46604022-MAXTRON-450-KC237305

February 1997

Form:

TM-2206

Effective With Serial No. KC237305

TECHNICAL MANUAL Service And Parts

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

Maximum OpenCircui Voltage DC

Input Power

Rated We Welding Output

Voltage Range In CV Mode

Three Phase

450 A @ 38 Volts DC, 100% Duty Cycle; 565 A, 43 Volts DC, 60% Duty Cycle

10 – 38

5 – 56 5

Single Phase

325 A @ 33 Volts DC, 100% Duty Cycle; 325 A, 33 Volts DC, 60% Duty Cycle

10 – 38

5 – 32 5

Amperes Input At Rated Load Output 60 Hz, Three-Phase 230 V

460 V

5 75 V

KVA

KW

80

72 (2.0)*

36 (1.0)*

29 (0.8)*

28 (0.23)*

20 (0.17)*

80

89.6 (2.0)*

47.2 (1.0)*

37.7 (0.8)*

18 (0.23)*

13 (0.17)*

*While idling cover_tm 4/95 – ST-150 171-B

© 1997 MILLER Electric Mfg. Co.

PRINTED IN USA

TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. 1-2. 1-3.

1

Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 2

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

3

2-1. 2-2. 2-3. 2-4. 2-5. 2-6. 2-7. 2-8. 2-9. 2-10. 2-11.

Se S electing A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Sensing Terminal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote 17 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Volt AC Duplex Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Placing Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pl Connecting Input Conductors To Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – OPERAT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. 3-2. 3-3.

3 3 4 4 5 6 6 7 7 8 9 10

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Process Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 11 11

SECTION 4 – THEORY THEORY OF OPERAT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

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

14

5-1.

Checking Unit Before Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. 6-7. 6-8. 6-9. 6-10. 6-11. 6-12. 6-13. 6-14.

Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Circuit Diagram For Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . Waveforms For Section 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Board PC1 Testing Information (Use With Section 6-5) . . . . . . . . . . . . . . . . . . . . . . . Control Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Meter Board PC5 Testing Information (Use With Section 6-7) . . . . . . . . . . . . . . . . . . . Digital Meter Board PC5 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional MMP Board PC7 Testing Information (Use With Section 6-10) . . . . . . . . . . . . . . . . Optional MMP Board PC7 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional Optima Board PC7 Testing Information (Use With Section 6-12) . . . . . . . . . . . . . . Optional Optima Board PC7 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote 14 Filter Board PC8 Testing Information (Use With Section 6-14) . . . . . . . . . . . . . . Remote 14 Filter Board PC8 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 22 22 24 26 28 29 31 31 32 34 34 35 35 36 37

WHO DO I CONTACT FOR HELP? H

CALL: Miller Customer Service Department at 414-735-4505

H

FAX: 414-735-4136

H

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

Always provide Model Name and Serial or Style Number

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

TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. 1-2. 1-3.

1

Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 2

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

3

2-1. 2-2. 2-3. 2-4. 2-5. 2-6. 2-7. 2-8. 2-9. 2-10. 2-11.

Se S electing A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Sensing Terminal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote 17 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Volt AC Duplex Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Placing Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pl Connecting Input Conductors To Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – OPERAT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. 3-2. 3-3.

3 3 4 4 5 6 6 7 7 8 9 10

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Process Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 11 11

SECTION 4 – THEORY THEORY OF OPERAT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

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

14

5-1.

Checking Unit Before Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. 6-7. 6-8. 6-9. 6-10. 6-11. 6-12. 6-13. 6-14.

Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Circuit Diagram For Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . Waveforms For Section 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Board PC1 Testing Information (Use With Section 6-5) . . . . . . . . . . . . . . . . . . . . . . . Control Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Meter Board PC5 Testing Information (Use With Section 6-7) . . . . . . . . . . . . . . . . . . . Digital Meter Board PC5 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional MMP Board PC7 Testing Information (Use With Section 6-10) . . . . . . . . . . . . . . . . Optional MMP Board PC7 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional Optima Board PC7 Testing Information (Use With Section 6-12) . . . . . . . . . . . . . . Optional Optima Board PC7 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote 14 Filter Board PC8 Testing Information (Use With Section 6-14) . . . . . . . . . . . . . . Remote 14 Filter Board PC8 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 22 22 24 26 28 29 31 31 32 34 34 35 35 36 37

WHO DO I CONTACT FOR HELP? H

CALL: Miller Customer Service Department at 414-735-4505

H

FAX: 414-735-4136

H

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

Always provide Model Name and Serial or Style Number

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

SECTION 7 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. 7-2. 7-3. 7-4.

38

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional Ground Current Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Breakers And Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 39 39 40

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

41

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

79

SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING safety_stm1 4/95

1-1.

Symbol Usage Y Marks a special safety message.

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

. Means NOTE; not safety related.

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

1-2. Servicing Hazards

WARNING The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. Only qualified persons should service, test, maintain, and repair this unit. During servicing, keep everybody, especially children, away. ELECTRIC SHOCK can kill. 1.

Do not touch live electrical parts.

2. Stop engine or turn OFF welding power source and wire feeder, and disconnect and lockout input power using line disconnect switch, circuit breakers, or by removing plug from receptacle before servicing unless the procedure specifically requires an energized unit. 3. Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground. 4. Do not leave live unit unattended. 5. When testing a live unit, use the one-hand method. Do not put both hands inside unit. Keep one hand free. 6. Disconnect input power conductors from deenergized supply line BEFORE moving a welding power source.

HOT PARTS can cause severe burns. 1.

Do not touch hot parts bare handed.

2.

Allow cooling period before servicing welding gun or torch.

EXPLODING PARTS can cause injury. 1. Failed parts can explode or cause other parts to explode when power is applied to inverters. 2.

ELECTRIC SHOCK HAZARD incorrect use of test equipment.

from

1.

Turn Off welding power source and wire feeder or stop engine before making or changing meter lead connections.

7. Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts.

2.

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

STATIC ELECTRICITY can damage parts on circuit boards.

HIGH-FREQUENCY RADIATION can interfere with radio navigation, safety services, computers, and communications equipment.

SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters.

1. Put on grounded wrist strap BEFORE handling boards or parts. 2. Use proper static-proof bags to store, move, or ship PC boards.

FIRE OR EXPLOSION can result from placing unit on, over, or near combustible surfaces. 1. Do not place unit on, over, or near combustible surfaces. 2.

Do not service unit near flammables.

3. Read instructions for test equipment.

1. Have only qualified persons familiar with electronic equipment perform this installation. 2. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. 3. If notified by the FCC about interference, stop using the equipment at once.

FLYING PIECES OF METAL or DIRT can injure eyes.

4. Have the installation regularly checked and maintained.

1. Wear safety glasses with side shields or face shield during servicing.

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

2.

Maxtron 450

Always wear a face shield and long sleeves when servicing inverters.

Be careful not to short metal tools, parts, or wires together during testing and servicing.

TM-2206 Page 1

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

MOVING PARTS can cause injury.

1. Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.

OVERUSE can cause OVERHEATED EQUIPMENT.

1.

2. Use equipment of adequate capacity to lift unit.

MAGNETIC CURRENTS operation.

1.

FIELDS FROM HIGH can affect pacemaker

3. Follow rated duty cycle.

READ INSTRUCTIONS. 1. Use MILLER Testing Booklet (Part No. 150 853) when servicing this unit.

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

2.

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

Allow cooling period.

2. Reduce current or reduce duty cycle before starting to weld again.

1. Pacemaker wearers keep away from servicing areas until consulting your doctor. 1.

Keep away from moving parts.

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

2. Consult the Owner’s Manual for welding safety precautions. 3.

Use only genuine MILLER replacement parts.

1-3. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields The following is a quotation from the General Conclusions Section of the U.S. 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.”

TM-2206 Page 2

To reduce magnetic fields in the workplace, use the following procedures: 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 as practical. 5. Connect work clamp to workpiece as close to the weld as possible. About Pacemakers: The above procedures are also recommended for pacemaker wearers. Consult your doctor for complete information.

Maxtron 450

SECTION 2 – INSTALLATION 2-1. Selecting A Location 1

Lifting Eye

2

Lifting Forks

Use lifting eye or lifting forks to move unit. Movement

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

1

3

Rating Label

Use rating label to determine input power needs. Label is on nameplate.

OR

4

2

Line Disconnect Device

Locate unit near correct input power supply. Y Special installation may be required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 20.

Location 4

3 18 in (460 mm)

ST-800 611 / ST-150 171-C

2-2. Dimensions And Weights Dimensions D C

6 Holes

B

A

Height

23 in (584 mm)

Width

15-1/2 in (394 mm)

Depth

26-1/8 in (664 mm)

A

24-1/16 in (611 mm)

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) Maxtron 450

TM-2206 Page 3

2-3. Weld Output Terminals And Selecting Cable Sizes Total Cable (Copper) Length In Weld Circuit Not Exceeding 100 ft (30 m) Or Less Weld Output Terminals

200 ft (60 m)

250 ft (70 m)

300 ft (90 m)

350 ft (105 m)

400 ft (120 m)

Welding Amperes

10 – 60% Duty Cycle

60 – 100% Duty Cycle

100

4

4

4

3

2

1

1/0

1/0

150

3

3

2

1

1/0

2/0

3/0

3/0

200

3

2

1

1/0

2/0

3/0

4/0

4/0

250

2

1

1/0

2/0

3/0

4/0

2-2/0

2-2/0

300

1

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

350

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

2-4/0

400

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

2-4/0

500

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

3-3/0

3-3/0

600

3/0

4/0

2-2/0

2-3/0

2-4/0

3-3/0

3-4/0

3-4/0

700

4/0

2-2/0

2-3/0

2-4/0

3-3/0

3-4/0

3-4/0

4-4/0

800

4/0

2-2/0

2-3/0

2-4/0

3-4/0

3-4/0

4-4/0

4-4/0

Negative (–)

Positive (+)

150 ft (45 m)

10 – 100% Duty Cycle

Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

S-0007-D

2-4. Voltage Sensing Terminal Connections The voltage sensing terminals provide exact voltage measurement at the welding arc. Strip 1/2 in (13 mm) insulation 7

6

1

Positive (+) Voltage Sensing Terminal

2

Negative (–) Voltage Sensing Terminal

3

Receptacle

4

Proper Plug (Not Supplied)

5

18 Gauge Lead (Not Supplied)

6

Nut

7

Lead Hole

Or 5

3

4

For Electrode Positive (DCEP), connect remaining end of negative (–) terminal lead to work. Connect remaining end of positive (+) terminal lead to weld cable conductor at electrode holder end of weld cable.

5

2 1

3

+

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

– 

Tools Needed:

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

TM-2206 Page 4

Maxtron 450

2-5. Remote 14 Receptacle Information Socket* 24 VOLTS AC A B

K

J

I

H C L N D M G E F

115 VOLTS AC

REMOTE OUTPUT CONTROL

A/V AMPERAGE VOLTAGE ST-800 617

GND

Socket Information

A

24 volts ac. Protected by circuit breaker CB2.

B

C t

o a

cn c

l t t

oa o

sc r

u-t

I

115 volts ac. Protected by circuit breaker CB1.

J

Contact closure to I completes 115 volts ac contactor control circuit.

C

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

D

Remote control circuit common.

E

0 to +10 volts dc input command signal from remote control.

F

Current feedback; +1 volt dc per 100 amperes.

H

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

G

Circuit common for 24 and 115 volts ac circuits.

K

Chassis common.

*The remaining sockets are not used.

Maxtron 450

TM-2206 Page 5

r c

e o

2-6. Remote 17 Receptacle Information REMOTE 17

B C D

A

M

L P NT K R S J E H FG

REMOTE OUTPUT CONTROL

Socket*

Socket Information

D

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

A

+10 volts dc output to remote control.

B

0 to +10 volts dc input command signal from remote control; full control of A/V output from remote control.

H

+24 volts dc; fused at 1 ampere.

K

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

L

–24 volts dc; fused at 1 ampere.

E

Current feedback; +1 volt dc per 100 amperes.

M

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

C

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

G

Arc force (dig)/inductance control; 0 to +10 volts dc set by panel Arc Force (Dig)/Inductance control.

F

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

P

Circuit common for sockets H and L.

S

Chassis common.

METER

CV/CC

ST-800 617

ARC CONTROL

GND

*The remaining sockets are not used.

2-7.

115 Volt AC Duplex Receptacle 1

115 Volt AC Duplex Receptacle RC10

This receptacle supplies up to 10 amperes of 115 volt ac power. This receptacle has GFI (Ground Fault Interrupters). If a ground current is sensed at RC10, output to RC10 stops. Check tools connected to RC10 for damage, and press Reset button. Power output is shared between this receptacle and the Remote 14 receptacle (see Section 2-5).

1

Ref. ST-153 999

TM-2206 Page 6

Maxtron 450

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 Circuit Breaker Rating In Amperes

110

50

40

125

60

45

4

8

10

4

8

8

179 (54)

309 (94)

322 (98)

160 (49)

277 (85)

433 (132)

6

10

10

6

10

10

Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil Reference: 1993 National Electrical Code (NEC).

S-0092J

2-9. Placing Jumper Links Y Turn Off welding power source, disconnect input power, and check voltage on input capacitors according to Section 7-2 before proceeding. Check input voltage available at site. Remove side panel. 1

Jumper Link Label

2

Jumper Links

Move jumper links to match input voltage, and label on unit. Continue to Section 2-10, or reinstall side panel.

2

230 VOLTS

460 VOLTS Do not overtighten. S-155 568

1

460 VOLTS

575 VOLTS

S-157 126

Tools Needed: 3/8 in Ref. ST-150 172-D

Maxtron 450

TM-2206 Page 7

2-10. Connecting Input Conductors To Unit Y Turn Off welding power source, disconnect input power, and check voltage on input capacitors according to Section 7-2 before proceeding.

For Standard Units

1

1

Input And Grounding Conductors

See Section 2-8.

2

2

Terminal Block TE2

Strain Relief Connector

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

L1 L2 L3

3

Reed Relay (Ground Current Sensor – Optional)

If unit is equipped with optional ground current sensor, route grounding conductor through reed switch two times and connect to grounding terminal as shown.

L1 L2 L3

Reinstall side panel(s). 3 1

=GND/PE

Connect to L1, L2, L3 Connect to L1, L2

Y Always connect grounding conductor first.

For Units With Optional Ground Current Sensor

1 2 Terminal Block TE2 L1 L2 L3 L1 L2 L3

=GND/PE 3 1

Connect to L1, L2, L3 Connect to L1, L2

Y Always connect grounding conductor first.

Tools Needed:

7/16 in 3

3/8 in

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

TM-2206 Page 8

Maxtron 450

2-11. Connecting Input Power 1

Input And Grounding Conductors

2

Line Disconnect Device

See Section 2-8.

3

1

2 2

L1 L2

L1

L3

L2

1 1

1

Y Always connect grounding conductor first. = GND/PE

Tools Needed:

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

Maxtron 450

TM-2206 Page 9

SECTION 3 – OPERATION 3-1.

Controls

1

2

3

4

5

6

7

8

1 Power Switch 2 Digital Meters When the contactor is not energized, preset amperage is displayed in SMAW and GTAW modes, and preset voltage is displayed in GMAW mode. 3 Amperage/Voltage Adjustment Control Control adjusts voltage with process switch in GMAW position, and adjusts amperage in SMAW and GTAW positions. This is a ten turn control. When contactor is not energized, control presets output. 4 Process Switch Switch selects type of weld output. Use SMAW position for SMAW. Use GTAW position for GTAW, GMAW-P, and CAC-A. Use GMAW position for GMAW, and FCAW. 5 Amperage/Voltage Control Switch

For front panel control, place switch in Panel position. For remote control, place switch in Remote 14 position (see Section 2-5), or Remote 17 position (see Section 2-6), and connect remote device. 6 Output (Contactor) Control Switch For front panel control of output, place switch in On position. For remote control of output, place switch in Remote 17/14 position, and connect remote device (see Sections 2-5 and 2-6). Y Weld output terminals are energized when Output switch is On and Power is On. 7 Arc Force/Inductance Control Switch Switch selects panel or remote control of arc force/inductance. 8 Dig/Inductance Control

With process switch in SMAW position, control increases short-circuit amperage which allows the operator to use a very short arc length without sticking the electrode. When set towards 0 (zero), short-circuit amperage at low arc voltage is the same as normal welding amperage. When set towards 100, short-circuit amperage is increased at low arc voltage. Control adjusts inductance with process switch in GMAW. Inductance determines the “wetness” of the weld puddle. When set towards 100, “wetness” (puddle fluidity) increases. This control is not functional with process switch in GTAW. Numbers around control are for reference only.

Ref. ST-152 069-D

TM-2206 Page 10

Maxtron 450

3-2. Process Switch Settings Shielded Metal Arc (SMAW) Welding; Panel Amperage Control

Tungsten Inert Gas (GTAW) Welding; Remote Amperage Control

Gas Metal Arc (GMAW) Welding; Remote Voltage Control

For remote control, place A/V switch in Remote 14 position, and Output (Contactor) switch in Remote 17/14 position.

For panel control, place A/V switch in Panel position, and Output (Contactor) switch in On position.

For panel control of voltage, place A/V switch in Panel position.

Gas Metal Arc (GMAW) Welding With 60M Series Wire Feeder

Ref. ST-165 852-B

3-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. Y Exceeding duty cycle can damage unit and void warranty.

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 S ingle-Phase

6 Minutes Welding

Continuous Welding Overheating

4 Minutes Resting

A/V

0

15 Minutes

Maxtron 450

OR Reduce Duty Cycle duty1 4/95 / ST-145 897

TM-2206 Page 11

SECTION 4 – THEORY OF OPERATION 1

Input Terminal Board TE1 And Input Terminal Block TE2

TE1 links welding power source for correct input voltage and TE2 connects line input power. 2

1 3-Phase Line Input Power

Power Switch S1

Input Terminal Board TE1 And Terminal Block TE2

3φ

4

3φ

5 Input Rectifier SR1

Contactor W1

Provides on/off control of welding power source. 3

2

Precharge Resistors R1 And R19

9

7

Contactor W1

GFI Receptacle RC10

Enables precharge network R1, R19, and S1 and connects input rectifier SR1 to the input line. 5

11

Input Rectifier SR1

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

18

Transformer T2

Supplies power to control board PC1, Remote 14 receptacle RC2, and GFI receptacle RC10. 8

9

Remote 14 Receptacle RC2

10

13 Mode Switch S2

19

14 Output (Contactor) Switch S3

GFI Receptacle RC10

Provides 10 amperes of 115 volts ac for auxiliary equipment.

Fan Motor FM

Arc Force (Dig)/  Inductance Control R2

Fan Motor FM

Provides cooling of internal components.

Transformer T2

12

Filter the dc output voltage of SR1. 7

115 VAC

8

Amperage/  Voltage Control R3

Changes the ac line input power to full-wave rectified dc. 6

Precharge Resistors R1, R19

Power Switch S1

Allow initial charge of buss capacitors C8, C9, C10, C11, C12, C13, C18, and C19 through input rectifier SR1 and power switch S1 before contactor W1 is energized. 4

3

Remote 14 Filter Board PC8

Control Board PC1

10 Control Board PC1 Controls weld output by changing the pulse width modulation signal (wider or narrower pulses meaning more or less voltage) to IGBT power modules PM1 and PM2 after comparing current and voltage feedbacks to reference levels set by R3 and R2. 11 Amperage/Voltage Control R3

19 15 Remote 17 Filter Board PC10

18

Sets amount of Dig amperage in CC mode or amount of inductance in CV mode. 13 Mode Switch S2 Selects volt-ampere characteristic for process used.

16 Arc/Inductance And CC/CV Control Switch S5

Sets weld output amperage or voltage level. 12 Arc Force (Dig)/Inductance Control R2

Amperage/  Voltage Control Switch S4

17 Digital Meter Board PC5

Remote 17 Receptacle RC1

14 Output (Contactor) Switch S3 Selects On or Remote for remote contactor control.

TM-2206 Page 12

Maxtron 450

15 Amperage/Voltage Control Switch S4 6

Selects front panel or remote amperage/voltage control.

25

Bus Capacitors C8, C9, C10, C11, C12, C13, C18, C19

Output Diodes D1-D8 25

16 Arc/Inductance And CC/CV Control Switch S5

26

Output Diodes D9-D16

28 Positive (+) Weld Output Terminal

Hall Device HD1

Work

22

23

24 Resonant Tank Circuit

27

28 Negative (–) Weld Output Terminal

Stabilizers Z1, Z2

Current Transformer CT1

Gating Signals

17 Digital Meter Board PC5 Displays preset and actual amperage and voltage.

Electrode

IGBT Power Modules PM1 And PM2

Allows selection of weld process and arc/inductance control from front panel or Remote 17 receptacle RC1.

18 Remote 14 Receptacle RC2 And Remote 17 Receptacle RC1 Connect remote amperage/voltage and contactor controls. 19 Remote 14 Filter Board PC8 And Remote 17 Filter Board PC10 Filter (block) HF and other noise from getting into power source. 20 Optima Option Synergically controls pulsing parameters for GMAW-P. 21 Manual Mig Pulser (MMP) Option Manually controls pulsing parameters for GMAW-P.

Fault Protection

22 IGBT Power Modules PM1 And PM2 Current Feedback

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

20♦

23 Current Transformer CT1 Pulsed GMAW Switch S4

Provides a pulsed current signal to PC1 for fault protection.

Optima Board PC7

24 Resonant Tank Circuit A tuned frequency circuit consisting of capacitors C1-C4, inductors L1-L4, and main transformer T1. T1 steps down the high frequency ac input to low voltage and high current.

21♦ MMP Board PC7

25 Output Diodes D1 Thru D16

Potentiometers R1-R4

Rectify output of T1 to provide dc weld output. 26 Hall Device HD1

GMAW-P Pulse Control Panel

Provides current feedback signal to PC1.

Voltage Feedback Voltage Feedback

27 Stabilizers Z1 And Z2 Smooth welding current. AC Or DC Control Circuits 3φ Power

28 Positive (+) And Negative (–) Weld Output Terminals Provide weld output and allow changing of output polarity.

Weld Current Circuit ♦

Maxtron 450

Optional

TM-2206 Page 13

SECTION 5 – PRE-POWER CHECKLIST 5-1. Checking Unit Before Applying Power . See Section 6-2 for test points and values and  Section 9 for parts location.

. Use MILLER Testing Booklet (Part No. 150 853) when servicing this unit. Y Discharge input capacitors according to Section 7-2 and be sure voltage is near zero before touching any parts. Y Before troubleshooting or applying power to unit, complete following checks to avoid causing further damage. Y Although some parts are briefly checked in this procedure, more complete tests may be needed later. This check is simply to get a basic okay to power up unit.

A. IGBT Modules PM1, PM2 Visually inspect IGBT modules PM1 and PM2 for damage. Isolate terminals C1 and E2 on PM1 and PM2 for testing. Check C1 to E1 and C2 to E2 (diode test). Reassemble IGBTs.

IGBT Module PM1 Or PM2

Remove plugs PLG4 and PLG1 from receptacles RC4 and RC1 on PC1. Check G1 to E1 and G2 to E2 (red to white leads) from PLG4 and PLG1 for infinite resistance in both directions. Reinstall PLG4 and PLG1 For best test, use an IGBT tester (MILLER Part No. 043 553). IGBT Module PM1 Or PM2

Terminal C2/E1

Terminal E2

Terminal C1

G2 (B2) E2

E1 G1 (B1)

IGBT Module PM1 Or PM2

ST-155 791

TM-2206 Page 14

Maxtron 450

B. Control Board PC1 Visually inspect control board PC1 for signs of component failure. Check 8 diodes on PC1 in locations shown. Diodes

Replace PC1 if any diodes are shorted.

Diodes

.

If any diodes are shorted, check IGBTs for failure (see  item C).

Receptacle RC1

Diodes

Receptacle RC4 Control Board PC1

Diodes

ST-155 791 / Ref. SC-164 972

Maxtron 450

TM-2206 Page 15

C. Output Diodes D1-D16 Visually inspect output rectifier diodes D1-D16 for discolored sleeving or signs of heat damage.

Diodes D1-D16

First, perform a diode test across weld output receptacles. If diode test indicates a short, isolate diodes D1-D16 and retest them individually.

Diodes D1-D16

Weld Output Receptacles

ST-155 791

TM-2206 Page 16

Maxtron 450

D. Input Rectifier SR1 1

Visually inspect SR1 for damage.

2

To isolate SR1 for testing, disconnect lead 25 from positive (+) terminal of SR1.

3

Check 6 diodes (diode test). Check from each ac terminal to the positive (+) terminal and from each ac terminal to the negative (–) terminal.

Input Rectifier SR1

Positive (+)

D

A

AC (L1)

Negative (–) (Not Used)

E

B

AC (L2)

Negative (–)

F

C

AC (L3)

Input Rectifier SR1

ST-155 791

E. Clamping Rectifiers SR2 And SR3 Prior To KD414913 1

Check SR2 and SR3 according to MILLER Testing Booklet (Part No. 150 853).

Clamping Rectifiers SR2 And SR3

Clamping Rectifiers SR2 And SR3

ST-155 791

Maxtron 450

TM-2206 Page 17

F.

Hall Device HD1 Visually inspect hall device HD1. Remove plug to isolate for testing. Check from pin 1 to pin 3 for 1500-2000 ohms. Replace HD1 if necessary.

Hall Device HD1

Hall Device HD1 ST-155 791

G. Bus Capacitors C8, C9, C10, C11, C12, C13, C18, And C19 1

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

Bus Capacitors C8 – C13, C18 – C19

Bus Capacitors C8 – C13, C18 – C19

ST-155 791

TM-2206 Page 18

Maxtron 450

H. Tank Capacitors C1, C2, C3, C4 1

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

Tank Capacitors C1 – C4

Tank Capacitors C1 – C4

ST-155 791

I.

Precharge Resistors R1, R19 And Bleeder Resistors R13-R16 1

Check resistance of precharge resistors R1 and R19; R1 and R19 are each 100 ohms ±10%. Effective with Serial No. KF907 718, the values were changed to 25 ohms ±10%

2

Check resistance of bleeder resistors R13-R16. For 230/460 volt models, each resistance is 2500 ohms ±10%. For 460/575 volt models, each resistance is 5k ohms ±10%.

Precharge Resistors R1, R19

Bleeder Resistors R13-R16

ST-155 791

Maxtron 450

TM-2206 Page 19

J.

Contactor W1 1 Contactor W1

Check condition of contacts. Be sure normally-open contacts are open. Replace contactor W1 if necessary.

ST-155 791

TM-2206 Page 20

Maxtron 450

NOTES

Maxtron 450

TM-2206 Page 21

SECTION 6 – TROUBLESHOOTING 6-1. Troubleshooting Table

Trouble No weld output; unit completely inoperative.

.

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

.

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

Remedy 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 for proper connections. Check secondary voltages. Replace T2 if necessary.

No weld output; fan motor FM running and digital meters illuminated.

Place Output (Contactor) switch S3 in the On position or connect remote contactor control to proper remote 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/or TP2 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 1 and 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 proper remote 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%. Replace R3 if necessary. Check resistance and connections of hall device HD1; HD1 is 1600 ohms ±10% between pins 1 and 3 of receptacle RC62. Check input and output voltages. Replace HD1 if necessary. Check control board PC1 and connections, and replace if necessary (see Section 6-4).

Maximum weld output with no control.

Check resistance and connections of Amperage/Voltage control R3; R3 is 1000 ohms ±10%. Replace R3 if necessary. Place Mode switch S2 in proper position for weld process (see Section 3-2). Maximum weld output would occur if a CC process is attempted with S2 in the GMAW/CV position. Check resistance and connections of hall device HD1; HD1 is 1600 ohms ±10% between pins 1 and 3 of receptacle RC62. Check input and output voltages. Replace HD1 if necessary. Check control board PC1 and connections, and replace if necessary (see Section 6-4).

TM-2206 Page 22

Maxtron 450

Trouble Limited weld output and/or low opencircuit voltage.

Remedy 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%. Replace R3 if necessary. Check resistance and connections of remote amperage/voltage control potentiometer, and replace if necessary. 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. Check resistance and connections of hall device HD1; HD1 is 1600 ohms ±10% between pins 1 and 3 of receptacle RC62. Check input and output voltages. Replace HD1 if necessary. Check control board PC1 and connections, and replace if necessary (see Section 6-4).

Remote device for Remote 14 receptacle 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 receptacle RC1 completely inoperative.

Connect remote control to proper Remote receptacle. Be sure pins on remote device are not pushed 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 output available.

Check and clear blocked fan blade. Check fan motor FM, and replace if necessary.

Readings on digital meter not accurate.

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

Wandering arc; poor control of arc direction.

Reduce gas flow rate. Select proper size tungsten. Properly prepare tungsten.

Tungsten electrode oxidizing and not remaining bright after conclusion of weld.

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.

Maxtron 450

TM-2206 Page 23

6-2. Troubleshooting Circuit Diagram For Welding Power Source Y Discharge input capacitors according to Section 7-2, and be sure voltage is near zero before touching any parts.

See Section 3-9 for TE2 information

R5 V6

R2

R1

See Section 3-9 for TE1 information

V1 Contactor W1

V2

See Section 7-5 for PC5 data and Section 7-6 for meter calibration

V5 See Section 7-9 for PC8 data

V3

See Section 3-6 for RC2 data V4

See Section 3-7 for RC1 data

Test Equipment Needed:

See Section 5 for PC10 information

TM-2206 Page 24

Maxtron 450

Resistance Values a)

Tolerance – ±10% unless specified

b)

Turn Off unit and disconnect input power before checking resistance

R1 and R2

100 ohms

R3 and R4

Less than 2 ohms

R5 thru R18

Less than 1 ohm

Voltage Readings

R8

a)

Tolerance – ±10% unless specified

b)

Reference – to circuit common (lead 42) unless noted

c)

Wiring Diagram – see Section 11

R7 R10

V1

230 volts ac

V2

115 volts ac

V3

18 volts ac

V4

18 volts ac

V5

24 volts ac

V6

325 volts dc with 230 volts ac input, 650 volts dc with 460 volts ac input, 812 volts dc with 575 volts ac input

V7

 –0.825 volts dc per 100 amperes weld output

V8

 –24 volts dc

V9

75 to 80 volts dc open-circuit voltage

R9 See Section 7-8 for PC7 (Optima) data

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

See Section 7-7 for PC7 (MMP) data

R11

R13

R15

R17

R3 V9, A, B, C, D, E See Section 7-3 for output waveforms A, B, C, D, E

R12

R14

R16

R18

R4

V7

V8

SD-167 529

Maxtron 450

TM-2206 Page 25

6-3. Waveforms For Section 6-2

5 ms 50 V

gnd

20 µs 20 V

gnd

A. DC Open-Circuit Voltage, Mode Switch S2 In GMAW/CV Position

B. 20.0 Volts DC, 187 Amperes, Mode Switch S2 In GMAW/CV Position (Resistive Load)

5 ms 50 V

gnd

C. DC Open-Circuit Voltage, Mode Switch S2 In GTAW/CC Position

TM-2206 Page 26

20 µs 20 V

gnd

D. 21.4 Volts DC, 200 Amperes, Mode Switch S2 In GTAW/CC Position (Resistive Load)

Maxtron 450

5 ms 50 V

gnd Test Equipment Needed:

E. DC Open-Circuit Voltage, Mode Switch S2 In SMAW/CC Position

Maxtron 450

TM-2206 Page 27

6-4. Control Board PC1 Testing Information (Use With Section 6-5) Y Discharge input capacitors according to Section 7-2, and be sure voltage is near zero before touching any parts. Be sure plugs are secure before testing. See Section 6-5 for specific values during testing. 2

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

6

10 4

7 3

1

8

9

5

Test Equipment Needed:

ST-155 791 / Ref. SC-164 972

TM-2206 Page 28

Maxtron 450

6-5. Control Board PC1 Test Point Values a) Tolerance – ±10% unless specified PC1 Voltage Readings

Receptacle

Pin

RC1

RC2

RC3

Maxtron 450

Value

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

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

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

6

 –24 volts dc output

7

Not used

8

Circuit common

9

Circuit common

10

Circuit common

RC4

RC5

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

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

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 Off position

5

+1 volt dc input per 100 amperes of weld output

6

+1 volt dc input per 10 volts of weld output

7

+24 volts dc output

8

Not used TM-2206 Page 29

Receptacle

Pin

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

5

+15 volts dc output

6

Pulsed command input

7

Same as Positive (+) weld output terminal

8

Same as Negative (–) weld output t erminal

9

Pulse reference voltage, 0 to +10 volts dc output

10

 –24 volts dc output

11

+24 volts dc output

12

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

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/CC or GTAW/CC position

3

Arc control, 0 to +10 volts dc input

4

+1 volt dc output per 100 amperes of weld output

5

+15 volts dc 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 t erminal

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/CV or GTAW/CC position

RC7

Value

RC8

1, 2, 3

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

TM-2206 Page 30

Not used

Maxtron 450

6-6. Digital Meter Board PC5 Testing Information (Use With Section 6-7) Y Discharge input capacitors according to Section 7-2, and be sure voltage is near zero before touching any parts. Be sure plugs are secure before testing. See Section 6-7 for specific values during testing.

1

1

Digital Meter Board PC5

2

Receptacle RC50

2

See Section 6-8  for meter calibration. Test Equipment Needed:

ST-155 830 / SA-150 332-A

6-7. Digital Meter Board PC5 Test Point Values a) Tolerance – ±10% unless specified PC5 Voltage Readings

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

Receptacle

Pin

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 in SMAW/CC or GTAW/CC position

8

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

9

Not used

10

Not used

11

Not used

Maxtron 450

Value

TM-2206 Page 31

6-8. Digital Meter Calibration

Be sure plugs are secure before calibrating meters. 1

Digital Meter Board PC5

2

Voltmeter

3

Ammeter

4

Access Slot

5

Potentiometer R36

6

Potentiometer R1

7

Potentiometer R6

8

Potentiometer R3

9

Potentiometer R8

5

7

8

10

6

9

10 Potentiometer R4

1

2

4

3

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

TM-2206 Page 32

Maxtron 450

GTAW/CC Mode

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

Top View

Top View

R36

R1

00.0

565 Amperes (±2)

Volts (±0.5)

R36

R6

R3

R4

R1

R8

Top View 6. Adjust R6 for voltage gain to match external calibrated meter using load bank set at desired load

R6

00.0 Volts

GMAW/CV Mode

7. Change top switch

8. Adjust R3 for ammeter offset or zero

9. Adjust R8 for voltage preset

Top View

Top View

R3

R8

000

38.0

Amperes (±2)

R36

R6

Volts (±0.5)

R3

R4

R1

R8

Top View R4 10. Adjust R4 for amperage gain to match external calibrated meter using load bank set at desired load

Maxtron 450

000 Amperes

TM-2206 Page 33

6-9. Optional MMP Board PC7 Testing Information (Use With Section 6-10) Y Discharge input capacitors according to Section 7-2, and be sure voltage is near zero before touching any parts.

1

Be sure plugs are secure before testing. See Section 6-10 for specific values during testing. 1

MMP Board PC7

2

Receptacle RC1

3

Receptacle RC2

Test Equipment Needed:

2

3

Ref. ST-157 330 / SA-155 031

6-10. Optional MMP Board PC7 Test Point Values a) Tolerance – ±10% unless specified PC7 Voltage Readings

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

Receptacle

Pin

RC1

1

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

2

Circuit common

3

+15 volts dc output

4

+15 volts dc output

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

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

RC2

TM-2206 Page 34

Value

Maxtron 450

6-11. Optional Optima Board PC7 Testing Information (Use With Section 6-12) Y Discharge input capacitors according to Section 7-2, and be sure voltage is near zero before touching any parts.

1

Be sure plugs are secure before testing. See Section 6-12 for specific values during testing. 1

Optima Board PC7

2

Receptacle RC1

3

Receptacle RC2

4

Receptacle RC3

Test Equipment Needed:

3

2

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

6-12. Optional Optima Board PC7 Test Point Values a) Tolerance – ±10% unless specified PC7 Voltage Readings

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

Receptacle

Pin

RC1

A

Input from Positive (+) weld output receptacle

B

Input from Negative (–) weld output receptacle

A

Not used

B

Pulse reference, 0 to +10 volts dc input

C

Not used

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

RC2

RC3

Maxtron 450

Value

TM-2206 Page 35

6-13. Remote 14 Filter Board PC8 Testing Information (Use With Section 6-14) Y Discharge input capacitors according to Section 7-2, and be sure voltage is near zero before touching any parts. Be sure plugs are secure before testing. See Section 6-14 for specific values during testing.

1 3

6

2

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

5

4

Test Equipment Needed:

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

TM-2206 Page 36

Maxtron 450

6-14. Remote 14 Filter Board PC8 Test Point Values a) Tolerance – ±10% unless specified PC8 Voltage Readings

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

Receptacle

Pin

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 dc input

11

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

12

+1 volt dc input per 10 volts of weld output

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

RC31

Value

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

Maxtron 450

TM-2206 Page 37

SECTION 7 – MAINTENANCE 7-1. Routine Maintenance . Maintain more often 

Y Disconnect power before maintaining.

during severe conditions.

3 Months Repair Or Replace Cracked Cables

Replace Damaged Or Unreadable Labels

Replace Cracked Torch Body

Repair Or Replace Cracked Cables And Cords

Clean And Tighten Weld Terminals

6 Months Blow Out Or Vacuum Inside

TM-2206 Page 38

Maxtron 450

7-2.

Measuring Input Capacitor Voltage Turn Off welding power source, and disconnect input power. Remove top cover. Significant DC voltage can remain on capacitors after unit is Off. The input capacitor voltage can be measured across terminals on input rectifier SR1. Always check the voltage as shown to be sure the input capacitors have discharged before working on unit.

1

Input Rectifier SR1

2

Voltmeter

Measure the dc voltage across the positive (+) and negative (–) terminals until voltage drops to near 0 (zero) volts. Proceed with job inside unit. Reinstall top cover when finished.

1

2

Tools Needed: 3/8 in ST-150 222-F / ST-150 173-C

7-3.

Optional Ground Current Sensor 1

Reed Relay (Ground Current Sensor – Optional)

Defects in external electrical circuitry may cause the ground wire to conduct welding current. Relays CR1 and CR2 sense excessive current in the ground conductor and open the solid state contactor, shutting down weld output. Open circuit voltage is not available, but the fan motor FM runs and the pilot light PL1 stays on. If the welding power source shuts down due to the ground current sensor, disconnect all power, and correct the problem before welding again. 1

ST-156 172-D

Maxtron 450

TM-2206 Page 39

7-4. Circuit Breakers And Fuses Y Turn Off welding power source, disconnect input power, and check voltage on input capacitors according to Section 7-2 before proceeding. 1

Circuit Breaker CB1

If CB1 opens, remote devices using 115 volts from Remote 14 receptacle stop. Manually reset CB1. 2

5 4

6

Circuit Breaker CB2

If CB2 opens, remote devices using 24 volts from Remote 14 receptacle stop. Manually reset CB2. 3

Circuit Breaker CB3

If CB3 opens, devices connected to the 115 volt duplex receptacle and remote devices using 115 volts from Remote 14 receptacle stop. Manually reset CB3. 4

Fuse F1

If F1 opens, the welding power source shuts down. 5

Fuse F3

6

Fuse F4

If F3 or F4 opens, remote control devices connected to Remote 17 receptacle RC1 may shut down. See Parts List for fuse ratings. Use proper tool when removing fuses.

1

2

3

Tools Needed:

3/8 in ST-150 222-F / Ref. ST-152 069-C / ST-150 173-C

TM-2206 Page 40

Maxtron 450

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 inside  machine 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 Maxtron 450 (230/460)

Serial Or Style Number

Circuit Diagram

Wiring Diagram

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

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

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

Maxtron 450 (460/575)

Circuit Board PC1 (230/460)

♦

Optional

♦♦

Not included in this manual

Maxtron 450

TM-2206 Page 41

Figure 8-1. Circuit Diagram For Maxtron 450 (230/460 Volts) Effective With Serial No. KC237305 Thru KD342941 TM-2206 Page 42

Maxtron 450

SD-142 760-H

Maxtron 450

TM-2206 Page 43

Figure 8-2. Circuit Diagram For Maxtron 450 (230/460 Volts) Effective With Serial No. KD342942 Thru KD375311 TM-2206 Page 44

Maxtron 450

SD-158 709-B

Maxtron 450

TM-2206 Page 45

Figure 8-3. Circuit Diagram For Maxtron 450 (230/460 Volts) Effective With Serial No. KD375312 Thru KD414912 TM-2206 Page 46

Maxtron 450

SD-159 815-B

Maxtron 450

TM-2206 Page 47

Figure 8-4. Circuit Diagram For Maxtron 450 (230/460 Volts) Effective With Serial No. KD414913 Thru KD433774 TM-2206 Page 48

Maxtron 450

SD-160 564-A

Maxtron 450

TM-2206 Page 49

Figure 8-5. Circuit Diagram For Maxtron 450 (230/460 Volts) Effective With Serial No. KD433775 Thru KD485760 TM-2206 Page 50

Maxtron 450

SD-164 041

Maxtron 450

TM-2206 Page 51

Figure 8-6. Circuit Diagram For Maxtron 450 (230/460 Volts) Effective With Serial No. KD485761 Thru KD523654 TM-2206 Page 52

Maxtron 450

SD-164 676

Maxtron 450

TM-2206 Page 53

Figure 8-7. Circuit Diagram For Maxtron 450 (230/460 Volts) Effective With Serial No. KD523655 Thru KE575507 TM-2206 Page 54

Maxtron 450

SD-165 760

Maxtron 450

TM-2206 Page 55

Figure 8-8. Circuit Diagram For Maxtron 450 (230/460 Volts) Effective With Serial No. KE575508 And Following TM-2206 Page 56

Maxtron 450

SD-167 529-A

Maxtron 450

TM-2206 Page 57

Figure 8-9. Wiring Diagram For Maxtron 450 (230/460 Volts) Effective With Serial No. KE575508 And Following TM-2206 Page 58

Maxtron 450

SD-167 531

Maxtron 450

TM-2206 Page 59

Figure 8-10. Circuit Diagram For Maxtron 450 (460/575 Volts) Effective With Serial No. KC237305 Thru KD485760 TM-2206 Page 60

Maxtron 450

SD-157 431-B

Maxtron 450

TM-2206 Page 61

Figure 8-11. Circuit Diagram For Maxtron 450 (460/575 Volts) Effective With Serial No. KD485761 Thru KD523654 TM-2206 Page 62

Maxtron 450

SD-164 680

Maxtron 450

TM-2206 Page 63

Figure 8-12. Circuit Diagram For Maxtron 450 (460/575 Volts) Effective With Serial No. KD523655 Thru KE575507 TM-2206 Page 64

Maxtron 450

SD-165 762

Maxtron 450

TM-2206 Page 65

Figure 8-13. Circuit Diagram For Maxtron 450 (460/575 Volts) Effective With Serial No. KE575508 And Following TM-2206 Page 66

Maxtron 450

SD-167 530-A

Maxtron 450

TM-2206 Page 67

Figure 8-14. Wiring Diagram For Maxtron 450 (460/575 Volts) Effective With Serial No. KE575508 And Following TM-2206 Page 68

Maxtron 450

SD-167 532

Maxtron 450

TM-2206 Page 69

Figure 8-15. Circuit Diagram For Control Board PC1 Effective With Serial No. KG111783 And Following (Part 1 Of 2) TM-2206 Page 70

Maxtron 450

SD-180 871-A (1 Of 2)

Maxtron 450

TM-2206 Page 71

Figure 8-16. Circuit Diagram For Control Board PC1 Effective With Serial No. KG111783 And Following (Part 2 Of 2) TM-2206 Page 72

Maxtron 450

SD-180 871-A (1 Of 2)

Maxtron 450

TM-2206 Page 73

SC-150 334-A

Figure 8-17. Circuit Diagram For Digital Meter Board PC5 Effective With Serial No. KC237305 And Following TM-2206 Page 74

Maxtron 450

SC-155 033

Figure 8-18. Circuit Diagram For Optional MMP Board PC7 Effective With Serial No. KC260558 And Following Maxtron 450

TM-2206 Page 75

Figure 8-19. Circuit Diagram For Optional Optima Board PC7 Effective With Serial No. KC237305 And Following TM-2206 Page 76

Maxtron 450

SD-160 657

Maxtron 450

TM-2206 Page 77

SB-142 337

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

SA-124 988-B

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

TM-2206 Page 78

Maxtron 450

February 1997

Form:

TM-2206

Effective With Serial No. KC237305

SECTION 9 – PARTS LIST

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

Maxtron 450

TM-2206 Page 79

        9         2

   5      9   g    i    F

        0         3

        1         3

        8         2

   4      9   g    i    F

        7         2

        2         3

        6         2

   3      9   g    i    F

        1         1         6         5         5         2

        7

        8         3         3

        4

        1         2

        4         2

        3         2

        8         1

        9         1         0         2

        7         1

        2         2

        4         3

        6         1

        5         1

        1         2

        9         4         1

        3         1

        2         1

        7         8        9

        2

        0 1

        1 1

        5         3         6         3

        6         5         4

        1         7         3

        3

        9         3

        8         3

        1         4

   2      9   g    i    F

        0         4

ST-150 054-H

Figure 9-1. Main Assembly TM-2206 Page 80

Maxtron 450

Item No.

Dia. Mkgs.

Part No.

Description

Quantity

Figure 9-1. Main Assembly . . . 1 . . . . . . . . . . . . . . . . 152 346 . . . . . . . . . . . . . . . . . . . . . . 155 653 . . . 2 . . . . . . . . . . . . . . . +147 962 . . . . . . . . . . . . . . . . . . . . . . 155 652 . . . 3 . . . . C50,51 . . . . 164 812 . . . 4 . . . . . . . . . . . . . . . . 155 642 . . . 5 . . . . . . . . . . . . . . . . 143 748 . . . 6 . . . . . . . . . . . . . . . . 145 245 . . . 7 . . . . . . . . . . . . . . . . 143 749 . . . 8 . . C8-13,18,19 . . 135 786 . . . 8 . . C8-13,18,19 . . 140 891 . . . 9 . . . . . . . . . . . . . . . . 148 556 . . . 10 . . . . . . . . . . . . . . . . 148 553 . . . 11 . . . . . . . . . . . . . . . . 126 026 . . . 12 . . . . . . . . . . . . . . . . 145 743 . . . 13 . . . . . TE2 . . . . . 147 386 . . . 14 . . . . . TE1 . . . . . 148 446 . . . 14 . . . . . TE1 . . . . . 157 322 . . . 15 . . . . . . . . . . . . . . . . 147 899 . . . 16 . . . . . . Z1 . . . . . . 144 050 . . . 17 . . . . . . Z2 . . . . . . 147 901 . . . 18 . . . . . . T1 . . . . . . 144 274 . . . 18 . . . . . . T1 . . . . . . 157 501 . . . 19 . . . . . . . . . . . . . . . . 143 731 . . . 20 . . . . . . . . . . . . . . . . 604 126 . . . 21 . . . . . . . . . . . . . . . . 153 178 . . . 22 . . . . . . . . . . . . . . . . 144 929 . . . 23 . . . . . . . . . . . . . . . . 143 732 . . . 24 . . . . . . . . . . . . . . . . 088 058 . . . 25 . . . . . . . . . . . . . . . +143 746 . . . 26 . . . . . . . . . . . . . . . . 145 053 . . . 27 . . . . . . . . . . . . . . . . . Fig 9-4 . . . 28 . . . . . . . . . . . . . . . . . Fig 9-5 . . . . . . . . . . PLG18 . . . . 131 054 . . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . . . . . . . . RC18 . . . . . 135 635 . . . . . . . . . . . . . . . . . . . . . . 114 656 . . . 29 . . . . . . . . . . . . . . . . 605 603 . . . 30 . . . . . . . . . . . . . . . . 143 741 . . . 31 . . . . . . . . . . . . . . . . 070 592 . . . 32 . . . . . . . . . . . . . . . . . Fig 9-3 . . . 33 . . . . . . . . . . . . . . . . 154 066 . . . 34 . . . . . . . . . . . . . . . . 605 538 . . . . . . . . . . C31-38 . . . . 139 849 . . . . . . . . . . . . . . . . . . . . . . 152 077 . . . . . . . . . . . . . . . . . . . . . . 159 257 . . . . . . . . . . SR2,3 . . . . . 149 219 . . . 35 . . . . . . . . . . . . . . . +143 745 . . . 35 . . . . . . . . . . . . . . . +157 427 . . . 36 . . . . . . . . . . . . . . . . 145 477 . . . 37 . . . . . . T2 . . . . . . 148 448 . . . 37 . . . . . . T2 . . . . . . 154 852 . . . 37 . . . . . . T2 . . . ♦♦154 083

. . COVER, top w/insulation (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSULATOR, top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, side RH w/insulator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSULATOR, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR, (Eff w/KD523655) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREW, set .250-28 x 1.000 cup pt sch stl (Eff w/KC295487) . . . . . . . . . BUS BAR, (across front of C8,9,18,19 & C10-13) . . . . . . . . . . . . . . . . . . . . INSULATOR, elctlt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUS BAR, (across back of C8,9,18,19 & C10-13) . . . . . . . . . . . . . . . . . . . . CAPACITOR, elctlt 4000uf 250VDC (230/460V) . . . . . . . . . . . . . . . . . . . . . . CAPACITOR, elctlt 2800uf 300VDC (460/575V) . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUG, univ w/scr 600V 2-14 wire .250 stud . . . . . . . . . . . . . . . . . . . . . . . . . . . BLOCK, term 70A 3P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TERMINAL ASSEMBLY, pri (230/460V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TERMINAL ASSEMBLY, pri (460/575V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg term block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STABILIZER, left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STABILIZER, right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSFORMER, HF (Prior to KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSFORMER, HF (Eff w/KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT EYE, upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREW, cap stl hexhd .500-13 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning exploding parts can seriously injure . . . . . . . . . . . . . . . . . GASKET, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, .500-13 stl elastic stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, shldr nyl .298 OD x .203 ID x 1.000 . . . . . . . . . . . . . . . . . . . . . . . CHASSIS, mid upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAN MOTOR/MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS, (part of FM) (consisting of) . . . . . . . . . . . . . . . . CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . . . . . . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR, rect pin 24-18ga Molex 39-00-0040 . . . . . . . . . . . . . . . . . TUBING, gl acryl 1.000-1.036 ID (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TUBING, gl acryl .500-.524 ID (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS, mid lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSULATOR, capacitor (Eff w/KC234210) . . . . . . . . . . . . . . . . . . . . . . . . . . . CABLE TIE, 0-4.500 bundle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR ASSEMBLY, (Prior to KD414913) . . . . . . . . . . . . . . . . . . . . . . HEAT SINK, spillover (Prior to KD350778) . . . . . . . . . . . . . . . . . . . . . . . . . . HEAT SINK, spillover (Eff w/KD350778 thru KD414913) . . . . . . . . . . . . . . KIT, rectifier integ 35A (Prior to KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . BASE, (Prior to KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BASE, (Eff w/KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STIFFENER, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSFORMER, control (Prior to KC260558) . . . . . . . . . . . . . . . . . . . . . . . TRANSFORMER, control (Eff w/KC260558 thru KD375312) . . . . . . . . . . . TRANSFORMER, kVA 1.5 115-230/230-18/18-24 (230/460V) (Eff w/KD375312 thru KE575507) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 . . . . . . T2 . . . . . . 167 521 . . TRANSFORMER, kVA 1.5 115/230/230-18-18-24 (230/460V) (Eff w/KE575508 and on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 . . . . . . T2 . . . . . . 160 978 . . TRANSFORMER, kVA 1.5 115-230/460/575-18/18-24 (460/575V) (Prior to KE575508) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 . . . . . . T2 . . . . . . 167 522 . . TRANSFORMER, kVA 1.5 115-230/460/575-18/18-24 (460/575V) (Eff w/KE575508) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maxtron 450

1 1 1 1 2 16 4 4 2 8 8 2 2 2 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 12 1 1 1 2 1 2 3ft 4 3ft 1 2 16 2 2 2 2 1 1 2 1 1 1 1 1 1

TM-2206 Page 81

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Part No.

Description

Quantity

Figure 9-1. Main Assembly (Continued) . . . . . . . . . . PLG21 . . . . 168 165 . . . . . . . . . . . . . . . . . . . . . . 114 066 . . . . . . . . . . . RC21 . . . . . 130 204 . . . . . . . . . . . . . . . . . . . . . . 113 633 . . . 38 . . . . . . . . . . . . . . . . . Fig 9-2 . . . . . . . . . RC11,15 . . . 116 045 . . . . . . . . . . . . . . . . . . . . . . 113 633 . . . . . . . . . PLG11,15 . . . 135 556 . . . . . . . . . . . . . . . . . . . . . . 114 066 . . . 39 . . . . . . . . . . . . . . . . 134 327 . . . 40 . . . . . . . . . . . . . . . +147 961 . . . 41 . . . . . . . . . . . . . . . . 155 651 . . . . . . . . . . . . . . . . . . . . . . 134 756 . . . . . . . . . . . CR2 . . . ♦155 757 . . . . . . . . . . . . . . . . . . . . . . 010 014 . . . . . . . . . . . . . . . . . . . . . . 010 143

. . CONNECTOR & SOCKETS, (Eff w/KE575508) (consisting of) . . . . . . . . . . . CONNECTOR, rect skt 20-14ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & PINS, (Eff w/KE575508) (consisting of) . . . . . . . . . . . . . . . . CONNECTOR, rect pin 20-14ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR, rect pin 20-14ga Amp 350218-1 . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR, rect skt 20-14ga Amp 350536-1 . . . . . . . . . . . . . . . . . . . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, side LH w/insulator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSULATOR, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning electric shock can kill (on LH panel) . . . . . . . . . . . . . . . . . SWITCH, reed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLAMP, stl cush .750dia x .203mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLAMP, nyl .375clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 3 1 3 1 2 6 2 6 2 1 1 1 1 4 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. 1 6

2

7

3 4

8

5

9 17 10

39 48

11

47

12 13 16 14 15

46 43

19

42

18

20

45 44

22

31

23

21 24

25

26

30

27 28 29 30

43 42 41

32 33

37 34 35 36 40

39

31

38 ST-150 167-F

Figure 9-2. Panel, Front w/Components TM-2206 Page 82

Maxtron 450

Item No.

Dia. Mkgs.

Part No.

Description

Quantity

Figure 9-2. Panel, Front w/Components (Fig 9-1 Item 38) . . . 1 . . . . . . . . . . . . . . 146 684 . . . INSULATOR, switch pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . S1 . . . . . . 128 756 . . . SWITCH, tgl 3PST 40A 600VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . . 148 297 . . . NUT, speed U type 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . . . . . . . . 071 230 . . . BEZEL/FILTER, blk bezel/red filter 2.000 viewing . . . . . . . . . . . . . . . . . . . . . . . . 5 . . . . . . . . . . . . . . 135 299 . . . LOCK, shaft pot .375-32 x .250dia shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . PC5 . . . . . 150 331 . . . CIRCUIT CARD, amp/volt meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG50 . . . . 089 222 . . . CONNECTOR, rect 11skt plug Amp 1-640440-1 . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . . . . . . . . . . . 153 374 . . . ENCLOSURE, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . . . . . . . . . . . 134 201 . . . STAND-OFF SUPPORT, PC card .312/.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 . . . . . . . . . . . . . . 604 311 . . . GROMMET, rbr .250 ID x .375mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . . R3 . . . . . 030 856 . . . POTENTIOMETER, WW sltd sft 10/T 2W 1K ohm . . . . . . . . . . . . . . . . . . . . . . . 11 . . . . R2 . . . . . 035 897 . . . POTENTIOMETER, C sltd sft 1/T 2W 1K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . . S2 . . . . . . 088 409 . . . SWITCH, tgl DPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 . . . . . S4 . . . . . . 128 808 . . . SWITCH, tgl SPTT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 . . . . . S3 . . . . . . 011 609 . . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 . . . . . S5 . . . . . . 011 611 . . . SWITCH, tgl DPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 . . . . R1-4 . . . ♦073 562 . . . POTENTIOMETER, C sltd sft 1/T 2W 10K ohm . . . . . . . . . . . . . . . . . . . . . . . . . 17 . . . . . . . . . . . . ♦141 690 . . . GROMMET, scr No. 8/10 panel hole .281sq .197 high . . . . . . . . . . . . . . . . . . . 17 . . . . . . . . . . . ♦♦153 994 . . . GROMMET, scr No. 8/10 panel hole .281sq .547 high . . . . . . . . . . . . . . . . . . . 18 . . . . . . . . . . . . +153 260 . . . ENCLOSURE, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . . . . . . . . . . ♦157 453 . . . INSULATOR, PC card (Eff w/KC299794) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 . . . . PC7 . . . ♦155 030 . . . CIRCUIT CARD, remote pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 . . . . PC7 . . ♦♦162 076 . . . CIRCUIT CARD, pulse control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG1 . . ♦115 092 . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . . CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG2 . . +135 558 . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 079 747 . . . . . CONNECTOR, rect skt 24-18ga Amp 350980-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG3 . . +079 796 . . . CONNECTOR, rect 3skt plug Amp 640250-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +079 747 . . . CONNECTOR, rect skt 24-18ga Amp 350980-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG4 . . +135 557 . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 079 747 . . . . . CONNECTOR, rect skt 24-18ga Amp 350980-1 . . . . . . . . . . . . . . . . . . . . . . . 21 . . . . . S6 . . . . . +011 609 . . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 860. . . BLANK, snap-in nyl .187mtg hole (not used when unit has either option) . . . . . . . . . . . . . . . . . . . . . 119 951. . . BLANK, snap-in nyl .437mtg hole (not used when unit has either option) . . . . . . . . . . . . . . . . . . . . . 107 983. . . BLANK, snap-in nyl .500mtg hole (not used when unit has either option) . . . 22 . . . . RC2 . . . . . 143 976 . . . CONNECTOR w/SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 079 534 . . . . . CONNECTOR, circ skt push-in 14-18ga Amp 66358-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . . . . CB2 . . . . . 083 432 . . . CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . . . . CB3 ♦♦♦083 432 . . . CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 057 359 . . . BLANK, snap-in nyl .375mtg hole (Prior to KD375312) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 715 . . . STRIP, mtg circuit breakers (Prior to KD375312) . . . . . . . . . . . . . . . . . . . . . . . . 26 . . . . R17 . . . . . 030 945 . . . RESISTOR, C 2W 4.7K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 . . . . R5 . . . . . 028 271 . . . RESISTOR, C .5W 100K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 . . . . C39 . . . . . 074 200 . . . CAPACITOR, polye film .047uf 400VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 . PC10,RC1 . . 137 542 . . . CIRCUIT CARD, connector 17skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 . . . . Neg . . . . . 039 046 . . . TERMINAL, pwr output black (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 . . . . Pos . . . . . 039 047 . . . TERMINAL, pwr output red (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 . . . . . . . . . . . . . . 601 976 . . . . . SCREW, cap stl hexhd .500-13 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 . . . . . . . . . . . . . . 039 045 . . . . . TERMINAL BOARD, black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 . . . . . . . . . . . . . . 039 049 . . . . . TERMINAL BOARD, red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 . . . . . . . . . . . . . . 601 880 . . . . . NUT, stl hex jam .500-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . . 039 044 . . . . . BUS BAR, term bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 . . . . . . . . . . . . . . 601 879 . . . . . NUT, stl hex full .500-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 . . . . . . . . . . . . . . 143 747 . . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maxtron 450

1 1 2 2 1 1 1 1 4 1 1 1 1 1 1 1 4 4 4 1 1 1 1 1 8 1 7 1 3 1 2 1 4 4 1 1 14

1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1

TM-2206 Page 83

Item No.

Dia. Mkgs.

Part No.

Description

Quantity

Figure 9-2. Panel, Front w/Components (Fig 9-1 Item 38) (Continued) . . 38 . . . RC10 ♦♦♦147 939 . . . RECEPTACLE, str dx grd 2P3W 15A 125V GFCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 073 690. . . PLUG, str grd armd 2P3W 15A 125V P & S 5266DF . . . . . . . . . PLG20 . . . . 168 165 . . . CONNECTOR & SOCKETS, (Eff w/KE575508) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 066 . . . . . CONNECTOR, rect skt 20-14ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RC20 . . . . 130 204 . . . CONNECTOR & PINS, (Eff w/KE575508) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 633 . . . . . CONNECTOR, rect pin 20-14ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . . 40 . . . . . . . . . ♦♦♦154 022 . . . COVER, receptacle duplex GFCI weather proof . . . . . . . . . . . . . . . . . . . . . . . . . 41 . . . . . . . . . . . . . . 039 885 . . . CONNECTOR, circ protective cap Amphenol 9760-20 . . . . . . . . . . . . . . . . . . . 42 . . . . . . . . . . . . . . 039 654 . . . POST, bdg black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 . . . . . . . . . . . . . . 039 655 . . . POST, bdg red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 . . . . . . . . . . . . ♦097 922 . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 . . . . . . . . . . . ♦♦097 922 . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 . . . . . . . . . . . . . . . . . . . . + . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . . 46 . . . . . . . . . . . . . . 097 922 . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 . . . . . . . . . . . . . . 143 797 . . . SPACER, nyl .312 OD x .194 ID x .437 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 . . . . PC8 . . . . . 167 679 . . . CIRCUIT CARD, receptacle bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG30,31 . . 130 203 . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . . CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . . . . . . . .

1 1 3 1 3 1 1 2 1 1 4 1 1 2 4 1 2 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.

Item No.

Dia. Mkgs.

Part No.

Description

Quantity

Figure 9-3. Chassis, Mid Lower (Fig 9-1 Item 32) ... 1 .............. ... 2 .............. ... 2 .............. ... 3 .............. ... 3 .............. ... 3 .............. ... 4 .............. ... 4 .............. ... 4 .............. . . . . . . . . . C22-29, 40-47 . . . . . . . . . . . . CM1,2 . . . . . . . . . . . . . D1-16 . . . . . . . . . . . . . PM1,2 . . . . . . . . . . . . . PM1,2 . . . . . . . . . . . . . TP1,2 . . . .................... .................... ... 5 .............. ... 6 .............. ... 7 .............. . . . . . . . . . . R9-12 . . . .................... ... 8 .............. ... 8 .............. ... 9 .............. ... 9 .............. TM-2206 Page 84

153 403 . . . 153 380 . . . 157 425 . . . 145 265 . . . 160 765 . . . 157 571 . . . 145 266 . . . 160 766 . . . 157 572 . . .

BUSHING, snap-in nyl .750 ID x 1.000mtg hole . . . . . . . . . . . . . . . . . . . . . . BAFFLE, air (Prior to KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BAFFLE, air (Eff w/KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODULE, pwr LH (230/460V) (Prior to KD414913) (consisting of) . . . . . . MODULE, pwr LH (230/460V) (Eff w/KD414913) (consisting of) . . . . . . . . MODULE, pwr LH (460/575V) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . MODULE, pwr LH (230/460V) (Prior to KD414913) (consisting of) . . . . . . MODULE, pwr RH (230/460V) (Eff w/KD414913) (consisting of) . . . . . . . MODULE, pwr RH (460/575V) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . .

3 2 2 1 1 1 1 1 1

031 689 . . . . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 157 497 . . . . . MODULE, capacitor (Eff w/KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 149 209 . . . . . KIT, diode fast recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 149 238 . . . . . KIT, transistor IGBT module (230/460V) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 157 566 . . . . . KIT, transistor IGBT module (460/575V) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 006 334 . . . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 072 253 . . . . . STUD, connection single 10-32 x .500 x 1.250 . . . . . . . . . . . . . . . . . . . . . 8 143 722 . . . . . HEAT SINK, pwr module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 142 592 . . . BAR, support heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 135 661 . . . EDGE TRIM, style 3100-1/16 (order by ft) (Eff w/KD414913) . . . . . . . . . . 2ft 047 838 . . . BLANK, snap-in nyl 1.000mtg hole (Eff w/KD414913) . . . . . . . . . . . . . . . . . 1 149 729 . . . 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) . . . . . . . . . 3 143 738 . . . TRAY, mtg cmpts lower (Prior to KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . 1 157 426 . . . TRAY, mtg cmpts lower (Eff w/KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 057 357 . . . BUSHING, snap-in nyl .937 ID x 1.125mtg hole (Prior to KD523655) As Req’d 057 358 . . . BUSHING, snap-in nyl 1.000 ID x 1.375mtg hole (Eff w/KD523655) As Req’d Maxtron 450

Item No.

Dia. Mkgs.

Part No.

Description

Quantity

Figure 9-3. Chassis, Mid Lower (Fig 9-1 Item 32) (Continued) . . . 10 . . . R13-16 . . . . . . 10 . . . R13-16 . . . . . . . . . . . . CM1,2 . . . . . . 11 . . . RM1,2 . . . . . . 12 . . . . C1-4 . . . . . . . 13 . . . . . . . . . . . . . . . . . 14 . . . . . . . . . . . . . . . . . 15 . . . . . . . . . . . . . . . . . 15 . . . . . . . . . . . . . . . . . 16 . . . . L1-4 . . . . . . . . . . . . . . . CT1 . . . . .................... .................... ....................

147 902 . . . 139 812 . . . 151 198 . . . 153 336 . . . 143 359 . . . 145 162 . . . 006 426 . . . 133 405 . . . 148 297 . . . 144 325 . . . 140 328 . . . 122 681 . . . 097 863 . . . 097 865 . . . 1

RESISTOR, WW fxd 30W 2500 ohm (230/460V) . . . . . . . . . . . . . . . . . . . . . RESISTOR, WW fxd 30W 5K ohm (460/575V) . . . . . . . . . . . . . . . . . . . . . . . MODULE, capacitor 2 polye MF .0047uf 1000V (Prior to KD414913) . . . MODULE, resistor 2 2W 100K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR, polyp film .6uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STRIP, comb mrm .007 x 3.000 x 7.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLAMP, capacitor 2.000dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, speed 10-24 flat rectangular (Prior to KD523655) . . . . . . . . . . . . . . . NUT, 10-32 push-on stl (Eff w/KD523655) . . . . . . . . . . . . . . . . . . . . . . . . . . . CHOKE, DVDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COIL, current transformer 500/1 (Prior to KD414913) . . . . . . . . . . . . . . . . . INSULATOR, coil (Prior to KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CORE, ferrite E (Prior to KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOLT, U brs 6-32 x 1.925 wide x 2.250 deep (Prior to KD414913) . . . . . .

4 4 2 2 4 4 4 4 4 2 1 1 2 1

2 3

4

2

1

5 1

6

7 8 9 10

11 12

16

13 14 15

ST-150 170-D

Figure 9-3. Chassis, Mid Lower BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. Maxtron 450

TM-2206 Page 85

9

12

8

10

11

6 7

4 2

13

5

14

3

15

1

16

25

17

24

23 19

22

18 21

20 ST-150 169-H

Figure 9-4. Chassis, Mid Upper

TM-2206 Page 86

Maxtron 450

Item No.

Dia. Mkgs.

Part No.

Description

Quantity

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

Maxtron 450

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