Zone Midpoint between high-frequency welding torch. source Welding A circle 50 ft directions. 4 Weld (15 m) from Output 6 Water Bonding Pipe And Fixtures pipe every External Power Or 7 Locate high-frequency (15 m) away from Zone center point in all 9 Electrically join (bond) all conduit sections using copper straps or braided wire. Ground conduit every 50 ft (15 m). Ground water and 3 Conduit Joint 5 8 Metal Building source Panel specifications. Windows And Doorways (15 m). Telephone Lines power and Consult the National Electrical Code for 10 50 ft Grounding Rod at least 50 ft Cover all windows and grounded copper screen 1/4 in (6.4 mm) mesh. doorways of not more with than phone lines. Bonding 11 Overhead Door Track Methods Cables Bolt or weld copper cables short and close toaether. seams, building panels together, install straps or braided wire across and ground frame Figure Ground the track. 7-3. Correct Installation OM-2204 Page 25 SECTION 8- TUNGSTEN ELECTRODE mod2.1 1)94 N OTE ~ For additional information, see your distributor for Tungsten Arc Welding (GTAW) process. Wear clean 8-1. Selecting Tungsten gloves to handbook the Gas on prevent contamination of tungsten electrode. Electrode Table 8-1. Tungsten Size Amperage Range Electrode Diameter a DC Electrode Argon Negative/Straight Polarity - Gas DC Argon Electrode Positive/Reverse Polarity Type - Polarity Argon Using High Frequency AC AC Argon Wave Using Balanced High Freq. Pure Tungsten (Green Band) .010 Uptol5 Uptol5 UptolO .020 5-20 5-20 10-20 .040 15-80 10-60 20-30 1/16 70-150 10-20 50-100 30-80 3/32 125-225 15-30 100-160 60-130 1/8 225-360 25-40 150-210 100-180 5/32 360-450 40-55 200-275 160-240 3/16 450-720 55-80 250-350 190-300 1/4 720-950 80-1 25 325-450 250-400 Upto2O Uptol5 15-35 5-20 2% Thorium Alloyed Tungsten (Red Band) .010 Upto25 .020 15-40 * .040 25-85 * 1/16 50-160 10-20 20-80 20-60 50-150 60-120 3/32 135-235 15-30 130-250 100-180 1/8 250-400 25-40 225-360 160-250 5/32 400-500 40-55 300-450 200-320 3/16 500-750 55-80 400-500 290-390 1/4 750-1000 80-125 600-800 340-525 Upto2O Uptol5 Zirconium Alloyed Tungsten (Brown Band) .010 .020 15-35 5-20 .040 20-80 20-60 1/16 * 50-150 60-120 3/32 * 130-250 100-180 1/8 * 225-360 160-250 300-450 200-320 400-550 290-390 600-800 340-525 5/32 * 3/16 * 1/4 Typical argon shielding gas Not flow rates are 15 to 35 cfh (cubic feet per hour). Recommended. figures listed manufacturers. The OM-2204 Page 26 are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode s-000s 8-2. Preparing Tungsten Tungsten Balled End Electrode Ball end of tungsten before welding by applying either an ac amperage slightly higher than what Is recom mended for a given electrode di ameter (see Table 8-1), or a dc 1E:____ 1 1/2 Times Elect;ode Diameter _______________________ ______________________ 1 2 electrode positive amperage. 2 Ref. S-0161 Figure a ~ 8-1. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding CAUTION FLYING SPARKS AND HOT METAL can cause injury and start fires. Shape tungsten electrode only on gnnder with properguards in a safe location wearing proper face, hand, and body protection. Keep flammables away. warn2.1 9/91 2 1 Tungsten 2 Tapered Electrode End Grind end of tungsten on fine grit, hard abrasive wheel before weld ing. Do not use wheel for other jobs or tungsten can become contami nated causing lower weld quality. 2-1/2 Times Electrode Diameter Ref. S-0161 1 c1~ 1 Stable Arc 2 Flat 2 Diameter of this flat determines amperage capacity. 3 3 Grinding Wheel 4 Straight Ground 4 Ideal Tungsten Preparation Stable Arc 1 2 Ref. S-0182 1 Arc Wander 2 Point 3 Grinding 4 Radial Ground Wheel 3 4 Wrong Tungsten Preparation Figure 8-2. Preparing Tungsten Wandering Arc For DC Electrode Ref. S0162 Negative (DCEN) Welding OM-2204 Page 27 SECTION 9- PARTS LIST c~J 0) LL / -~ U, c~J c1 c~) 1 c~, CU 0 C.) 0) a) LI. C.- F 0 U) 0) ~ ST-146 121-F Figure OM-2204 Page 28 9-1. Main Assembly (208-230/460V Model Illustrated) Quantity Item No. Dia. Model Part No. Mkgs. Description Figure 9-1. Main 208-230/460V Assembly CLAMP~ saddle HANDLE, molded plastic LABEL, caution falling equipment 4 126 415 126416... 138 442... +141 350... 5 +141 574 1 ... 2 3 6 7 2 2 2 2 2 2 CASE 1 1 CASE, bottom 1 1 1 1 1 1 1 1 1 1 C25 SR4 135289... CAPACITOR 149219... KIT, rectifier integ 35A R17 136 191 CAP, protective 136185... RESISTOR 8 9 ... ... vinyl .313 ID x can cause .500 injury Ig ig 9-3... PANEL, front w/components 133405... NUT, speed 10-24 fIat type rectangular 108105... CLAMP, capacitor 2.500dia 136227... STRIP, mtg capacitor bracket 10 11 12 1 1 4 4 4 4 2 2 ... 2 2 ... 2 2 8 8 13 Li -4 133639 14 CHOKE, DVDT 145 245 15 INSULATOR, elctlt 155 642... SCREW, set .250-28 x 1.000 cup pt sch sti 16 17 Ci0,1i ....164812...CAPACITOR 143748... BUS BAR 18 19... C8,9,12,13 ..135 786... CAPACITOR, eIctlt4000uf25OVDC 19... C8,9,12,13... 140 981 CAPACITOR, elctIt2800uf300VDC W1A 157 661 20 INTERLOCK, cntor lEG 2N0-2NC 1OA 4P 158567... LINK, jumper Wi 21 157 660 CONTACTOR, lEG 25A 4P 2N0-2NC contacts 2 2 2 2 4 4 ... ... ... 158 567... LINK, jumper 158 568 LINK, jumper large 131 054... CONNECTOR & SOCKETS, (consisting of) 113746.... CONNECTOR, rect skt 24-l8ga Molex 39-00-0038 CONNECTOR & PINS, (consisting of) 135 635 114 656.... CONNECTOR, rect pin 24-l8ga Molex 39-00-0040 146 112 BLANK, snap-in nyl .2l8mtg hole 158 555 TRANSFORMER, current CABLE TIE, 0-1.750 bundle 020 265 ... PLG21 .... RC21 ... 1 3 1 1 1 1 1 2 2 1 1 2 2 2 ... 22 23 ...24 CT1 ... 1 1 ... 1 1 26 172012...TRANSFORMER,HF 139812... RESISTOR, WW fxd 30W 5K ohm CHASSIS, mid Fig 9-2 27 126 026... 25 Ti R13-16 .... ... LABEL, warning electric shock +161 438... CASE 28 SECTION, front/bottom/back (consisting of) 31 32 32 RC7 33 34 35 36 GS1 T3 40 41 C26 RiB 1 1 1 4 4 4 158559...CABLE,pwrl2ft 1 ... 1 1 1 CABLE, port No. 104/c (orderbyft) 2 TRANSFORMER, control 162 166 TRANSFORMER, control 166 680... CONNECTOR & PINS, (consisting of) 113 633.... CONNECTOR, rect pin 20-l4ga Amp 350218-1 CONNECTOR & SOCKETS, (consisting of) 166679 114066.... CONNECTOR, rect skt 20-l4ga Amp 350536-1 140 894... BRACKE1 mtg stab 605 227... NUT, nyl hex jam .75ONPST 158 583 VALVE, 24VAC 2way custom port 1/8 orf 1 165 658 ... ... 134 383 ... STARTER, pulser HF NUT,speedUtypelo-32 ARC BUS BAR 134421 138 115...CAPACITOR 031 613... 601 394... CAPACITOR, elctlt bOut 15OVDC RESISTOR, C 2W 10K ohm 2 1 ... ... 1 12ff 141 437... STABILIZER ... C7 1 1 4 136190... 38 1 NUT, .312-18 stl insert NUT,1O-32 stl insert 148 329 LABEL, caution incorrect voltage will damage unit 148 330... LABEL, caution incorrect voltage will damage unit 134229... BUSHING, strain relief .640/.770 x 1 .47Omtg hole 152710 Z1 ,2 T2 T2 PLG7 1 4 .... ... 30 1 4 161 135.... 161 136 29 I 460/575V 1 1 12 12 1 1 12 12 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 OM-2204 Page 29 Quantity Item No. Model Part No. Dia. Mkgs. Description Figure 9-1. Main 208-230/460V Assembly (Continued) 49 RESISTOR, WW fxd 40W 500 ohm ENCLOSURE, arc starter (consisting of) 137 198 NUT, insert 10-24 015 712 GROMMET, rbr .625 ID x .875mtg hole 141 690 GROMMET, scr No. 8/10 panel hole .281sq .197 high 134 386 INSULATOR, arc starter 151 248 KIT, circuit card arc starter CONNECTOR & SOCKETS, (consisting of) 146 099 125748.... CONNECTOR, rectskt22-18gaJSTSVH-21T-1.1 CONNECTOR & SOCKETS, (consisting of) 165 884 125748.... CONNECTOR, rectskt22-18gaJSTSVH-21T-1.1 134 327... LABEL, warning general precautionary 133 948 FOOT, mtg 50 143915 134 198 162 960 R6 42 43 I 460/575V 1 1 ... 1 1 2 2 ... .... 44 ... 46 . 1 4 1 1 1 1 ... PC2 PLG5 47 PLG14 ... 1 1 .. 4 4 1 1 .. 3 3 ... .... 48 ... 2 2 4 4 4 4 ... PLG2O .... 115 093 ... ... MOUNT,sglstudl.5diaxl.000Ig.312-l8stud CONNECTOR & SOCKETS, (consisting of) CONNECTOR, rectskt 24-l8ga Molex 39-00-0038 CONNECTOR & PINS, (consisting of) 131 059 114 656.... CONNECTOR, rect pin 24-l8ga Molex 39-00-0040 169 771 SCREW, shld sti hexhd 10-32 x .875 113746.... RC2O .. 1 1 6 6 1 1 6 6 8 8 ... 51 +When 1 4 ... 45 .. ... ordering a component originally displaying a precautionary label, the label should also be ordered. BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. 22 24 17 46 25 26 45 27 44 40 32 34 35 ST-146 122-E Figure OM-2204 Page 30 9-2. Chassis, Mid (208-230/460V Model Illustrated) Quantity Item No. Dia. Model Part No. Mkgs. Description Figure 1 HD1 PLG62 156 313 .... 2 3 PLG11,13 ... .... TRANSDUCER, (Fig 9-1 Item ... GROMMET, No. 8/10 scr 1 panel hole .... CONNECTOR, rect skt 24-1 .312sq 8ga Molex .500 high of) 39-00-0038 131 054... CONNECTOR & SOCKETS, (consisting of) 113 746 CONNECTOR, rect skt 24-l8ga Molex 39-00-0038 .... 4 5 5 010 116... PCi PCi PLG2 GROMME1~ rbr .375 ID x .SOOmtg hole 171 902... CIRCUIT CARD, control 171 907... CIRCUIT CARD, control 131 054... CONNECTOR & 113746.... CONNECTOR, 115 094 PLG6 ... Molex 39-00-0038 CONNECTOR & SOCKETS, .... PLG8,18,28 PLG1O PLG12 ... .... 7 a 9 PC6 PLG1 PLG22 9 R27,28 .... .... 11 ... 137 768 ... TRAY, mtg PC card GROMMET, rbr .750 ID x .B75mtg hole 141 588... STAND-OFF, 8-32 x .500 lg 168 777... CIRCUIT CARD, driver 115 091 CONNECTOR & SOCKETS, (consisting of) 113746.... CONNECTOR, rect skt 24-l8ga Molex 39-00-0038 131 054... CONNECTOR & SOCKETS, (consisting of) 113 746.... CONNECTOR, rect skt 24-1 8ga Molex 39-00-0038 136 076... RESISTOR, WW fxd 30W 200 ohm 072253... STUD, connection single 10-32 x .500 x 1.25Omtg 012 571 HOLDER, fuse mintr *012 654... FUSE, mintr gI 2A ... F2 SN1 14 C40-43 .. D9-12 . . 152776...SUPPRESSOR 152 785... RECTIFIER, si diode LH (consisting 031 689.... CAPACITOR 149 209 KIT, diode fast recovery of) .... TP3 THERMOSTAT, NO 133290.... HEATSINK,rect 072 253.... STUD, connection single 10-32 x .500 x 1 .25Omtg 158 549... IGBT, LH (consisting of) 161 221 IGBT, LH (consisting of) ..157 451 CAPACITOR, polyemetfilm .Oluf 1600V 150 912 KIT, transistor IGBT module 150913.... KIT, transistor IGBT module 123 231 RESISTOR, WW fxd 50W 35 ohm 169402.... HEATSINK,IGBTLH 152 780... BAFFLE, air wind tunnel LH 000 527 BLANK, snap-in nyl .875mtg hole 146581 WINDTUNNEL, 6.500 in 133 295... CHAMBER, plenum 6.500 in 135661 EDGETRIM, style 3100-1/16 (orderbyft) 132 232 MOTOR, fan 220/230V 50/60Hz 3000RPM 131 054... CONNECTOR & SOCKETS, (consisting of) 113 746 CONNECTOR, rect skt 24-l8ga Molex 39-00-0038 086 323.... 15 15 1 3 3 10 10 1 1 2 2 12 12 1 1 2 2 2 2 1 1 2 2 1 1 4 4 1 1 6 6 3 3 8 8 1 1 10 10 1 1 12 12 1 1 1 1 4 1 1 .. 10 1 2 2 1 1 1 1 1 1 1 1 1 1 4 4 4 4 1 1 4 PM1 PM1 R9,i0 16 17 . . .... .... .... ... 18 ... 19 20 ... FM PLG9 ... .... 4 1 1 ... C14,15 21 162 096 ... 10 12 ... .... 6 1 1 1 24-l8ga (consisting of) 113 746.... CONNECTOR, rect skt 24-l8ga Molex 39-00-0038 115 093... CONNECTOR & SOCKETS, (consisting of) 113 746 CONNECTOR, rect skt 24-1 8ga Molex 39-00-0038 115 092 CONNECTOR & SOCKETS, (consisting of) 113 746.... CONNECTOR, rect skt 24-1 8ga Molex 39-00-0038 115 091 CONNECTOR & SOCKETS, (consisting of) 113746.... CONNECTOR, rect skt 24-l8ga Molex 39-00-0038 130 203... CONNECTOR & SOCKETS, (consisting of) 113 746.... CONNECTOR, rect skt 24-1 8ga Molex 39-00-0038 PLG4 460/575V 1 SOCKETS, (consisting of) rect skt I 26) current 300A 163784... CIRCUIT CARD, HF preflow/postf low 130203... CONNECTOR & SOCKETS, (consisting 113 746 PLG19 9-2. Chassis, Mid 130 204... CONNECTOR & SOCKETS, (consisting of) 114 066.... CONNECTOR, rect skt 20-l4ga Amp 350536-1 083 147 PC3 ... 208-230/460V 2 2 1 2 2 1 1 1 1 2 2 1 1 1 1 2ft 2ft 1 1 1 1 2 2 OM-2204 Page 31 Quantity Item No. Dia Model Part No. Mkgs Description Figure 9-2. Chassis, (Continued) RC9 135 635 ... Mid CONNECTOR & PINS, 208-230/460V (Fig 9-1 Item 26) (consisting of) CONNECTOR, rect pin 24-lBga Molex 39-00-0040 155426... KIT, fan blade (consisting of) 134209.... NUT, speed push-on type .250 136 076 RESISTOR, WW fxd 30W 200 ohm 052 964... RELAY, end 24VDC DPDT 114215... CAPACITOR, polye film 2.3uf 25OVAC 146 689 BAFFLE, air wind tunnel RH 158 815 IGBT, RH (consisting of) 114656.... 22 23 24 R27 24 CR1 25 C50 I 460/575V 1 1 2 2 1 1 1 1 1 ... 26 1 1 1 1 ... 161 222... IGB1 27 C16,17 . . 155053.... 158816.... HEAT SINK, IGBTRH 1 169403.... HEATSINK,IGBTRH .... PM2 150 913.... 123 231 .... 149 208.... 006 334.... TP2 VR5 1 (consisting of) 2 150 912.... .... RH CAPACITOR, polye met film .Oluf 1600V KIT, transistor IGBT module KIT, transistor IGBT module RESISTOR, WW fxd 50W 35 ohm KIT, diode pwr module THERMOSTAT, NC THERMOSTAT, NO ..157 451 PM2 All ,12 SRi TP1 133 968 C44-47 . D13-16 . .... .... 149 209 .... . . 133290.... CAPACITOR KIT, diode fast recovery HEAT SINK, rect STUD, connection single 10-32 x .500 x 1 .2SOmtg 601 835... NUT, brs hex 10-32 139 743... INSULATOR, heat sink lower 030 170 BUSHING, snap-in nyl .750 ID x 1 .000mtg hole 145 407... CONTACTOR, def prp 25A 2P 24VAC 145 407... CONTACTOR, def prp 25A 2P 24VAC 152 775... SNUBBER, poly met film .luf 600VDC 072 253.... 29 30 ... 31 W2 31 Wi SN2 32 136190... 1 1 2 2 1 1 1 1 1 1 1 RECTIFIER, si diode RH (consisting of) ... 031 689 1 1 4 4 4 4 1 1 4 4 14 1 1 2 2 1 1 1 6 NUT,speedUtypelo-32 37 1 PANEL, center TRIM, style 62-1/16 (order by ft) 2 153 178 LABEL, warning exploding parts 164 849 MODULE, varistor/capacitor4 400 joule 1620-198OVDC 1 2 126 026... LABEL, warning electric shock 145 053 WASHER, shldr nyl .298 OD x .203 ID x 1.000 x 38 099037... EDGE 39 010 493... 40 006 426... 33 +158 442 1 ift 2 ... VCM1 36 1 ... 2 ... .O62shldr 133 405... 41 C1,2 ..42 132844... 43 158557... 44 158 443... 158444... 46 134058 is ... TRIM, style 62-1/16 (order by ft) BUSHING, snap-in nyl. 625 ID x .875mtg hole CLAMP, capacitor 2.000dia NUT~ speed 10-24 fIat type rectangular CAPACITOR, polyp film 2.luf 1000VDC BUS BAR, interconnecting INSULATOR, heat sink upper STRIP, busrect STAND-OFF SUPPORT, PC card .lS6dia 4 4 ift ift 1 1 2 2 2 2 2 2 1 1 1 1 1 1 2 2 part of 042 517 Optional Meter Kit. *Recommended Spare +When a ordenrig Parts. component originally displaying a precautionary label, the label should also be ordered. BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. OM-2204 6 ... 099 037... EDGE 34 2 1 091 033... VARISTOR 28 PLG8 1 ... 27 Page 32 Item No. Dia. Mkgs. Part No. Description Figure R2 ...2 ...8 073 562 R3 035 897 S5 134 849 S4 134 847 S3 134 848 PC5.... .157011 PLG5O 089 222 .134 058 .158 563 136 339 120 304 148 297 Si PLG3.... 128 756 131 054 113 746 RC3 135 635 114 656 11 146 684 R4,5 121 770 RC2 143 976 079 534 9-3. Panel, Front w/Components (Fig Quantity 9-1 Item 10) POTENTIOMETER, C std slot l/T 2W 10K ohm POTENTIOMETER, C std slot liT 2W 1K ohm SWITCH, tgl DPDT 15A 125VAC SWITCH, tgl SPDT 15A 125VAC 1 1 1 1 1 SWITCH, tgl DPDT 15A 125VAC 1 CIRCUITCARD, meter 1 CONNECTOR, rect llskt plug Amp 1-640440-1 STAND-OFF SUPPORT, PC card .l56dia 4 1 STRIP, protector PC card 1 COVER, opening meter (not used when unit has Meter Kit) BLANK, snap-in nyl .25Omtg hole (not used when unit has Meter Kit). 1 2 NUT, speed U type 10-32 1 SWITCH, tgl 3PST 40A 600VAC CONNECTOR & SOCKETS, (consisting of) 1 2 CONNECTOR, rect skt 24-1 8ga Molex 39-00-0038 CONNECTOR & PINS, (consisting of) 1 2 CONNECTOR, rect pin 24-l8ga Molex 39-00-0040 1 INSULATOR, switch power POTENTIOMETER, C sltd sft l/T 1W lOOK ohm CONNECTOR w/SOCKETS, (consisting of) CONNECTOR, circ skt push-in 14-l8ga Amp 66358-6 2 1 14 ST-146 120-C Figure 9-3. Panel, Front w/Components OM-2204 Page 33 Item No. Dia. Part No. Mkgs. Figure 9-3. Panel, (Continued) 1 129525 RECEPTACLE, twlk insul fem (Dinse type) 50/70 series CONNECTOR KIT, Dinse male 50 series (consisting of) WRENCH, hex 5mm short HOSE, SAE .187 ID x .41000 (order by ft) FITTING, gas CONNECTOR, circ protective cap Amphenol 9760-20 NAMEPLATE, (order by model and serial number) KNOB, .l25dia shaft w/.125 setscrews 2 115440 PC4 166064 130 203 .. C6 ... 042418 134746 18 134834 19 120854 20 039885 22 093551 PL1 157958 24 097924 ...25 135299 097922 Part of 042 517 10) CAPACITOR 143922 14 23 9-1 Item 138115 079 739 Pos,Neg w/Components (Fig 113746 134731 16 ..17.... Front CONNECTOR, circ 14 pin plug Amp 213571-2 CONNECTOR, circ pin push-in 14-l8ga Amp 21 3603-1 CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2 (or) CONNECTOR, circ clamp str rlf sz 17-20 Amp 206070-3 STAND-OFF, 6-32 x .687 Ig CIRCUIT CARD, receptacle bypass CONNECTOR & SOCKETS, (consisting of) CONNECTOR, rect skt 24-l8ga Molex 39-00-0038 134734 PLG3O,31 Quantity Description Optional LIGHT, KNOB, LOCK, KNOB, md wht lens 28V 12 2 1 2ft 1 1 1 2 1 x .25Odia shaft pointer Meter Kit. BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. OM-2204 Page 34 1 2 1 pointer shaft knob .375-32 4 1 1 NOTES OPTIONS AND ACCESSORIES lNTELLITIG~ 4 PRECISION Frequency: Adjust TIG CONTROLLER within (#042 598) high-frequency arc starting, timed gas solenoid control and metering, pulsing, sequencing, sloping, on-screen voltage and amperage metering, and two relay contacts for fixturing. The control provides four modes of operation: second to 200 Automatic, Semiautomatic, Manual wave GTAW and SMAW. For detailed information, refer to product power Literature Index No. AY/9.0. the electrode PC-300 PULSED GTAW the Provides be use with an pulses-per- Amphenol plug. Pulse Width: of on Adjust the amount time. Maintains stability. Adjusts arc from 1 to 5 milliseconds. Peak Current Level: Set the amperage that the pulse form will allow (25% to peak source). Helps pinch or droplet. second scale for both inverter and non-inverter type power sources, and a 10 to 300 pulses-per-second scale for inverter power sources precision pulse variety of wire sizes, gases, materials, and joint a (7.6 m) connector 17-pin plug for direct performance, the XMT on 200 Control includes 8 ft. (2.4 m) when using or panel controls provide: do not 208 pnma,y run voltage this accessoty. REMOTE CONTROLS scale RHC-14 HAND CONTROL pulses-per-second scale) Percent On Time Control Remote/Panel Control Amperage Output Contactor On/Off Control (#129 339) 14-pin plug. (#129 340) (102 mm) Includes 20 x 230 or 460 VAC on 230 or 460 VAC 8 Pak Rack houses 66 in. (1.68 m) wide x (1.04 m) deep x 72 in. (1.83 m) tall, and weighs 1700 lbs. (771 kg) when loaded with eight XMTs (with no welding cables). The 4 Pak Rack measures 66 in. (1.68 m) wide x 41 in. (1.04 m) deep x 57 in. (1.45 m) tall, and weighs just 800 lbs. (363 kg) with four XMT 300 units. (102 mm) x 4 3-1/4 in. (82 mm). ft. (6 m) cord and 575 VAC (#042 812) The XMT Rack Power On/Off Receptacle (for controls) on current and contactor control. Dimensions: 4 in. or (#042 648) Miniature hand control for remote Pulser On/Off Remote Control rugged 460 measures Foot current and contactor control. Includes 20 ft. (6 m) cord and 10 to 300 The operation on 41 in. Amperage Adjustment Background Amperage Adjustment Pulses-Per-Second Adjustment (0.5 to 20 pulses-per-second or operation (#042 813) and powers up to eight XMT 300 power sources. The rack RFC-14 FOOT CONTROL Peak operation 8 Pak Rack For cord and 115 VAC power cord. Front For 4 Pak Rack source. Note: For best only. XMT RACK For connection to the front of the power 14-pin Amphenol plug to a 14-pin Amphenol socket. lOft. (3 m) (#122 972) 25 ft. (7.6 m) (#122 973) 50 ft. (15.2 m) (#122 974) 75 ft. (22.8 m) (#122 975) 8 Pak Rack Includes 25 ft. a REMOTE CONTROLS AND wide configurations. cord and (#151 086)14-pin plug Rotary motion fingertip control fastens to TIG torch using two Velcro straps. Includes 28 ft. (8.5 m) control cord. 24 VAC WIRE FEEDERS This control allows welding with RCC-14 REMOTE CONTACTOR AND CURRENT CONTROL EXTENSION CORDS FOR off source). external for momentary contact. Includes 20 ft. (6 m) cord and 14-pin second. Background Current Level: Set background current level to sustain the arc (3% to 25% of high-frequency unit. The control has two internally switchable scales: a 0.5 to 20 pulses-per- interconnecting rate maximum output of power Can be used with power sources that have built-in high frequency, can pulse 100% of maximum output of (DC TIG) CONTROL (#042 297) it the range of 20 pulses-per- a in. 14-pin plug. remote hand or foot provides many important features: Two 115 VAC, 20 Amp GFCI duplex receptacles for auxiliary tools (8 Pak Racks only) Provisions for paralleling power TORCH-MOUNTED REMOTE HAND CONTROLS connections The MMP Manual MIG Pulser RMLS-1 4 down to prevent theft Captured secondary cable Control allows manual control of MMP MANUAL MUG PULSER PENDANT CONTROL (#042 727) sources or common Power pulse wave form. This control provides independent control of (#129 337) Momentary- and cables maintained-contact rocker switch Center the four for contactor control. Push forward the pulse parameters that affect the process: for maintained contact and back sources can work be locked hangers for work leads and weld lifting eye Rugged skids for dragging pushing or OPTIONS AND ACCESSORIES XMT ECONOMY CART (#134 505) lightweight. Small and convenient controls. Radiator, Watermate~, Slanted for front panel Storage compartment for access to gloves, helmet, operator or CooImate~ coolant systems. etc. to read actual weld values welding is stopped. Weld setting is held for 15 seconds before meter is automatically after UNIVERSAL CARRYING CART AND CYLINDER RACK are easy to read in outdoor environment. cleared. Meters (#042 934) Accommodates any XMT power indoor or XMT WIRE FEEDER QUICK source, plus gas cylinder up to 56 (142.2 cm) high measuring 6 to 9 inches (15.2 to 22.8 cm) in diameter. Also provides storage for auxiliary items such as electrodes, helmets, gloves, etc. Can also be used with Econotig~, Maxstarfi XMT INVERTER POWER DISCONNECT in. SOURCES VIDEOTAPE Series, Millermaticfi 130 and MILLER EXPERT PROGRAM~ Millermaticfi 150 power (#042 623) Easy-to-use computerized (#042 491) Attaches S-21 E feeder to XMT or S-22A wire case. XMT CYLINDER CART (#042 537) adjustable handles Has slanted for convenient and is access to power source front Carries two 160 lb. panel controls. (72.6 kg) gas cylinders, or one gas cylinder and one coolant system for GTAW (TIG) welding. Feeder mounted to tray above power source. Can be used with the Maxtron~, Miller Arc Pak~ or supplies. XMl inverter power Also accommodates INTERNATIONALSTYLE All XMT power BACK-LIT LCD DIGITAL (#042 518 Field) presettability and real time display of voltage and amperage. Presetting welding current and voltage helps to provide optimum welding conditions. Meters feature Allows a hold function that allows CONNECTOR KIT mm Accepts #1 or #2 AWG cable size. Required if male plugs shipped with power source must be replaced, if additional plugs needed. size cable is to be used. Kit includes male plug one International-style which attaches to the work and/or weld cables and into the International receptacles on plugs style the power source. sources. source. For detailed information, reference Miller Expert Program Literature Index No. AV/6.0. Note: The serial number of the power source and diskette size (5-1/4 or 3-1/2 in.) specified when ordering any Expert Program diskette. must be INTERNATIONAL-STYLE CABLE power source) on one end and Cam-Lok receptacle (for weld CONNECTORS cable Used to adapt and/or work cables. Kit includes one connection) on a other end. extend weld or INTERNATIONALJTIG TORCH male International-style plug CONNECTOR and one International-style receptacle. (#042 419) 50 mm Accepts #1 or #2 AWG size cable. (#042 534) 70 mm Accepts #1/0 or #2/0 AWG size cable. ADAPTER (#042 465) one-piece adapter which has an International-style male plug (to power source) on one end and a female Tweco receptacle (for weld cable connection) on other end. INTERNATIONAL/CAM-LOK direct connection of torches with a or air-cooled one-piece cable assembly. Kit includes gas hose, gas hose and International-style TIG fitting, Block. (#135 492) Amp, air-cooled torch one-piece cable assembly. with (#135 493) For 150 with (#135 494) Amp, air-cooled torch one-piece cable assembly. with Amp, air-cooled torch one-piece cable assembly. For 200 (#135 495) ADAPTER (#042 466) A one-piece adapter International-style Required for water-cooled torches For 80 A (#042 533) 70 mm Accepts #1/0 or #2/0 AWG cable size. Required if #1/0 or #2/0 AWG inverter power Miller INTERNATIONAL/TWECOfi are videotape family of the XMT CONNECTORS (will accept DinseTM or other International connectors.) in-line female INTERNATIONAL-STYLE describing software program used to diagnose and service the power METERS EXTENSION KIT FOR sources are equipped with Internationalstyle connectors for secondary connections. (Power source is shipped with two -50 mm male International-style plugs for use with #1 or #2 AWG size cable.) (#042418)50 sources. (#137 760) An 8 minute VHS Amp, water-cooled one-piece cable For 250/300 which has male plug (to an torch with assembly. 9n4