maxtron 450 (kc237305)

February 1997 Form: TM-2206

Effective With Serial No. KC237305

TECHNICAL MANUALService And Parts

cover_tm 4/95 – ST-150 171-B PRINTED IN USA 1997 MILLER Electric Mfg. Co.

Maxtron 450CC/CV DC Welding Power Source For GMAW, GTAW, SMAW, FCAW, CAC-A, GMAW-P, GTAW-P, And SAW Welding

InputPower

Rated WeldingO tp t

VoltageRange In

AmperageRange In

MaximumOpen-Circ it

Amperes Input At Rated LoadOutput 60 Hz, Three-Phase

Power OutputRange InCV Mode

Range InCC Mode Circu it

Voltage DC 230 V 460 V 575 V KVA KW

ThreePhase

450 A @ 38 VoltsDC, 100% Duty

Cycle; 565 A,43 Volts DC,

60% Duty Cycle

10 – 38 5 – 565 80 72(2.0)*

36(1.0)*

29(0.8)*

28(0.23)*

20(0.17)*

SinglePhase

325 A @ 33 VoltsDC, 100% Duty

Cycle; 325 A,33 Volts DC,

60% Duty Cycle

10 – 38 5 – 325 80 89.6(2.0)*

47.2 (1.0)*

37.7(0.8)*

18(0.23)*

13(0.17)*

*While idling

OM-2206G-4/96/SPM-2206B-2/95

� CALL:Miller Customer ServiceDepartment at414-735-4505

WHO DO I CONTACT FOR HELP?� FAX:

414-735-4136� WRITE:

Miller Electric Mfg. Co.P.O. Box 1079Appleton, WI 54912 USA

Always provide Model Name and Serial or Style Number

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Servicing Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. EMF Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – INSTALLATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Selecting A Location 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Dimensions And Weights 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Weld Output Terminals And Selecting Cable Sizes 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4. Voltage Sensing Terminal Connections 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Remote 14 Receptacle Information 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6. Remote 17 Receptacle Information 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7. 115 Volt AC Duplex Receptacle 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8. Electrical Service Guide 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9. Placing Jumper Links 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10. Connecting Input Conductors To Unit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11. Connecting Input Power 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – OPERATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Controls 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Process Switch Settings 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Duty Cycle And Overheating 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – THEORY OF OPERATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – PRE-POWER CHECKLIST 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Checking Unit Before Applying Power 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – TROUBLESHOOTING 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Troubleshooting Table 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Troubleshooting Circuit Diagram For Welding Power Source 24. . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Waveforms For Section 6-2 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4. Control Board PC1 Testing Information (Use With Section 6-5) 28. . . . . . . . . . . . . . . . . . . . . . . 6-5. Control Board PC1 Test Point Values 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6. Digital Meter Board PC5 Testing Information (Use With Section 6-7) 31. . . . . . . . . . . . . . . . . . . 6-7. Digital Meter Board PC5 Test Point Values 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8. Digital Meter Calibration 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9. Optional MMP Board PC7 Testing Information (Use With Section 6-10) 34. . . . . . . . . . . . . . . . 6-10. Optional MMP Board PC7 Test Point Values 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11. Optional Optima Board PC7 Testing Information (Use With Section 6-12) 35. . . . . . . . . . . . . . 6-12. Optional Optima Board PC7 Test Point Values 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13. Remote 14 Filter Board PC8 Testing Information (Use With Section 6-14) 36. . . . . . . . . . . . . . 6-14. Remote 14 Filter Board PC8 Test Point Values 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – MAINTENANCE 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Routine Maintenance 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Measuring Input Capacitor Voltage 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Optional Ground Current Sensor 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. Circuit Breakers And Fuses 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 – ELECTRICAL DIAGRAMS 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 – PARTS LIST 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TM-2206 Page 1Maxtron 450

SECTION 1 – SAFETY PRECAUTIONS FOR SERVICINGsafety_stm1 4/95

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with thisprocedure! The possible hazards are shown in the adjoining symbols.

This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVINGPARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessaryactions to avoid the hazards.

� Marks a special safety message.

� Means NOTE; not safety related.

1-2. Servicing Hazards

ELECTRIC SHOCK can kill.1. Do not touch live electrical parts.

2. Stop engine or turn OFF welding power sourceand wire feeder, and disconnect and lockout inputpower using line disconnect switch, circuitbreakers, or by removing plug from receptaclebefore servicing unless the procedure specificallyrequires an energized unit.

3. Insulate yourself from ground by standing orworking on dry insulating mats big enough toprevent contact with the ground.

4. Do not leave live unit unattended.

5. When testing a live unit, use the one-handmethod. Do not put both hands inside unit. Keepone hand free.

6. Disconnect input power conductors fromdeenergized supply line BEFORE moving awelding power source.

SIGNIFICANT DC VOLTAGE exists afterremoval of input power on inverters.7. Turn Off inverter, disconnect input power, and

discharge input capacitors according toinstructions in Maintenance Section beforetouching any parts.

STATIC ELECTRICITY can damage partson circuit boards.1. Put on grounded wrist strap BEFORE handling

boards or parts.

2. Use proper static-proof bags to store, move, orship PC boards.

FIRE OR EXPLOSION can result fromplacing unit on, over, or nearcombustible surfaces.1. Do not place unit on, over, or near combustible

surfaces.

2. Do not service unit near flammables.

FLYING PIECES OF METAL or DIRT caninjure eyes.1. Wear safety glasses with side shields or face

shield during servicing.

2. Be careful not to short metal tools, parts, or wirestogether during testing and servicing.

HOT PARTS can cause severe burns.

1. Do not touch hot parts bare handed.

2. Allow cooling period before servicing welding gunor torch.

EXPLODING PARTS can cause injury.

1. Failed parts can explode or cause other parts toexplode when power is applied to inverters.

2. Always wear a face shield and long sleeves whenservicing inverters.

ELECTRIC SHOCK HAZARD fromincorrect use of test equipment.

1. Turn Off welding power source and wire feeder orstop engine before making or changing meter leadconnections.

2. At least one meter lead should be a self-retainingspring clip such as an alligator clamp.

3. Read instructions for test equipment.

HIGH-FREQUENCY RADIATION caninterfere with radio navigation, safetyservices, computers, andcommunications equipment.

1. Have only qualified persons familiar withelectronic equipment perform this installation.

2. The user is responsible for having a qualifiedelectrician promptly correct any interferenceproblem resulting from the installation.

3. If notified by the FCC about interference, stopusing the equipment at once.

4. Have the installation regularly checked andmaintained.

5. Keep high-frequency source doors and panelstightly shut, keep spark gaps at correct setting,and use grounding and shielding to minimize thepossibility of interference.

The symbols shown below are used throughout this manual to call attention to and identify possiblehazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard.

Only qualified persons should service, test, maintain, and repair this unit.

During servicing, keep everybody, especially children, away.

WARNING

TM-2206 Page 2 Maxtron 450

FALLING EQUIPMENT can causeserious personal injury and equipmentdamage.1. Use lifting eye to lift unit only, NOT running gear,

gas cylinders, or any other accessories.

2. Use equipment of adequate capacity to lift unit.

MAGNETIC FIELDS FROM HIGHCURRENTS can affect pacemakeroperation.1. Pacemaker wearers keep away from servicing

areas until consulting your doctor.

MOVING PARTS can cause injury.1. Keep away from moving parts such as fans.

2. Keep all doors, panels, covers, and guards closedand securely in place.

MOVING PARTS can cause injury.1. Keep away from moving parts.

2. Keep away from pinch points such as drive rolls.

OVERUSE can cause OVERHEATEDEQUIPMENT.1. Allow cooling period.

2. Reduce current or reduce duty cycle beforestarting to weld again.

3. Follow rated duty cycle.

READ INSTRUCTIONS.1. Use MILLER Testing Booklet (Part No. 150 853)

when servicing this unit.

2. Consult the Owner’s Manual for welding safetyprecautions.

3. Use only genuine MILLER replacement parts.

1-3. EMF Information

Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsThe following is a quotation from the General Conclusions Sectionof the U.S. Congress, Office of Technology Assessment, BiologicalEffects 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 verylarge volume of scientific findings based on experiments at thecellular level and from studies with animals and people which clearlyestablish that low frequency magnetic fields can interact with, andproduce changes in, biological systems. While most of this work is ofvery high quality, the results are complex. Current scientificunderstanding does not yet allow us to interpret the evidence in asingle coherent framework. Even more frustrating, it does not yetallow us to draw definite conclusions about questions of possiblerisk or to offer clear science-based advice on strategies to minimizeor avoid potential risks.”

To reduce magnetic fields in the workplace, use the followingprocedures:

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 the body.

4. Keep welding power source and cables as far away aspractical.

5. Connect work clamp to workpiece as close to the weld aspossible.

About Pacemakers:

The above procedures are also recommended for pacemakerwearers. Consult your doctor for complete information.


SECTION 2 – INSTALLATION

2-1. Selecting A Location

1 Lifting Eye

2 Lifting Forks

Use lifting eye or lifting forks tomove unit.

If using lifting forks, extend forksbeyond opposite side of unit.

3 Rating Label

Use rating label to determine inputpower needs. Label is on name-plate.

4 Line Disconnect Device

Locate unit near correct input pow-er supply.

� Special installation may berequired where gasoline orvolatile liquids are present –see NEC Article 511 or CECSection 20.

4

18 in(460 mm)

OR

1

2

Movement

Location

ST-800 611 / ST-150 171-C

3

2-2. Dimensions And Weights

DimensionsDimensions

CD

Height 23 in (584 mm)

6 HolesCD

Width 15-1/2 in (394 mm)

Depth 26-1/8 in (664 mm)

BA

A 24-1/16 in (611 mm)

BA

B 20-3/4 in (527 mm)

C 12-3/8 in (314 mm)

D 9/32 in (7 mm) Dia

Weight

165 lbs (75 kg)


2-3. Weld Output Terminals And Selecting Cable Sizes

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less 150 ft(45 m)

200 ft(60 m)

250 ft(70 m)

300 ft(90 m)

350 ft(105 m)

400 ft(120 m)

Weld OutputTerminals

WeldingAmperes

10 – 60%DutyCycle

60 – 100%DutyCycle

10 – 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

N ti

400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

Positive (+)

Negative(–) 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

800 4/0 2-2/0 2-3/0 2-4/0 3-4/0 3-4/0 4-4/0 4-4/0

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. S-0007-D

2-4. Voltage Sensing Terminal Connections

The voltage sensing terminals pro-vide exact voltage measurement atthe welding arc.

1 Positive (+) Voltage SensingTerminal

2 Negative (–) Voltage SensingTerminal

3 Receptacle

4 Proper Plug (Not Supplied)

5 18 Gauge Lead (Not Sup-plied)

6 Nut

7 Lead Hole

For Electrode Positive (DCEP),connect remaining end of negative(–) terminal lead to work. Connectremaining end of positive (+) termi-nal lead to weld cable conductor atelectrode holder end of weld cable.

For Electrode Negative (DCEN),reverse terminal lead connections.

Ref. ST-152 069-C / Ref. ST-152 885-A

1

2

3

Tools Needed:

+ –

6 7

5

Strip 1/2 in (13 mm)insulation

Or

3

4

5


2-5. Remote 14 Receptacle Information

Socket* Socket Information

24 VOLTS ACA 24 volts ac. Protected by circuit breaker CB2.

A JB

K I

C L N H

24 VOLTS AC

B C o n t a c t c l o s u r e t o A c o m p l e t e s 2 4 v o l t s a c c o n-t a c t o r c o n t r o l c i r c u i t .

C L N H

D M GE F

115 VOLTS ACI 115 volts ac. Protected by circuit breaker CB1.

E F115 VOLTS AC

J Contact closure to I completes 115 volts ac con-tactor control circuit.

REMOTE

C Output to remote control; +10 volts dc in CV, 0 to+10 volts dc in CC.

REMOTEOUTPUT

CONTROLD Remote control circuit common.

CONTROLE 0 to +10 volts dc input command signal from re-

mote control.

A/VAMPERAGE

F Current feedback; +1 volt dc per 100 amperes.

ST-800 617

AMPERAGEVOLTAGE H Voltage feedback; +1 volt dc per 10 arc volts.

GNDG Circuit common for 24 and 115 volts ac circuits.

GNDK Chassis common.

*The remaining sockets are not used.


2-6. Remote 17 Receptacle Information

REMOTE 17 Socket* Socket Information

D Contactor on/off signal; +13 to +24 volts dc con-tactor On, 0 volts dc contactor Off.

A +10 volts dc output to remote control.

B MC N LD R S K

J

P T

A

REMOTE

B 0 to +10 volts dc input command signal from re-mote control; full control of A/V output from re-mote control.

D R S K

EG

J

F H

REMOTEOUTPUT

CONTROLH +24 volts dc; fused at 1 ampere.GF CONTROL

K 0 to +10 volts dc set by panel A/V control; remotecontrol percent of panel A/V control.

L –24 volts dc; fused at 1 ampere.

METER

E Current feedback; +1 volt dc per 100 amperes.

METERM Voltage feedback; +1 volt dc per 10 arc volts.

CV/CC C CV/CC select; +13 to +24 volts dc selects CV, 0volts dc selects CC.

ST-800 617

ARCCONTROL

G Arc force (dig)/inductance control; 0 to +10 voltsdc set by panel Arc Force (Dig)/Inductance con-trol.

F Circuit common for sockets A, B, D, E, K, and M.

GND P Circuit common for sockets H and L.

S Chassis common.

*The remaining sockets are not used.

2-7. 115 Volt AC Duplex Receptacle

Ref. ST-153 999

1 115 Volt AC Duplex Recep-tacle RC10

This receptacle supplies up to 10amperes of 115 volt ac power.

This receptacle has GFI (GroundFault Interrupters). If a ground cur-rent is sensed at RC10, output toRC10 stops. Check tools con-nected to RC10 for damage, andpress Reset button.

Power output is shared betweenthis receptacle and the Remote 14receptacle (see Section 2-5).

1


2-8. Electrical Service Guide

Three-Phase Single-Phase

Input Voltage 230 460 575 230 460 575

Input Amperes At Rated Output 72 36 29 89.6 47.2 37.7

Max Recommended Standard Fuse Or CircuitBreaker Rating In Amperes

110 50 40 125 60 45

Min Input Conductor Size In AWG/Kcmil 4 8 10 4 8 8

Max Recommended Input Conductor Length In Feet (Meters)

179 (54) 309 (94) 322 (98) 160 (49) 277 (85) 433 (132)

Min Grounding Conductor Size In AWG/Kcmil 6 10 10 6 10 10

Reference: 1993 National Electrical Code (NEC). S-0092J

2-9. Placing Jumper Links

Ref. ST-150 172-D

� Turn Off welding powersource, disconnect inputpower, and check voltage oninput capacitors accordingto Section 7-2 before pro-ceeding.

Check input voltage available atsite.

Remove side panel.

1 Jumper Link Label

2 Jumper Links

Move jumper links to match inputvoltage, and label on unit.

Continue to Section 2-10, or rein-stall side panel.

Tools Needed:

3/8 in

1

2

230 VOLTS

S-155 568

460 VOLTS

460 VOLTS

S-157 126

575 VOLTS

Do not overtighten.


2-10. Connecting Input Conductors To Unit


1 Input And Grounding Con-ductors

See Section 2-8.

2 Strain Relief Connector

Obtain and install. Hole in rear pan-el is 1-3/4 in (44 mm).

3 Reed Relay (Ground CurrentSensor – Optional)

If unit is equipped with optionalground current sensor, routegrounding conductor through reedswitch two times and connect togrounding terminal as shown.

Reinstall side panel(s).

ssb2.4* 1/94 – ST-150 172-D / ST-156 172-D

Tools Needed:

7/16 in

3/8 in

1

3

For Standard Units

For Units With Optional Ground Current Sensor

1

Terminal Block TE2

L1L2L3

Connect to L1, L2, L33Connect to L1, L21

L1

L2

L3

2

Terminal Block TE2

L1L2L3

Connect to L1, L2, L33Connect to L1, L21

L1

L2

L3

2

=GND/PE

� Always connect groundingconductor first.

=GND/PE



L1

2-11. Connecting Input Power

input_2 – 3/96 / Ref. ST-144 221 / Ref. ST-070 399-C / ST-150 171-C

1 Input And GroundingConductors

2 Line Disconnect Device

See Section 2-8.

22

1

1

1

L2

L3

L1

L2


13

= GND/PE

Tools Needed:


SECTION 3 – OPERATION

3-1. Controls

1 Power Switch2 Digital MetersWhen the contactor is not energized, presetamperage is displayed in SMAW and GTAWmodes, and preset voltage is displayed inGMAW mode.3 Amperage/Voltage Adjustment ControlControl adjusts voltage with process switchin GMAW position, and adjusts amperage inSMAW and GTAW positions.This is a ten turn control. When contactor isnot energized, control presets output.4 Process SwitchSwitch selects type of weld output. UseSMAW position for SMAW. Use GTAW posi-tion for GTAW, GMAW-P, and CAC-A. UseGMAW position for GMAW, and FCAW.5 Amperage/Voltage Control Switch

For front panel control, place switch in Pan-el position. For remote control, place switchin Remote 14 position (see Section 2-5), orRemote 17 position (see Section 2-6), andconnect remote device.6 Output (Contactor) Control SwitchFor front panel control of output, placeswitch in On position. For remote control ofoutput, place switch in Remote 17/14 posi-tion, and connect remote device (see Sec-tions 2-5 and 2-6).

� Weld output terminals are energizedwhen Output switch is On and Poweris On.

7 Arc Force/Inductance Control SwitchSwitch selects panel or remote control ofarc force/inductance.8 Dig/Inductance Control

With process switch in SMAW position, con-trol increases short-circuit amperage whichallows the operator to use a very short arclength without sticking the electrode. Whenset towards 0 (zero), short-circuit amperageat low arc voltage is the same as normalwelding amperage. When set towards 100,short-circuit amperage is increased at lowarc voltage.

Control adjusts inductance with processswitch in GMAW. Inductance determinesthe “wetness” of the weld puddle. When settowards 100, “wetness” (puddle fluidity) in-creases.

This control is not functional with processswitch in GTAW.

Numbers around control are for referenceonly.

Ref. ST-152 069-D

1 2 3 4

5

6

7

8


3-2. Process Switch Settings

Ref. ST-165 852-B

Shielded Metal Arc (SMAW) Welding;

Panel Amperage Control

Tungsten Inert Gas (GTAW) Welding;

Remote Amperage Control

Gas Metal Arc (GMAW) Welding;

Remote Voltage Control

Gas Metal Arc (GMAW) Welding With

60M Series Wire Feeder

For remote control,place A/V switch inRemote 14 position,

and Output (Contactor)switch in Remote

17/14 position.

For panel control,place A/V switch inPanel position, andOutput (Contactor)

switch in On position.

For panel control ofvoltage, place A/V

switch in Panel position.

3-3. Duty Cycle And Overheating

Duty Cycle is percentage of 10minutes that unit can weld at ratedload without overheating.

If unit overheats, thermostat(s)opens, output stops, and coolingfan runs. Wait fifteen minutes forunit to cool. Reduce amperage orduty cycle before welding.

� Exceeding duty cycle candamage unit and void war-ranty.

Overheating0

15

A/V

ORReduce Duty CycleMinutes

duty1 4/95 / ST-145 897

Continuous Welding

100% Duty Cycle At 450 Amperes, Three-Phase;325 Amperes, Single-Phase

60% Duty Cycle At 565 Amperes, Three-Phase;No Increase Beyond 325 Amperes For Single-Phase

6 Minutes Welding 4 Minutes Resting


1 Input Terminal Board TE1And Input Terminal Block TE2

TE1 links welding power source forcorrect input voltage and TE2 con-nects line input power.

2 Power Switch S1

Provides on/off control of weldingpower source.

3 Precharge Resistors R1 AndR19

Allow initial charge of buss capaci-tors C8, C9, C10, C11, C12, C13,C18, and C19 through input rectifi-er SR1 and power switch S1 beforecontactor W1 is energized.

4 Contactor W1

Enables precharge network R1,R19, and S1 and connects inputrectifier SR1 to the input line.

5 Input Rectifier SR1

Changes the ac line input power tofull-wave rectified dc.

6 Bus Capacitors C8, C9, C10,C11, C12, C13, C18, AndC19

Filter the dc output voltage of SR1.

7 Transformer T2

Supplies power to control boardPC1, Remote 14 receptacle RC2,and GFI receptacle RC10.

8 Fan Motor FM

Provides cooling of internal com-ponents.

9 GFI Receptacle RC10

Provides 10 amperes of 115 voltsac for auxiliary equipment.

10 Control Board PC1

Controls weld output by changingthe pulse width modulation signal(wider or narrower pulses meaningmore or less voltage) to IGBT pow-er modules PM1 and PM2 aftercomparing current and voltagefeedbacks to reference levels setby R3 and R2.

11 Amperage/Voltage ControlR3

Sets weld output amperage or volt-age level.

12 Arc Force (Dig)/InductanceControl R2

Sets amount of Dig amperage inCC mode or amount of inductancein CV mode.

13 Mode Switch S2

Selects volt-ampere characteristicfor process used.

14 Output (Contactor) Switch S3

Selects On or Remote for remotecontactor control.

SECTION 4 – THEORY OF OPERATION

Input TerminalBoard TE1 And

Terminal Block TE2

GFI ReceptacleRC10

Amperage/Voltage

Control R3

Arc Force (Dig)/Inductance

ModeSwitch S2

Output(Contactor)Switch S3

Amperage/Voltage Control

Switch S4

Arc/InductanceAnd CC/CV Control

Switch S5

Digital MeterBoard PC5

Remote 14Receptacle

RC2

Remote 17Receptacle

RC1

ContactorW1

PowerSwitch S1

Transformer T2

InputRectifier SR1

PrechargeResistorsR1, R19

Fan MotorFM

ControlBoardPC1

3-PhaseLine Input

Power

115 VAC

3φ 3φ

Remote 17Filter Board

PC10

Remote 14Filter Board

PC8

1 4 5

2 3

9 7 8

1011

12

13

18

19 14

15

16

17

19

18

Control R2


15 Amperage/Voltage ControlSwitch S4

Selects front panel or remote am-perage/voltage control.

16 Arc/Inductance And CC/CVControl Switch S5

Allows selection of weld processand arc/inductance control fromfront panel or Remote 17 receptacleRC1.

17 Digital Meter Board PC5

Displays preset and actual amper-age and voltage.

18 Remote 14 Receptacle RC2And Remote 17 ReceptacleRC1

Connect remote amperage/voltageand contactor controls.

19 Remote 14 Filter Board PC8And Remote 17 Filter BoardPC10

Filter (block) HF and other noisefrom getting into power source.

20 Optima Option

Synergically controls pulsing pa-rameters for GMAW-P.

21 Manual Mig Pulser (MMP) Op-tion

Manually controls pulsing parame-ters for GMAW-P.

22 IGBT Power Modules PM1And PM2

Use very fast on/off switching actionto effectively turn the dc into ac.

23 Current Transformer CT1

Provides a pulsed current signal toPC1 for fault protection.

24 Resonant Tank Circuit

A tuned frequency circuit consistingof capacitors C1-C4, inductorsL1-L4, and main transformer T1. T1steps down the high frequency ac in-put to low voltage and high current.

25 Output Diodes D1 Thru D16

Rectify output of T1 to provide dcweld output.

26 Hall Device HD1

Provides current feedback signal toPC1.

27 Stabilizers Z1 And Z2

Smooth welding current.

28 Positive (+) And Negative (–)Weld Output Terminals

Provide weld output and allowchanging of output polarity.

Optional♦

AC Or DC Control Circuits

3φ Power

Weld Current Circuit

PulsedGMAW

Switch S4

MMPBoard PC7

OptimaBoard PC7

PotentiometersR1-R4

CurrentTransformer

CT1

OutputDiodesD1-D8

OutputDiodesD9-D16 Hall

DeviceHD1

StabilizersZ1, Z2

Positive (+)Weld Output

Terminal

Negative (–)Weld Output

Terminal

Electrode

Work

BusCapacitors

C8, C9,

ResonantTank

Circuit

Gating

IGBTPower

ModulesPM1 And

PM2

C10, C11,C12, C13,C18, C19

Signals

Fault Protection

Current Feedback

Voltage Feedback

625

25 26 28

22

23 24 27 28

20

21♦

♦

GMAW-P Pulse Control Panel

Voltage Feedback


SECTION 5 – PRE-POWER CHECKLIST

5-1. Checking Unit Before Applying Power

� See Section 6-2 for test points and values andSection 9 for parts location.

� Use MILLER Testing Booklet (Part No. 150 853)when servicing this unit.

� Discharge input capacitors according to Section 7-2 and be sure voltage is near zero before touching any parts.

� Before troubleshooting or applying power to unit, complete following checks to avoid causing further damage.

� Although some parts are briefly checked in this procedure, more complete tests may be needed later . This check is simply to geta basic okay to power up unit.

A. IGBT Modules PM1, PM2

Visually inspect IGBT modulesPM1 and PM2 for damage.

Isolate terminals C1 and E2 onPM1 and PM2 for testing. CheckC1 to E1 and C2 to E2 (diode test).Reassemble IGBTs.

Remove plugs PLG4 and PLG1from receptacles RC4 and RC1 onPC1. Check G1 to E1 and G2 to E2(red to white leads) from PLG4 andPLG1 for infinite resistance in bothdirections. Reinstall PLG4 andPLG1

For best test, use an IGBT tester(MILLER Part No. 043 553).

TerminalC1

TerminalE2Terminal

C2/E1

IGBT Module PM1 Or PM2

G1 (B1)

E1

E2

G2 (B2)

ST-155 791




B. Control Board PC1

ST-155 791 / Ref. SC-164 972

Visually inspect control board PC1for signs of component failure.

Check 8 diodes on PC1 in loca-tions shown.

Replace PC1 if any diodes areshorted.

� If any diodes are shorted,check IGBTs for failure (seeitem C).

Control Board PC1

Receptacle RC1

Receptacle RC4

DiodesDiodes

Diodes

Diodes


C. Output Diodes D1-D16

ST-155 791

Visually inspect output rectifierdiodes D1-D16 for discoloredsleeving or signs of heat damage.

First, perform a diode test acrossweld output receptacles. If diodetest indicates a short, isolatediodes D1-D16 and retest them in-dividually.

Diodes D1-D16

Weld OutputReceptacles

Diodes D1-D16


D. Input Rectifier SR1

ST-155 791

1 Visually inspect SR1 fordamage.

2 To isolate SR1 for testing,disconnect lead 25 frompositive (+) terminal of SR1.

3 Check 6 diodes (diode test).Check from each ac terminalto the positive (+) terminaland from each ac terminal tothe negative (–) terminal.

Input Rectifier SR1

Input Rectifier SR1

AC (L3)

AC (L2)

AC (L1)Positive (+)

Negative (–)(Not Used)

A

B

C

D

E

FNegative (–)

E. Clamping Rectifiers SR2 And SR3 Prior To KD414913

1 Check SR2 and SR3according to MILLER TestingBooklet (Part No. 150 853).

Clamping RectifiersSR2 And SR3

ST-155 791

Clamping RectifiersSR2 And SR3


F. Hall Device HD1

Visually inspect hall device HD1.

Remove plug to isolate for testing.Check from pin 1 to pin 3 for1500-2000 ohms. Replace HD1 ifnecessary.Hall Device HD1

ST-155 791

Hall Device HD1

G. Bus Capacitors C8, C9, C10, C11, C12, C13, C18, And C19

1 Check C8, C9, C10, C11,C12, C13, C18, and C19 fora short (ohms position).

Bus Capacitors C8 – C13,C18 – C19

ST-155 791

Bus Capacitors C8 – C13,C18 – C19


H. Tank Capacitors C1, C2, C3, C4

ST-155 791

1 Check C1 thru C4 for a short(ohms position).

Tank Capacitors C1 – C4

Tank Capacitors C1 – C4

I. Precharge Resistors R1, R19 And Bleeder Resistors R13-R16

ST-155 791

1 Check resistance ofprecharge resistors R1 andR19; R1 and R19 are each100 ohms ±10%. Effectivewith Serial No. KF907 718,the values were changed to25 ohms ±10%

2 Check resistance of bleederresistors R13-R16. For230/460 volt models, eachresistance is 2500 ohms±10%. For 460/575 voltmodels, each resistance is 5kohms ±10%.

Precharge ResistorsR1, R19

Bleeder ResistorsR13-R16


J. Contactor W1

1 Check condition of contacts.Be sure normally-opencontacts are open. Replacecontactor W1 if necessary.Contactor W1

ST-155 791


NOTES


SECTION 6 – TROUBLESHOOTING

6-1. Troubleshooting Table

� See Section 6-2 for test points and values andSection 9 for parts location.

� Use MILLER Testing Booklet (Part No. 150 853)when servicing this unit.

Trouble Remedy

No weld output; unit completely inop-erative.

Place line disconnect device in On position (see Section 2-11).

Check line fuse(s), and replace if necessary (see Section 2-11).

Check for proper input power connections (see Section 2-10).

Check position of input voltage jumper links (see Section 2-9).

Check fuse F1, and replace if necessary (see Section 7-4).

Check continuity of Power switch S1, and replace if necessary.

Check transformer T2 for signs of winding failure. Check continuity across windings, and check forproper connections. Check secondary voltages. Replace T2 if necessary.

No weld output; fan motor FM runningand digital meters illuminated.

Place Output (Contactor) switch S3 in the On position or connect remote contactor control to properremote receptacle.

Check remote control device for proper operation, and replace if necessary.

Allow a cooling period of approximately five minutes (see Section 3-3). If thermostats TP1 and/orTP2 remain open, check continuity and replace if necessary.

Check coil voltage and connections of contactor W1. Check continuity of coil and condition of con-tacts. Replace W1 if necessary.

Check resistance and connections of hall device HD1; HD1 is 1600 ohms ±10% between pins 1and 3 of receptacle RC62. Check input and output voltages. Replace HD1 if necessary.

Check output diodes D1 thru D16, and replace if necessary.

Check input rectifier SR1, and replace if necessary.

Check IGBT power modules PM1 and PM2, and replace if necessary.

Check control board PC1 and connections, and replace if necessary (see Section 6-4).

Low weld output with no control. Place Amperage/Voltage Control switch S4 in Panel position or connect remote control to properremote receptacle.

Place Mode switch S2 in proper position for weld process (see Section 3-2).

Check resistance and connections of Amperage/Voltage control R3; R3 is 1000 ohms ±10%. Re-place R3 if necessary.



Maximum weld output with no control. Check resistance and connections of Amperage/Voltage control R3; R3 is 1000 ohms ±10%. Re-place R3 if necessary.

Place Mode switch S2 in proper position for weld process (see Section 3-2). Maximum weld outputwould occur if a CC process is attempted with S2 in the GMAW/CV position.




Trouble Remedy

Limited weld output and/or low open-circuit voltage.

Check incoming power for correct voltage. Replace line fuse if open.

Check position of input voltage jumper links (see Section 2-9).

Check for proper input and output connections.

Erratic or improper weld output. Tighten all weld cable connections.

Check for proper size and type of cable.

Check for proper input and output connections.

Replace electrode.

Check resistance and connections of Amperage/Voltage control R3; R3 is 1000 ohms ±10%. Re-place R3 if necessary.

Check resistance and connections of remote amperage/voltage control potentiometer, and replace ifnecessary.

Rotate Arc Force (Dig)/Inductance control R2 to proper setting.

Check resistance and connections of Arc Force (Dig)/Inductance control R2; R2 is 1000 ohms±10%. Replace R2 if necessary.



Remote device for Remote 14 recep-tacle RC2 completely inoperative.

Connect remote control to proper Remote receptacle.

Reset circuit breakers CB1 and/or CB2 (see Section 7-4).

Remote device for Remote 17 recep-tacle RC1 completely inoperative.

Connect remote control to proper Remote receptacle. Be sure pins on remote device are notpushed back into the plug.

Check fuses F3 and/or F4, and replace if necessary (see Section 7-4).

Fan motor FM does not run; weld out-put available.

Check and clear blocked fan blade.

Check fan motor FM, and replace if necessary.

Readings on digital meter not accu-rate.

Calibrate digital meter board PC5 (see Section 6-8).

Wandering arc; poor control of arc di-rection.

Reduce gas flow rate.

Select proper size tungsten.

Properly prepare tungsten.

Tungsten electrode oxidizing and notremaining bright after conclusion ofweld.

Shield weld zone from drafts.

Increase postflow time.

Check and tighten all gas fittings.

Properly prepare tungsten.

Check for water in torch, and repair torch if necessary. See torch manual.


6-2. Troubleshooting Circuit Diagram For Welding Power Source

Test Equipment Needed:

See Section 7-9for PC8 data

See Section 5for PC10 information

See Section 3-6for RC2 data

See Section 3-7for RC1 data

V6

R5

R1

R2

V1Contactor

W1

See Section 7-5for PC5 data and

V5

V2

V3

V4

See Section 3-9for TE2

information

See Section 3-9for TE1

information Section 7-6 formeter calibration

� Discharge input capacitors according to Section 7-2,and be sure voltage is near zero before touching anyparts.


Resistance Values

a) Tolerance – ±10% unless specified

b) Turn Off unit and disconnect inputpower before checking resistance

R1 and R2 100 ohms

R3 and R4 Less than 2 ohms

R5 thru R18 Less than 1 ohm

SD-167 529

Voltage Readings

a) Tolerance – ±10%unless specified

b) Reference – tocircuit common(lead 42) unlessnoted

c) Wiring Diagram –see Section 11

V1 230 volts ac

V2 115 volts ac

V3 18 volts ac

V4 18 volts ac

V5 24 volts ac

V6 325 volts dc with230 volts ac input,650 volts dc with460 volts ac input,812 volts dc with575 volts ac input

V7 –0.825 volts dc per100 amperes weldoutput

V8 –24 volts dc

V9 75 to 80 volts dcopen-circuitvoltage

R7

R8

R10

R9

R4

R3

R11 R13 R15 R17

R12 R14 R16 R18

See Section 7-7for PC7 (MMP)

See Section 7-8for PC7 (Optima)

data

data

V9, A, B, C, D, E

See Section 7-3for output waveforms

A, B, C, D, E

Effective with Serial No. KD414913,SR2 and SR3 with capacitors wereremoved from unit.

V7 V8


6-3. Waveforms For Section 6-2

5 ms 50 V

A. DC Open-Circuit Voltage, Mode Switch S2In GMAW/CV Position

20 µs 20 V

B. 20.0 Volts DC, 187 Amperes, Mode SwitchS2 In GMAW/CV Position (Resistive Load)

5 ms 50 V

C. DC Open-Circuit V oltage, Mode Switch S2 InGTAW/CC Position

20 µs 20 V

D. 21.4 Volts DC, 200 Amperes, Mode Switch S2In GTAW/CC Position (Resistive Load)

gnd gnd

gnd gnd



5 ms 50 V

E. DC Open-Circuit Voltage, Mode Switch S2In SMAW/CC Position

gnd


6-4. Control Board PC1 Testing Information (Use With Section 6-5)


� Discharge input capacitorsaccording to Section 7-2,and be sure voltage is nearzero before touching anyparts.

Be sure plugs are secure beforetesting. See Section 6-5 for specificvalues during testing.

1 Control Board PC1

2 Receptacle RC1

3 Receptacle RC2

4 Receptacle RC3

5 Receptacle RC4

6 Receptacle RC5

7 Receptacle RC6

8 Receptacle RC7

9 Receptacle RC8

10 Receptacle RC9

ST-155 791 / Ref. SC-164 972

1

2

3

4

5

6

7

8

10

9


6-5. Control Board PC1 Test Point Values

PC1 Voltage Readings

a) Tolerance – ±10% unless spe-cified

b) Reference – to circuit common(lead 42) unless noted

Receptacle Pin Value

RC1 Make no connections – damage to test equipment or components can occur .

RC2 1 After 4 to 5 seconds of turning Power switch S1 On, 1 to 2 volts ac output

2 Circuit common

3 18 volts ac input

4 24 volts ac input

5 –24 volts dc output

6 18 volts ac input

7 Not used

8 Not used

9 Not used

10 Not used

RC3 1 +24 volts dc output

2 Voltage sensing input from Negative (–) sense jack

3 +15 volts dc output

4 Voltage sensing input from Positive (+) sense jack

5 Circuit common


7 Not used

8 Circuit common

9 Circuit common

10 Circuit common

RC4 Make no connections – damage to test equipment or components can occur .

RC5 1 Circuit common

2 CC/CV select, CV = +15 volts dc input, CC = 0 volts dc input

3 Command input for GTAW/CC mode, 0 to +10 volts dc

4 +15 volts dc input with Output (Contactor) switch S3 in On position, 0 volts dc input with S3 in Offposition

5 +1 volt dc input per 100 amperes of weld output

6 +1 volt dc input per 10 volts of weld output


8 Not used


Receptacle ValuePin

RC6 1 +1 volt dc output per 100 amperes of weld output

2 +1 volt dc output per 10 volts of weld output

3 Circuit common

4 Circuit common


6 Pulsed command input

7 Same as Positive (+) weld output terminal

8 Same as Negative (–) weld output terminal

9 Pulse reference voltage, 0 to +10 volts dc output



12 +13.6 volts dc input with Amperage/Voltage Control switch S4 in the On position, 0 volts dc inputwith S4 in Off position

RC7 1 Input from hall device HD1, –0.825 volts dc per 100 amperes of weld output

2 +24 volts dc input with Mode switch S2 in GMAW/CV position, 0 volts dc input with S2 in SMAW/CCor GTAW/CC position

3 Arc control, 0 to +10 volts dc input

4 +1 volt dc output per 100 amperes of weld output


6 +1 volt dc output per 10 volts of weld output

7 Remote input, 0 to +10 volts dc

8 Not used

9 Remote output, 0 to +10 volts dc

10 Reference input, 0 to +10 volts dc

11 Same as Positive (+) weld output terminal

12 Same as Negative (–) weld output terminal

13 Not used

14 Not used

15 +24 volts dc input with Mode switch S2 in SMAW/CC position, 0 volts dc input with S2 in GMAW/CVor GTAW/CC position

RC8 1, 2, 3 Not used

RC9 1 Current transformer CT1 feedback input

2 Current transformer CT1 feedback input

3 Remote contactor input for 115 volts ac

4 Remote contactor input for +24 volts dc

5 Remote contactor input for 24 volts ac

6 +10 volts dc

7 Circuit common

8 Not used


6-6. Digital Meter Board PC5 Testing Information (Use With Section 6-7)



Be sure plugs are secure beforetesting. See Section 6-7 for specificvalues during testing.


2 Receptacle RC50

ST-155 830 / SA-150 332-A

1

2

See Section 6-8for meter calibration.

6-7. Digital Meter Board PC5 Test Point Values





RC50 1 +24 volts dc input

2 Circuit common

3 Not used

4 Current feedback signal, +1 volt dc input per 100 amperes of weld output

5 Command input signal, 0 to +10 volts dc with Mode switch S2 in GTAW/CC position

6 Voltage feedback signal, +1 volt dc input per 10 volts of weld output

7 Input from Mode switch S2, +15 volts dc with S2 in GMAW/CV position, 0 volts dc with S2 inSMAW/CC or GTAW/CC position

8 Contactor signal, +15 volts dc input with Output (Contactor) switch S3 in On position, 0 volts dcinput with S3 in Off position

9 Not used

10 Not used

11 Not used


Be sure plugs are secure beforecalibrating meters.


2 Voltmeter

3 Ammeter

4 Access Slot

5 Potentiometer R36

6 Potentiometer R1

7 Potentiometer R6

8 Potentiometer R3

9 Potentiometer R8

10 Potentiometer R4

6-8. Digital Meter Calibration

Ref. ST-155 830-A / SA-150 332-A

1

4

5 68 9

3

2

7 10


R36 R6 R3 R4 R1 R8

R36 R6 R3 R4 R1 R8

1. Set switches 2. Rotate to max 3. Turn On unit

4. Adjust R36 for voltmeter offset or zero

5. Adjust R1 for amperage preset

GTAW/CCMode

Top View

R3

000Amperes (±2)

Top View

R8

38.0Volts (±0.5)

6. Adjust R6 for voltage gainto match external cali-brated meter using loadbank set at desired load

7. Change top switch 8. Adjust R3 for ammeter offsetor zero

GMAW/CVMode

Top View

R1

565

Top View

R36

00.0Amperes (±2)Volts (±0.5)

9. Adjust R8 for voltage preset

10. Adjust R4 for amperage gainto match external calibratedmeter using load bank set atdesired load

Top View

R6

00.0Volts

Top View

R4

000Amperes


6-9. Optional MMP Board PC7 Testing Information (Use With Section 6-10)



Be sure plugs are secure beforetesting. See Section 6-10 for spe-cific values during testing.

1 MMP Board PC7

2 Receptacle RC1

3 Receptacle RC2

Ref. ST-157 330 / SA-155 031

1

32

6-10. Optional MMP Board PC7 Test Point Values





RC1 1 0 to +15 volts dc input from Pulse Width control R4

2 Circuit common



5 0 to +15 volts dc input from Pulse Frequency control R1

6 0 to +15 volts dc input from Background Current control R2

7 0 to +15 volts dc input from Peak Current control R3

8 Not used

RC2 1 Not used

2 –24 volts dc input

3 Circuit common

4 +24 volts dc input

5 Not used

6 Pulsed command output to control board PC1

7 Arc voltage feedback, +1 volt dc input per 10 volts of weld output


6-11. Optional Optima Board PC7 Testing Information (Use With Section 6-12)




1 Optima Board PC7

2 Receptacle RC1

3 Receptacle RC2

4 Receptacle RC3

Ref. ST-157 330 / SB-160 655-B

1

3 2 4

6-12. Optional Optima Board PC7 Test Point Values





RC1 A Input from Positive (+) weld output receptacle

B Input from Negative (–) weld output receptacle

RC2 A Not used

B Pulse reference, 0 to +10 volts dc input

C Not used

RC3 A Voltage feedback signal, +1 volt dc input per 10 volts of weld output

B Pulse command output to control board PC1

C Current feedback signal, +1 volt dc input per 100 amperes of weld output

D +24 volts dc input

E Circuit common

F –24 volts dc input

G Not used


6-13. Remote 14 Filter Board PC8 Testing Information (Use With Section 6-14)




1 Remote 14 Filter Board PC8

2 Receptacle RC30

3 Receptacle RC31

4 Receptacle RC32

5 Terminals A, B, C

6 Terminals D, E, F

Ref. ST-157 330 / SA-142 335-A

6

4

2

5

1

3


6-14. Remote 14 Filter Board PC8 Test Point Values





RC30 1 Not used

2 Not used

3 Not used

4 115 volts ac remote contactor output to control board PC1

5 115 volts ac input from circuit breaker CB1

6 Not used

7 Not used

8 Command voltage output to control board PC1, 0 to +10 volts dc (max.)

9 Command circuit common

10 Remote command input from control board PC1, CV = +10 volts dc input, CC = 0 to +10 volts dcinput

11 Remote contactor output to control board PC1, 24 volts ac output

12 +1 volt dc input per 10 volts of weld output

RC31 1 Not used

2 Command voltage input from Remote 14 receptacle RC2, 0 to +10 volts dc input (max.)

3 Command circuit common

4 Remote command output to Remote 14 receptacle

5 Remote contactor input from Remote 14 receptacle RC2, 24 volts ac input

6 +1 volt dc input per 10 volts of weld output to Remote 14 receptacle RC2

7 Not used

8 Not used

9 Not used

10 Remote contactor input from Remote 14 receptacle RC2, 115 volts ac input

11 115 volts ac output to Remote 14 receptacle RC2

12 Chassis ground

RC32 1 thru 12 Not used

Terminals A Not used

B 24 volts ac input from circuit breaker CB2

C 24 volts ac output to Remote 14 receptacle RC2

D Not used

E Chassis ground

F Circuit common for 24 and 115 volts ac circuits


SECTION 7 – MAINTENANCE

7-1. Routine Maintenance

� Disconnect power before maintaining.

� Maintain more oftenduring severe conditions.

3 Months

ReplaceDamaged OrUnreadable

Labels

Replace CrackedTorch Body

Repair OrReplaceCrackedCables

Repair Or ReplaceCracked Cables

And Cords

Clean AndTightenWeld

Terminals

6 Months

Blow Out OrVacuum Inside


7-2. Measuring Input Capacitor Voltage

Turn Off welding power source,and disconnect input power.

Remove top cover.

1 Input Rectifier SR1

2 Voltmeter

Measure the dc voltage across thepositive (+) and negative (–) termi-nals until voltage drops to near 0(zero) volts.

Proceed with job inside unit. Rein-stall top cover when finished.

Tools Needed:

3/8 in

ST-150 222-F / ST-150 173-C

12

Significant DC voltage can remain on capacitors after unit is Off.The input capacitor voltage can be measured across terminals oninput rectifier SR1. Always check the voltage as shown to be surethe input capacitors have discharged before working on unit.

7-3. Optional Ground Current Sensor

1 Reed Relay (Ground CurrentSensor – Optional)

Defects in external electrical cir-cuitry may cause the ground wireto conduct welding current. RelaysCR1 and CR2 sense excessivecurrent in the ground conductorand open the solid state contactor,shutting down weld output.

Open circuit voltage is not avail-able, but the fan motor FM runsand the pilot light PL1 stays on. Ifthe welding power source shutsdown due to the ground currentsensor, disconnect all power, andcorrect the problem before weldingagain.

ST-156 172-D

1


7-4. Circuit Breakers And Fuses


1 Circuit Breaker CB1

If CB1 opens, remote devices us-ing 115 volts from Remote 14 re-ceptacle stop. Manually reset CB1.


If CB2 opens, remote devices us-ing 24 volts from Remote 14 recep-tacle stop. Manually reset CB2.


If CB3 opens, devices connectedto the 115 volt duplex receptacleand remote devices using 115 voltsfrom Remote 14 receptacle stop.Manually reset CB3.

4 Fuse F1

If F1 opens, the welding powersource shuts down.

5 Fuse F3

6 Fuse F4

If F3 or F4 opens, remote controldevices connected to Remote 17receptacle RC1 may shut down.

See Parts List for fuse ratings. Useproper tool when removing fuses.

Tools Needed:

3/8 in

ST-150 222-F / Ref. ST-152 069-C / ST-150 173-C

1 32

5

6 4


SECTION 8 – ELECTRICAL DIAGRAMS

� The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit insidemachine case or contact factory for actual circuit, if needed.

The following is a list of all diagrams for models covered by this manual. To order a copy, proceed as follows:

1 Know unit Model and Serial or Style Number.

2 Use this list to find diagram number.

3 Include your FAX number or mailing address with your request.

4 FAX Technical Publications Department at 414-735-4011 or call 414-735-4356.

Model Serial Or Style Number Circuit Diagram Wiring Diagram

Maxtron 450 (230/460) KC237305 thru KD342941 SD-142 760-H D-143 318-G♦♦

KD342942 thru KD375311 SD-158 709-B D-158 710-A♦♦

KD375312 thru KD414912 SD-159 815-B D-159 814♦♦

KD414913 thru KD433774 SD-160 564-A D-160 565♦♦

KD433775 thru KD485760 SD-164 041 D-160 042♦♦

KD485761 thru KD523654 SD-164 676 D-164 677♦♦

KD523655 thru KE575507 SD-165 760 D-165 761♦♦

KE575508 and following SD-167 529-A SD-167 531

Maxtron 450 (460/575) KC237305 thru KD485760 SD-157 431-B D-157 756-B♦♦

KD485761 thru KD523654 SD-164 680 D-164 681♦♦

KD523655 thru KE575507 SD-165 762 D-165 763♦♦

KE575508 and following SD-167 530-A SD-167 532

Circuit Board PC1 (230/460) KC237305 thru KC301173 D-151 898-B♦♦

KC301174 thru KD350777 D-157 294♦♦

KD350778 thru KE557396 D-159 073♦♦

Circuit Board PC1 (460/575) KC237305 thru KE557396 D-161 113♦♦

Circuit Board PC1 (All) KE557397 thru KF844514 D-164 974♦♦

KF844515 thru KG033270 D-170 847♦♦

KG033271 thru KG111782 D-175 759♦♦

KG111783 and follwing SD-180 871-A

Circuit Board PC5 KC237305 and following SC-150 334-A

Circuit Board PC7(Remote Pendant)♦

KC237305 thru KC260557 C-150 422♦♦

KC260558 and following SC-155 033

Circuit Board PC7(Pulse Control)♦

KC237305 and following SD-160 657

Circuit Board PC8 KC237305 and following SB-142 337

Circuit Board PC10 KC237305 and following SA-124 988-B

♦ Optional

♦♦ Not included in this manual


Figure 8-1. Circuit Diagram For Maxtron 450 (230/460 Volts) Effective WithSerial No. KC237305 Thru KD342941


SD-142 760-H


Figure 8-2. Circuit Diagram For Maxtron 450 (230/460 Volts) Effective WithSerial No. KD342942 Thru KD375311


SD-158 709-B


SD-159 815-B


SD-160 564-A


SD-164 041


SD-164 676


Figure 8-7. Circuit Diagram For Maxtron 450 (230/460 Volts) Effective WithSerial No. KD523655 Thru KE575507


SD-165 760


Figure 8-8. Circuit Diagram For Maxtron 450 (230/460 Volts) Effective WithSerial No. KE575508 And Following


SD-167 529-A


Figure 8-9. Wiring Diagram For Maxtron 450 (230/460 Volts) Effective WithSerial No. KE575508 And Following


SD-167 531


Figure 8-10. Circuit Diagram For Maxtron 450 (460/575 Volts) Effective WithSerial No. KC237305 Thru KD485760


SD-157 431-B


SD-164 680


Figure 8-12. Circuit Diagram For Maxtron 450 (460/575 Volts) Effective WithSerial No. KD523655 Thru KE575507


SD-165 762


Figure 8-13. Circuit Diagram For Maxtron 450 (460/575 Volts) Effective WithSerial No. KE575508 And Following


SD-167 530-A


Figure 8-14. Wiring Diagram For Maxtron 450 (460/575 Volts) Effective WithSerial No. KE575508 And Following


SD-167 532


Figure 8-15. Circuit Diagram For Control Board PC1 Effective WithSerial No. KG111783 And Following (Part 1 Of 2)


SD-180 871-A (1 Of 2)


Figure 8-16. Circuit Diagram For Control Board PC1 Effective WithSerial No. KG111783 And Following (Part 2 Of 2)


SD-180 871-A (1 Of 2)


Figure 8-17. Circuit Diagram For Digital Meter Board PC5 Effective With Serial No. KC237305 And Following

SC-150 334-A


Figure 8-18. Circuit Diagram For Optional MMP Board PC7 Effective With Serial No. KC260558 And Following

SC-155 033


Figure 8-19. Circuit Diagram For Optional Optima Board PC7 Effective WithSerial No. KC237305 And Following


SD-160 657


SB-142 337

Figure 8-20. Circuit Diagram For Remote 14 Filter Board PC8 Effective WithSerial No. KC237305 And Following

SA-124 988-B

Figure 8-21. Circuit Diagram For Remote 17 Filter Board PC10 Effective WithSerial No. KC237305 And Following

February 1997 Form: TM-2206

Effective With Serial No. KC237305

SECTION 9 – PARTS LIST


Maxtron 450CC/CV DC Welding Power Source For

GMAW, GTAW, SMAW, FCAW, CAC-A, GMAW-P, GTAW-P, And SAW Welding


1

2

14

8 10

11

12

13

15

16

1718

19

20

22

23 24

25

2627

11

32

4

349

37

39

40

41

Figure 9-1. Main Assembly

Fig

9-4

Fig

9-5

Fig

9-3

Fig

9-2

ST-150 054-H

46

7

6

8

33

3536

21

28

29 30 31

38

35

9

21

7

5


DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 9-1. Main Assembly

Quantity

1 152 346 COVER, top w/insulation (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 653 INSULATOR, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 +147 962 PANEL, side RH w/insulator (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 652 INSULATOR, side RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 C50,51 164 812 CAPACITOR, (Eff w/KD523655) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 155 642 SCREW, set .250-28 x 1.000 cup pt sch stl (Eff w/KC295487) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 143 748 BUS BAR, (across front of C8,9,18,19 & C10-13) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 145 245 INSULATOR, elctlt 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 143 749 BUS BAR, (across back of C8,9,18,19 & C10-13) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 C8-13,18,19 135 786 CAPACITOR, elctlt 4000uf 250VDC (230/460V) 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 C8-13,18,19 140 891 CAPACITOR, elctlt 2800uf 300VDC (460/575V) 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 148 556 BRACKET, mtg capacitor 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 148 553 BAFFLE, air 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 126 026 LABEL, warning general precautionary 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 145 743 LUG, univ w/scr 600V 2-14 wire .250 stud 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 TE2 147 386 BLOCK, term 70A 3P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 TE1 148 446 TERMINAL ASSEMBLY, pri (230/460V) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 TE1 157 322 TERMINAL ASSEMBLY, pri (460/575V) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 147 899 BRACKET, mtg term block 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Z1 144 050 STABILIZER, left 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Z2 147 901 STABILIZER, right 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 T1 144 274 TRANSFORMER, HF (Prior to KD414913) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 T1 157 501 TRANSFORMER, HF (Eff w/KD414913) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 143 731 LIFT EYE, upright 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 604 126 SCREW, cap stl hexhd .500-13 x 1.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 153 178 LABEL, warning exploding parts can seriously injure 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 144 929 GASKET, lift eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 143 732 LIFT EYE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 088 058 NUT, .500-13 stl elastic stop 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 +143 746 PANEL, rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 145 053 WASHER, shldr nyl .298 OD x .203 ID x 1.000 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Fig 9-4 CHASSIS, mid upper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Fig 9-5 FAN MOTOR/MOUNTING BRACKET 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG18 131 054 CONNECTOR & SOCKETS, (part of FM) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 746 CONNECTOR, rect skt 24-18ga Molex 39-00-0038 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC18 135 635 CONNECTOR & PINS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 656 CONNECTOR, rect pin 24-18ga Molex 39-00-0040 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 605 603 TUBING, gl acryl 1.000-1.036 ID (order by ft) 3ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 143 741 SPACER 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 070 592 TUBING, gl acryl .500-.524 ID (order by ft) 3ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Fig 9-3 CHASSIS, mid lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 154 066 INSULATOR, capacitor (Eff w/KC234210) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 605 538 CABLE TIE, 0-4.500 bundle 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C31-38 139 849 CAPACITOR ASSEMBLY, (Prior to KD414913) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 077 HEAT SINK, spillover (Prior to KD350778) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 257 HEAT SINK, spillover (Eff w/KD350778 thru KD414913) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SR2,3 149 219 KIT, rectifier integ 35A (Prior to KD414913) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 +143 745 BASE, (Prior to KD414913) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 +157 427 BASE, (Eff w/KD414913) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 145 477 STIFFENER, base 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 T2 148 448 TRANSFORMER, control (Prior to KC260558) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 T2 154 852 TRANSFORMER, control (Eff w/KC260558 thru KD375312) 1. . . . . . . . . . . . . . . . . . . . . . . . . . 37 T2 ♦♦ 154 083 TRANSFORMER, kVA 1.5 115-230/230-18/18-24 (230/460V). . . . . . . . . . . . . .

(Eff w/KD375312 thru KE575507) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 T2 167 521 TRANSFORMER, kVA 1.5 115/230/230-18-18-24 (230/460V). . . . . . . . . . . . . . . . .

(Eff w/KE575508 and on) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 T2 160 978 TRANSFORMER, kVA 1.5 115-230/460/575-18/18-24 (460/575V). . . . . . . . . . . . . . . . .

(Prior to KE575508) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 T2 167 522 TRANSFORMER, kVA 1.5 115-230/460/575-18/18-24 (460/575V). . . . . . . . . . . . . . . . .

(Eff w/KE575508) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 9-1. Main Assembly (Continued)

Quantity

PLG21 168 165 CONNECTOR & SOCKETS, (Eff w/KE575508) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . 114 066 CONNECTOR, rect skt 20-14ga 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC21 130 204 CONNECTOR & PINS, (Eff w/KE575508) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 633 CONNECTOR, rect pin 20-14ga 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 Fig 9-2 PANEL, front w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RC11,15 116 045 CONNECTOR & PINS, (consisting of) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113 633 CONNECTOR, rect pin 20-14ga Amp 350218-1 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG11,15 135 556 CONNECTOR & SOCKETS, (consisting of) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114 066 CONNECTOR, rect skt 20-14ga Amp 350536-1 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 134 327 LABEL, warning general precautionary 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 +147 961 PANEL, side LH w/insulator (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 155 651 INSULATOR, side LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134 756 LABEL, warning electric shock can kill (on LH panel) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CR2 ♦ 155 757 SWITCH, reed 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010 014 CLAMP, stl cush .750dia x .203mtg hole 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 010 143 CLAMP, nyl .375clp dia 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.♦ Part of 042 779 (230/460V) and 042 961 (460/575V) Ground Current Sensor Option.♦♦ Eff w/KD375312 these components became standard.BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

23

45

67

8

9

10

1112

131415

16

17

1819

20

2223

2425 26

27282930

31

3233

34

3536

37

383940

46

47

48

39

43

42

4544

31

30

434241

ST-150 167-F

1

21

Figure 9-2. Panel, Front w/Components


DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 9-2. Panel, Front w/Components (Fig 9-1 Item 38)

Quantity

1 146 684 INSULATOR, switch pwr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 S1 128 756 SWITCH, tgl 3PST 40A 600VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 148 297 NUT, speed U type 10-32 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 071 230 BEZEL/FILTER, blk bezel/red filter 2.000 viewing 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 135 299 LOCK, shaft pot .375-32 x .250dia shaft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 PC5 150 331 CIRCUIT CARD, amp/volt meter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG50 089 222 CONNECTOR, rect 11skt plug Amp 1-640440-1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 153 374 ENCLOSURE, PC card 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 134 201 STAND-OFF SUPPORT, PC card .312/.375 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 604 311 GROMMET, rbr .250 ID x .375mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 R3 030 856 POTENTIOMETER, WW sltd sft 10/T 2W 1K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 R2 035 897 POTENTIOMETER, C sltd sft 1/T 2W 1K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 S2 088 409 SWITCH, tgl DPDT 15A 125VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 S4 128 808 SWITCH, tgl SPTT 15A 125VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 S3 011 609 SWITCH, tgl SPDT 15A 125VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 S5 011 611 SWITCH, tgl DPDT 15A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 R1-4 ♦ 073 562 POTENTIOMETER, C sltd sft 1/T 2W 10K ohm 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ♦ 141 690 GROMMET, scr No. 8/10 panel hole .281sq .197 high 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ♦♦ 153 994 GROMMET, scr No. 8/10 panel hole .281sq .547 high 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 +153 260 ENCLOSURE, PC card 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 ♦ 157 453 INSULATOR, PC card (Eff w/KC299794) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 PC7 ♦ 155 030 CIRCUIT CARD, remote pendant 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 PC7 ♦♦ 162 076 CIRCUIT CARD, pulse control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG1 ♦ 115 092 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 746 CONNECTOR, rect skt 24-18ga Molex 39-00-0038 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG2 +135 558 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 079 747 CONNECTOR, rect skt 24-18ga Amp 350980-1 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG3 +079 796 CONNECTOR, rect 3skt plug Amp 640250-3 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +079 747 CONNECTOR, rect skt 24-18ga Amp 350980-1 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG4 +135 557 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 079 747 CONNECTOR, rect skt 24-18ga Amp 350980-1 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 S6 +011 609 SWITCH, tgl SPDT 15A 125VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 860 BLANK, snap-in nyl .187mtg hole (not used when unit has either option) 4. . . . . . . . . . . . . . . . . . . . . . . . 119 951 BLANK, snap-in nyl .437mtg hole (not used when unit has either option) 4. . . . . . . . . . . . . . . . . . . . . . . . 107 983 BLANK, snap-in nyl .500mtg hole (not used when unit has either option) 1. . . . . . . . . . . . . . . . . . . . . . . .

22 RC2 143 976 CONNECTOR w/SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 079 534 CONNECTOR, circ skt push-in 14-18ga Amp 66358-6 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 734 CONNECTOR, circ 14 pin plug Amp 213571-2. . . . . . . . . . . . . . . . . . . . . . . 134 731 CONNECTOR, circ pin push-in 14-18ga Amp 213603-1. . . . . . . . . . . . . . . . . . . . . . . 079 739 CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2 (or). . . . . . . . . . . . . . . . . . . . . . . 143 922 CONNECTOR, circ clamp str rlf sz 17-20 Amp 206070-3. . . . . . . . . . . . . . . . . . . . . . .

23 CB1 089 807 CIRCUIT BREAKER, man reset 1P 2.5A 250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 CB2 083 432 CIRCUIT BREAKER, man reset 1P 10A 250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 CB3 ♦♦♦ 083 432 CIRCUIT BREAKER, man reset 1P 10A 250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

057 359 BLANK, snap-in nyl .375mtg hole (Prior to KD375312) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 715 STRIP, mtg circuit breakers (Prior to KD375312) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 R17 030 945 RESISTOR, C 2W 4.7K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 R5 028 271 RESISTOR, C .5W 100K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 C39 074 200 CAPACITOR, polye film .047uf 400VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 PC10,RC1 137 542 CIRCUIT CARD, connector 17skt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

097 866 CONNECTOR, circ 17 pin plug Amphenol MS-3106A-20-29P. . . . . . . . . . . . . . . . . . . . . . . 073 296 CONNECTOR, circ clamp str rlf sz 20-22 Amphenol 97-3057-12-6. . . . . . . . . . . . . . . . . . . . . . .

30 C6,7 138 115 CAPACITOR 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Neg 039 046 TERMINAL, pwr output black (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Pos 039 047 TERMINAL, pwr output red (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 601 976 SCREW, cap stl hexhd .500-13 x 1.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 039 045 TERMINAL BOARD, black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 039 049 TERMINAL BOARD, red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 601 880 NUT, stl hex jam .500-13 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 039 044 BUS BAR, term bd 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 601 879 NUT, stl hex full .500-13 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 143 747 PANEL, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 9-2. Panel, Front w/Components (Fig 9-1 Item 38) (Continued)

Quantity

38 RC10 ♦♦♦ 147 939 RECEPTACLE, str dx grd 2P3W 15A 125V GFCI 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 073 690 PLUG, str grd armd 2P3W 15A 125V P & S 5266DF. . . . . . . . . . . . . . . . . . . . . . .

PLG20 168 165 CONNECTOR & SOCKETS, (Eff w/KE575508) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . 114 066 CONNECTOR, rect skt 20-14ga 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC20 130 204 CONNECTOR & PINS, (Eff w/KE575508) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 633 CONNECTOR, rect pin 20-14ga 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 NAMEPLATE, (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ♦♦♦ 154 022 COVER, receptacle duplex GFCI weather proof 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 039 885 CONNECTOR, circ protective cap Amphenol 9760-20 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 039 654 POST, bdg black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 039 655 POST, bdg red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ♦ 097 922 KNOB, pointer 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ♦♦ 097 922 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 + NAMEPLATE, (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 097 922 KNOB, pointer 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 143 797 SPACER, nyl .312 OD x .194 ID x .437 lg 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 PC8 167 679 CIRCUIT CARD, receptacle bypass 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG30,31 130 203 CONNECTOR & SOCKETS, (consisting of) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 746 CONNECTOR, rect skt 24-18ga Molex 39-00-0038 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦ Part of 042 741 (230/460V) MMP Panel Option.♦♦ Part of 042 635 (230/460V) Optima 450 Panel Option.♦♦♦ Eff w/KD375312 these components became standard+Part of 042 741 (230/460V) MMP Panel Option and 042 635 (230/460V) Optima 450 Panel Option.BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 9-3. Chassis, Mid Lower (Fig 9-1 Item 32)

Quantity

1 153 403 BUSHING, snap-in nyl .750 ID x 1.000mtg hole 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 153 380 BAFFLE, air (Prior to KD414913) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 157 425 BAFFLE, air (Eff w/KD414913) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 145 265 MODULE, pwr LH (230/460V) (Prior to KD414913) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . 3 160 765 MODULE, pwr LH (230/460V) (Eff w/KD414913) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 157 571 MODULE, pwr LH (460/575V) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 145 266 MODULE, pwr LH (230/460V) (Prior to KD414913) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . 4 160 766 MODULE, pwr RH (230/460V) (Eff w/KD414913) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . 4 157 572 MODULE, pwr RH (460/575V) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C22-29,. . . . . . . . . 40-47 031 689 CAPACITOR 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CM1,2 157 497 MODULE, capacitor (Eff w/KD414913) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1-16 149 209 KIT, diode fast recovery 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM1,2 149 238 KIT, transistor IGBT module (230/460V) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM1,2 157 566 KIT, transistor IGBT module (460/575V) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TP1,2 006 334 THERMOSTAT, NC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

072 253 STUD, connection single 10-32 x .500 x 1.250 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 722 HEAT SINK, pwr module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 142 592 BAR, support heat sink 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 135 661 EDGE TRIM, style 3100-1/16 (order by ft) (Eff w/KD414913) 2ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 047 838 BLANK, snap-in nyl 1.000mtg hole (Eff w/KD414913) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R9-12 149 729 RESISTOR, WW fxd 40W 25 ohm (Prior to KD414913) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 797 SPACER, nyl .312 OD x .194 ID x .437 lg (Prior to KD414913) 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 143 738 TRAY, mtg cmpts lower (Prior to KD414913) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 157 426 TRAY, mtg cmpts lower (Eff w/KD414913) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 057 357 BUSHING, snap-in nyl .937 ID x 1.125mtg hole (Prior to KD523655) As Req’d. . . . . . . . . . . . . . . . . . . . 9 057 358 BUSHING, snap-in nyl 1.000 ID x 1.375mtg hole (Eff w/KD523655) As Req’d. . . . . . . . . . . . . . . . . . . .


DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 9-3. Chassis, Mid Lower (Fig 9-1 Item 32) (Continued)

Quantity

10 R13-16 147 902 RESISTOR, WW fxd 30W 2500 ohm (230/460V) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 R13-16 139 812 RESISTOR, WW fxd 30W 5K ohm (460/575V) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CM1,2 151 198 MODULE, capacitor 2 polye MF .0047uf 1000V (Prior to KD414913) 2. . . . . . . . . . . . . . . . . . 11 RM1,2 153 336 MODULE, resistor 2 2W 100K ohm 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 C1-4 143 359 CAPACITOR, polyp film .6uf 1000VDC 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 145 162 STRIP, comb mrm .007 x 3.000 x 7.000 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 006 426 CLAMP, capacitor 2.000dia 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 133 405 NUT, speed 10-24 flat rectangular (Prior to KD523655) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 148 297 NUT, 10-32 push-on stl (Eff w/KD523655) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 L1-4 144 325 CHOKE, DVDT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CT1 140 328 COIL, current transformer 500/1 (Prior to KD414913) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 681 INSULATOR, coil (Prior to KD414913) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 097 863 CORE, ferrite E (Prior to KD414913) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 097 865 BOLT, U brs 6-32 x 1.925 wide x 2.250 deep (Prior to KD414913) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

3

4

5

1

6

7

9

10

11

12

1314

15

16

1 2

ST-150 170-D

1

8

Figure 9-3. Chassis, Mid Lower

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


12

12

34

5

6

7

13

16

17

18

22

2120

ST-150 169-H

9

23

24

25

8

1011

14

15

19

Figure 9-4. Chassis, Mid Upper


DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 9-4. Chassis, Mid Upper (Fig 9-1 Item 27)

Quantity

1 HD1 156 313 TRANSDUCER, current 300A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG62 130 204 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114 066 CONNECTOR, rect skt 20-14ga Amp 350536-1 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 C30 158 707 LEAD ASSEMBLY, elect (Eff w/KD342492 thru KE575507) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 134 058 STAND-OFF SUPPORT, PC card .156dia 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 098 376 HOLDER, fuse mintr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F3,4 *012 643 FUSE, mintr gl slo-blo 1A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 VCRM1 153 289 MODULE, capacitor/varistor/resistor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CT1 ++157 568 TRANSFORMER, current (Eff w/KD414913) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 W1 132 889 CONTACTOR, def prp 40A 3P 24VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 170 626 BRACKET, mtg contactor (Eff w/KE678979) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 057 358 BUSHING, snap-in nyl 1.000 ID x 1.375mtg hole As Req’d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 057 357 BUSHING, snap-in nyl .937 ID x 1.125mtg hole As Req’d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 PC1 180 868 CIRCUIT CARD, control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG1,3-5,9 148 439 CONNECTOR & SOCKETS, (consisting of) 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 995 CONNECTOR, rect skt 22-18ga Amp 170362-3 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG2 153 501 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 995 CONNECTOR, rect skt 22-18ga Amp 170362-3 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG6 ♦ 158 720 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 995 CONNECTOR, rect skt 22-18ga Amp 170362-3 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG7 152 249 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 995 CONNECTOR, rect skt 22-18ga Amp 170362-3 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 083 147 GROMMET, scr No. 8/10 panel hole .312sq .500 high As Req’d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 PLG19 131 054 CONNECTOR & SOCKETS, (part of CT1) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . .

113 746 CONNECTOR, rect skt 24-18ga Molex 39-00-0038 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 RC19 135 635 CONNECTOR & PINS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114 656 CONNECTOR, rect pin 24-18ga Molex 39-00-0040 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 +143 737 TRAY, mtg cmpts upper (Prior to KD414913) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 +157 549 TRAY, mtg cmpts upper (Eff w/KD414913) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 142 592 BAR, support heat sink 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 VCM1 151 199 MODULE, varistor/capacitor 3 220 joule 730VDC (230/460V). . . . . . . . . . . . .

(Prior to KD523655) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 VCM1 162 097 MODULE, varistor/capacitor 3 400 joule 1620-1980VDC (460/575V). . . . . . . . . . . . .

(Prior to KD523655) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 VCM1 164 849 MODULE, varistor/capacitor 4 400 joule (Eff w/KD523655) 1. . . . . . . . . . . . . . . . . . . . . . . . . 19 126 026 LABEL, warning electric shock can kill 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 R1,19 **141 424 RESISTOR, WW fxd 30W 25 ohm (230/460V) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 R1,19 136 076 RESISTOR, WW fxd 30W 200 ohm (460/575V) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 095 847 HOLDER, fuse crtg 30A 600V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F1 *099 398 FUSE, crtg 3A 500V time delay (230/460V) (Prior to KD375312) 1. . . . . . . . . . . . . . . . . . . . . . 22 F1 *148 524 FUSE, crtg 9A 500V time delay (230/460V) (Eff w/KD375312) 1. . . . . . . . . . . . . . . . . . . . . . . . 22 F1 *162 312 FUSE, crtg 5A 600V time delay (460/575V) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 143 723 HEAT SINK, rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 SR1 141 317 RECTIFIER, integ 110A 1600V 3ph 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 099 037 EDGE TRIM, style 62-1/16 (order by ft). . . . . . . . . . . . . . . . . . . .

(Eff w/KD414913 thru KE613733) 1ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 148 001 EDGE TRIM, style 62-3/32 (order by ft) (Eff w/KE613734 and on) 1ft. . . . . . . . . . . . . . . . . . . . . . . . . .

CR1 ♦♦ 110 386 RELAY, encl 24VAC DPDT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*Recommended Spare Parts.♦ Part of 042 741 (230/460V) MMP Panel Option and 042 635 (230/460V) Optima 450 Panel Option.+When ordering a component originally displaying a precautionary label, the label should also be ordered.♦♦ Part of 042 779 (230/460V) and 042 961 (460/575V) Ground Current Sensor Option.++Prior to KD414913 located on Chassis, Mid lower.**Note: When replacing resistor, make sure both resistors are of the same value.BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.


DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 9-5. Fan Motor/Mounting Bracket (Fig 9-1 Item 28)

Quantity

1 R9-12 157 297 RESISTOR, WW fxd 55W 25 ohm (Eff w/KD414913) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 143 797 SPACER, nylon .312 OD x .194 ID x .437 lg (Eff w/KD414913) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 143 730 INLET, fan (Prior to KD414913) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 157 429 INLET, fan (Eff w/KD414913) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 135 661 EDGE TRIM, style 3100-1/16 (order by ft) (Eff w/KD414913) 2ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 107 983 BLANK, snap-in nyl .500mtg hole (Eff w/KD523655) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 153 219 BLADE, fan 7.600 in 5wg 24deg .312 bore CCW 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 143 729 BRACKET, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 FM 153 280 MOTOR, fan 230V 3000RPM .312dia shaft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 9-5. Fan Motor/Mounting Bracket

ST-150 168-C

12

3

5

6

78

4

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

maxtron 450 (kc237305)

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