May 1997 Form: TM-2203

Effective With Serial No. KB058453

TECHNICAL MANUAL
Service And Parts

Deltaweld 300

cover_tm 4/95 – ST-106 875  1997 MILLER Electric Mfg. Co. PRINTED IN USA
 EMF INFORMATION
Considerations About Welding And The Effects Of Low Frequency Electric And
NOTE Magnetic Fields
The following is a quotation from the General Conclusions Section To reduce magnetic fields in the workplace, use the following
of the U.S. Congress, Office of Technology Assessment, Biological procedures:
Effects of Power Frequency Electric & Magnetic Fields – 1. Keep cables close together by twisting or taping them.
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): “. . . there is now a very 2. Arrange cables to one side and away from the operator.
large volume of scientific findings based on experiments at the 3. Do not coil or drape cables around the body.
cellular level and from studies with animals and people which clearly
4. Keep welding power source and cables as far away as
establish that low frequency magnetic fields can interact with, and practical.
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific 5. Connect work clamp to workpiece as close to the weld as
understanding does not yet allow us to interpret the evidence in a possible.
single coherent framework. Even more frustrating, it does not yet About Pacemakers:
allow us to draw definite conclusions about questions of possible The above procedures are among those also normally
risk or to offer clear science-based advice on strategies to minimize recommended for pacemaker wearers. Consult your doctor for
or avoid potential risks.” complete information. mod10.1 4/93

TABLE OF CONTENTS

SECTION 1 – SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SECTION 2 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2-1. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2-2. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION 3 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-1. Typical Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-2. Selecting A Location And Moving Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-3. Selecting And Preparing Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-4. Lower Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-5. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-6. Remote 14 Receptacle Information And Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-7. 115 Volts AC Duplex Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-8. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SECTION 5 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SECTION 6 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6-1. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6-2. Troubleshooting Circuit Diagram For Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-3. Waveforms For Section 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-4. Troubleshooting Main Control Board PC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-5. Input Voltage Labels And Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

SECTION 7 – LOCATION OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

SECTION 8 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

SECTION 9 – SHIPPING AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

SECTION 10 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

OM-2203C – 11/94
 ARC WELDING SAFETY PRECAUTIONS
WARNING ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.

ELECTRIC SHOCK can kill. terminal in disconnect box or that cord plug is connected to a
properly grounded receptacle outlet.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is 7. When making input connections, attach proper grounding
electrically live whenever the output is on. The input conductor first – double-check connections.
power circuit and machine internal circuits are also 8. Frequently inspect input power cord for damage or bare wiring –
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing, replace cord immediately if damaged – bare wiring can kill.
and all metal parts touching the welding wire are 9. Turn off all equipment when not in use.
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard. 10. Do not use worn, damaged, undersized, or poorly spliced
cables.
1. Do not touch live electrical parts. 11. Do not drape cables over your body.
2. Wear dry, hole-free insulating gloves and body protection. 12. If earth grounding of the workpiece is required, ground it directly
3. Insulate yourself from work and ground using dry insulating with a separate cable – do not use work clamp or work cable.
mats or covers big enough to prevent any physical contact with
13. Do not touch electrode if you are in contact with the work,
the work or ground.
ground, or another electrode from a different machine.
4. Disconnect input power or stop engine before installing or
14. Use only well-maintained equipment. Repair or replace
servicing this equipment. Lockout/tagout input power according
damaged parts at once. Maintain unit according to manual.
to OSHA 29 CFR 1910.147 (see Safety Standards).
5. Properly install and ground this equipment according to its 15. Wear a safety harness if working above floor level.
Owner’s Manual and national, state, and local codes. 16. Keep all panels and covers securely in place.
6. Always verify the supply ground – check and be sure that input 17. Clamp work cable with good metal-to-metal contact to
power cord ground wire is properly connected to ground workpiece or worktable as near the weld as practical.

ARC RAYS can burn eyes and skin; ARC RAYS

NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes. 2. Wear a welding helmet fitted with a proper shade of filter to
protect your face and eyes when welding or watching (see ANSI
Arc rays from the welding process produce intense Z49.1 and Z87.1 listed in Safety Standards).
visible and invisible (ultraviolet and infrared) rays that
can burn eyes and skin. Noise from some processes 3. Wear approved safety glasses with side shields.
can damage hearing. Chipping, grinding, and welds 4. Use protective screens or barriers to protect others from flash
cooling throw off pieces of metal or slag. and glare; warn others not to watch the arc.
NOISE 5. Wear protective clothing made from durable, flame-resistant
1. Use approved ear plugs or ear muffs if noise level is high. material (wool and leather) and foot protection.

FUMES AND GASES can be hazardous 5. Work in a confined space only if it is well ventilated, or while
to your health. wearing an air-supplied respirator. Always have a trained
Welding produces fumes and gases. Breathing watchperson nearby. Welding fumes and gases can displace
these fumes and gases can be hazardous to your air and lower the oxygen level causing injury or death. Be sure
health. the breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
1. Keep your head out of the fumes. Do not breathe the fumes. operations. The heat and rays of the arc can react with vapors to
2. If inside, ventilate the area and/or use exhaust at the arc to form highly toxic and irritating gases.
remove welding fumes and gases. 7. Do not weld on coated metals, such as galvanized, lead, or
3. If ventilation is poor, use an approved air-supplied respirator. cadmium plated steel, unless the coating is removed from the
4. Read the Material Safety Data Sheets (MSDSs) and the weld area, the area is well ventilated, and if necessary, while
manufacturer’s instruction for metals, consumables, coatings, wearing an air-supplied respirator. The coatings and any metals
cleaners, and degreasers. containing these elements can give off toxic fumes if welded.

CYLINDERS can explode if damaged. 4. Never drape a welding torch over a gas cylinder.
Shielding gas cylinders contain gas under high 5. Never allow a welding electrode to touch any cylinder.
pressure. If damaged, a cylinder can explode. Since 6. Never weld on a pressurized cylinder – explosion will result.
gas cylinders are normally part of the welding
process, be sure to treat them carefully. 7. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
1. Protect compressed gas cylinders from excessive heat, 8. Turn face away from valve outlet when opening cylinder valve.
mechanical shocks, slag, open flames, sparks, and arcs. 9. Keep protective cap in place over valve except when cylinder is
2. Install cylinders in an upright position by securing to a stationary in use or connected for use.
support or cylinder rack to prevent falling or tipping. 10. Read and follow instructions on compressed gas cylinders,
3. Keep cylinders away from any welding or other electrical associated equipment, and CGA publication P-1 listed in Safety
circuits. Standards.
sr1.1.1 2/94
 WELDING can cause fire or explosion. 6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
Welding on closed containers, such as tanks, drums,
or pipes, can cause them to blow up. Sparks can fly 7. Do not weld on closed containers such as tanks, drums, or
off from the welding arc. The flying sparks, hot pipes, unless they are properly prepared according to AWS
workpiece, and hot equipment can cause fires and F4.1 (see Safety Standards).
burns. Accidental contact of electrode to metal 8. Connect work cable to the work as close to the welding area as
objects can cause sparks, explosion, overheating, or
fire. Check and be sure the area is safe before doing practical to prevent welding current from traveling long,
any welding. possibly unknown paths and causing electric shock and fire
hazards.
1. Protect yourself and others from flying sparks and hot metal. 9. Do not use welder to thaw frozen pipes.
2. Do not weld where flying sparks can strike flammable material. 10. Remove stick electrode from holder or cut off welding wire at
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. contact tip when not in use.
If this is not possible, tightly cover them with approved covers. 11. Wear oil-free protective garments such as leather gloves,
4. Be alert that welding sparks and hot materials from welding can heavy shirt, cuffless trousers, high shoes, and a cap.
easily go through small cracks and openings to adjacent areas. 12. Remove any combustibles, such as a butane lighter or
5. Watch for fire, and keep a fire extinguisher nearby. matches, from your person before doing any welding.

WARNING ENGINES can be hazardous.

ENGINE EXHAUST GASES can kill. 1. Use equipment outside in open, well-ventilated areas.
Engines produce harmful exhaust gases. 2. If used in a closed area, vent engine exhaust outside and
away from any building air intakes.

ENGINE FUEL can cause fire or 3. Do not overfill tank – allow room for fuel to expand.
explosion. 4. Do not spill fuel. If fuel is spilled, clean up before starting
Engine fuel is highly flammable. engine.

1. Stop engine and let it cool off before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or
open flames.

MOVING PARTS can cause injury. 3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
Moving parts, such as fans, rotors, and belts can 4. To prevent accidental starting during servicing, disconnect
cut fingers and hands and catch loose clothing.
negative (–) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
1. Keep all doors, panels, covers, and guards closed and parts.
securely in place. 6. Reinstall panels or guards and close doors when servicing is
2. Stop engine before installing or connecting unit. finished and before starting engine.

SPARKS can cause BATTERY GASES 1. Always wear a face shield when working on a battery.
TO EXPLODE; BATTERY ACID can 2. Stop engine before disconnecting or connecting battery
burn eyes and skin. cables.
3. Do not allow tools to cause sparks when working on a battery.
Batteries contain acid and generate explosive 4. Do not use welder to charge batteries or jump start vehicles.
gases. 5. Observe correct polarity (+ and –) on batteries.

STEAM AND PRESSURIZED HOT 1. If the engine is warm and checking is needed, follow steps 2
COOLANT can burn face, eyes, and and 3.
skin. 2. Wear safety glasses and gloves and put a rag over cap.
It is best to check coolant level when engine is cold 3. Turn cap slightly and let pressure escape slowly before
to avoid scalding. completely removing cap.

PRINCIPAL SAFETY STANDARDS

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 P-1, from Compressed Gas Association, 1235 Jefferson Davis High-
way, Suite 501, Arlington, VA 22202.
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington, Code for Safety in Welding and Cutting, CSA Standard W117.2, from
D.C. 20402. Canadian Standards Association, Standards Sales, 178 Rexdale Bou-
levard, Rexdale, Ontario, Canada M9W 1R3.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Ameri- Safe Practices For Occupation And Educational Eye And Face Protec-
can Welding Society Standard AWS F4.1, from American Welding So- tion, ANSI Standard Z87.1, from American National Standards Insti-
ciety, 550 N.W. LeJeune Rd, Miami, FL 33126 tute, 1430 Broadway, New York, NY 10018.
National Electrical Code, NFPA Standard 70, from National Fire Cutting And Welding Processes, NFPA Standard 51B, from National
Protection Association, Batterymarch Park, Quincy, MA 02269. Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
sr1.1.1 2/94
 SECTION 1 – SAFETY INFORMATION
mod1.1 2/93

Read all safety messages throughout this manual.

Obey all safety messages to avoid injury.
Learn the meaning of WARNING and CAUTION.

1 Safety Alert Symbol

2 Signal Word
1 2 2
WARNING means possible death
or serious injury can happen.
WARNING 3 CAUTION CAUTION means possible minor
ELECTRIC SHOCK can kill. MOVING PARTS can injure. injury or equipment damage can
• Do not touch live electrical parts. • Keep away from moving parts. happen.
• Disconnect input power before 4 • Keep all panels and covers closed 3 Statement Of Hazard And
installing or servicing. when operating.
Result
4 Safety Instructions To Avoid
5 Hazard
5 Hazard Symbol (If Available)
6 Safety Banner
WARNING READ SAFETY BLOCKS at start of
Section 3-1 before proceeding. Read safety blocks for each sym-
6 bol shown.
7 NOTE
7 NOTE Turn Off switch when using high frequency. Special instructions for best op-
eration – not related to safety.

Figure 1-1. Safety Information

SECTION 2 – SPECIFICATIONS

Table 2-1. Welding Power Source

Specifications Description

Type Of Output Constant Voltage Direct Current (CV/DC)

Rated Weld Output NEMA Class I (100) – 300 Amperes, 32 Volts DC At 100% Duty Cycle (See Section 2-2)

Type Of Input Power Three-Phase; 200, 230, 460, Or 575 Volts AC; 60 Hz

Input Amperes At Rated Output 46.3 A At 200 V, 42 A At 230 V, 21 A At 460 V, 16.8 A At 575 V

Input Amperes While Idling 4 A At 200 V, 3.5 A At 230 V, 1.7 A At 460 V, 1.4 A At 575 V

KVA/KW Used At Rated Output 16.8 kVA/12.3 kW

KVA/KW Used While Idling 1.4 kVA/0.8 kW

Max. Open-Circuit Voltage 40 Volts DC

Welding Processes Gas Metal Arc (GMAW), Flux Cored Arc Welding (FCAW)

Overall Dimensions See Figure 3-3

Weight Net: 340 lb (154 kg); Ship: 350 lb (159 kg)

Deltaweld 300 TM-2203 Page 1

2-1. Volt-Ampere Curves

The volt-ampere curves show the

minimum and maximum voltage
and amperage output capabilities
of the welding power source.
Curves of other settings fall be-
tween the curves shown.

ssb1.1 10/91 – SB-142 603

Figure 2-1. Volt-Ampere Curves

2-2. Duty Cycle

CAUTION
WELDING LONGER THAN RATED DUTY CYCLE can damage unit and void warranty.
• Do not weld at rated load longer than shown below. warn7.1 8/93

Definition Chart

10 Duty Cycle is percentage of 10

minutes that unit can weld at
rated load without overheating.
Minutes

100% Duty Cycle At 300 Amperes

Continuous Welding

sb1.1 8/93 – SB-142 602-A

Figure 2-2. Duty Cycle

TM-2203 Page 2 Deltaweld 300
 SECTION 3 – INSTALLATION

3-1. Typical Process Connections

14-Pin Wire Feeder

Gun
Welding
Power GMAW
Source Work FCAW
Weld Power

Gun
GMAW
Welding Push-Pull
Power Feeder
Source Work
Weld Power

Gun
14-Pin
GMAW
24 V Control
Welding
Power
Source Work
Weld Power

Figure 3-1. Typical Process Connections

3-2. Selecting A Location And Moving Welding Power Source

WARNING
ELECTRIC SHOCK can kill. FUMES can be hazardous; LACK OF
• Do not touch live electrical parts. FRESH AIR AND PROPER
• Disconnect input power conductors from
VENTILATION can be harmful.
deenergized supply line BEFORE moving welding • Do not breathe welding fumes.
power source. • Place unit only where there is a good fresh air
supply and proper ventilation.
FIRE OR EXPLOSION can result from
p l a c i n g u n i t o n , o v e r, o r n e a r FA L L I N G E Q U I P M E N T c a n c a u s e
combustible surfaces. serious personal injury and equipment
• Do not locate unit on, over, or near combustible damage.
surfaces. • Use lifting eye to lift unit only, NOT running gear,
• Do not install unit near flammables. gas cylinders, or any other accessories.
BLOCKED AIRFLOW causes • Use equipment of adequate capacity to lift the unit.
overheating and possible damage to
unit.
• Do not block or filter airflow.
Warranty is void if any type of filter is used. swarn11.1 3/93

Deltaweld 300 TM-2203 Page 3

 Movement 1 Lifting Eye

1 2 Lifting Forks
Use lifting eye or lifting forks to
move unit.
OR If using lifting forks, extend forks
beyond opposite side of unit.
3 Rating Label
Use rating label to determine input
2 power needs.
4 Line Disconnect Device
Location And Airflow Locate unit near correct input pow-
4 er supply.

18 in
(460 mm)

ssb9.1 12/93 – ST-800 402 / ST-145 603-A

Figure 3-2. Movement And Location Of Welding Power Source

Inches Millimeters
A 29-1/4 743
B 19-1/4 489
A C 27 686
D 1 25
C E 1-1/2 38
B
F 27 686
G 24 610
F
H H 1-1/8 29
J 17 432
E G
K 19-1/4 489
L 7/16 Dia. 11 Dia.
4 Holes 4 Holes

J K
Front

L ST-155 296

Figure 3-3. Overall Dimensions And Base Mounting Hole Layout

TM-2203 Page 4 Deltaweld 300
3-3. Selecting And Preparing Weld Output Cables

1 Weld Output Cable

Determine total cable length in
weld circuit and maximum welding
amperes. Use Table 3-1 to select
proper cable size.
Use shortest cables possible.
Do not use damaged cables.
3 2 Terminal Lug
Use lugs of proper amperage ca-
pacity and hole size for connecting
to work clamp, wire feeder, and
weld output terminals.
3 Wire Feeder
Install according to manufacturer’s
2 instructions.
2 1 4 Work Clamp
Install onto work cable.

10 ft (3 m)

For Example,
4
Total Cable
Length In Weld
Circuit = 20 ft (6 m)
10 ft (3 m)

Tools Needed:

sb6.5* 11/92 – S-0752

Figure 3-4. Selecting And Preparing Weld Output Cables

Table 3-1. Weld Cable Size*

Total Cable (Copper) Length In Weld Circuit Not Exceeding

150 ft 200 ft 250 ft 300 ft 350 ft 400 ft

100 ft (30 m) Or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)

Welding 10 To 60% 60 Thru 100%

10 Thru 100% Duty Cycle
Amperes Duty Cycle 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

*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

Deltaweld 300 TM-2203 Page 5

3-4. Lower Front Panel

1 Access Door
2 Component Label
3 Remote 14 Receptacle
1 4 Electrode High Stabilizer
Weld Output Terminal
5 Electrode Low Stabilizer
2 Weld Output Terminal
6 115 Volts AC Duplex Recep-
tacle
8 7 Work Weld Output Terminal
8 Circuit Breakers CB1 And
3 CB2 (Section 8-2)
Go to Section 3-5, or close access
door.

Route all cables

under bar.

Tools Needed:
4 5 6 7

Ref. ST-155 295

Figure 3-5. Lower Front Panel

3-5. Connecting To Weld Output Terminals

WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off welding power source, and disconnect input power before making any weld output connections.
swarn12.1 2/93

1 Electrode High Stabilizer

Weld Output Terminal
2 Electrode Low Stabilizer
Weld Output Terminal
Use only one electrode terminal at a time. Use Electrode terminal that pro-
vides the best welding arc and
weld puddle properties for applica-
tion.
2 3 When connected to Low terminal,
ELECTRODE WORK low inductance results in a stiff,
1
fast-responding arc, and small,
fast-freezing puddle.
When connected to High terminal,
high inductance results in a soft,
HIGH LOW slower-responding, low spatter
STABILIZER STABILIZER arc, and more fluid weld puddle.
3 Work Weld Output Terminal
For Electrode Positive (DCEP),
connect work cable to Work termi-
nal and electrode holder cable to
an Electrode terminal.
Tools Needed:
For Electrode Negative (DCEN),
reverse cable connections.
Close access door.
3/4 in
Ref. S-142 465-A

Figure 3-6. Weld Output Connections

TM-2203 Page 6 Deltaweld 300
3-6. Remote 14 Receptacle Information And Connections

1 Remote 14 Receptacle RC1

1 2 (See Table 3-2)
2 Keyway
3 Plug
A J
K I 4 Threaded Collar
B
To connect to receptacle, align
C L N H
keyway, insert plug, and tighten
D M G threaded collar.
E F Close access door.

4
3

sb7.1* 12/93 – Ref. ST-800 738 / Ref. S-0004-A / S-0750

Figure 3-7. Remote 14 Connections

Table 3-2. Remote 14 Socket Information

Socket* Socket Information

A 24 volts ac. Protected by circuit breaker CB2.

B Contact closure to A completes 24 volts ac contactor control circuit.
I 115 volts ac. Protected by circuit breaker CB1.
J Contact closure to I completes 115 volts ac contactor control circuit.
G Circuit common for 24 and 115 volts ac circuits.
C +10 volts dc output to remote control.
D Remote control circuit common.
V VOLTAGE
E 0 to +10 volts dc input command signal from remote control.
K Chassis common.
*The remaining sockets are not used.

3-7. 115 Volts AC Duplex Receptacle

1 115 Volts AC Duplex Recep-

tacle RC2
115VAC 15A This welding power source sup-
1 plies up to 15 amperes of 115 volts
ac power.
This receptacle is protected from
overload by circuit breaker CB1
NEUTRAL BONDED TO FRAME (see Section 8-2).
NEUTRE RACCORDE AU GATI Power output is shared between
this receptacle and the Remote 14
receptacle (see Section 3-6).
Close access door.
Tools Needed:

Ref. ST-155 295 / Ref. S-142 465-A

Figure 3-8. Connecting To 115 Volts AC Duplex Receptacle

Deltaweld 300 TM-2203 Page 7
3-8. Connecting Input Power

WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off welding power source, and disconnect input power before inspecting or installing.
• Have only qualified persons install unit.
• Installation must meet National Electrical Code and all other codes. swarn3.1 2/93

A. Positioning Jumper Links

Jumper links allow operation on

different input voltages and are
factory set for the highest input
voltage.
Check input voltage available at
site.
Remove side panel to check jump-
er links.
1 Input Voltage Label
Look at jumper links and compare
link position with unit label.
2 Input Voltage Jumper Links
Move links to match input voltage.
For example, use 230 volts posi-
tion when 230 volts input power is
available.
Reinstall side panel or go on to
Figure 3-10.

1 2

230 VOLTS 460 VOLTS 575 VOLTS

L1 L2 L3 L1 L2 L3 L1 L2 L3

S-115 006-A

Tools Needed:

3/8 in

3/8 in

ssb5.1 2/92 – ST-155 298

Figure 3-9. Input Voltage Jumper Links Location

TM-2203 Page 8 Deltaweld 300
B. Connecting Input Power

4
Tools Needed:
2
3 3/8 in
7
6 5 7/16, 1/2 in
ssb2.4 1/94 – ST-145 604-B

Have only qualified persons make this proper amperage capacity and correct hole Install and connect grounding conductor
installation. size. and input conductors in conduit or equiva-
Remove side panel. 4 Strain Relief Connector lent to deenergized line disconnect device.
1 Line Disconnect Device Of Proper Rat- Insert conductors through strain relief. Be sure grounding conductor goes to an
ing earth ground.
5 Input Terminal Board
2 Input Conductors 6 Line Terminals Reinstall side panel.
3 Grounding Conductor 7 Ground Terminal 8 Overcurrent Protection
Select size and length using Table 3-3. Con- Connect grounding conductor to ground ter- Select type and size using Table 3-3. Install
ductor rating must comply with national, minal first. Then connect input conductors to into deenergized line disconnect device
state, and local electrical codes. Use lugs of line terminals. (fused disconnect switch shown).

Figure 3-10. Input Power Connections

Table 3-3. Electrical Service Requirements*

Input Voltage 200 230 460 575

Input Amperes At Rated Output 46.3 42 21 16.8

Recommended Standard Fuse Or Circuit Break-

70 60 30 25
er Rating In Amperes1
Input Conductor Size In AWG/Kcmil2 8 8 10 12

Max Input Conductor Length In Feet (Meters)3 101 (31) 133 (41) 355 (108) 338 (103)

Grounding Conductor Size In AWG/Kcmil4 8 10 10 12

* These values are calculated from the 1993 edition of the National Electrical Code (NEC).
1 Recommended fuse or circuit breaker size is that closest to 150% of rated input amperage of the welding power source. Article 630-12(a) of NEC
allows fuse or circuit breaker sizing up to 200% of rated input amperage.
2 Input conductor size is for insulated copper wire with 75°C rating with not more than three single current-carrying conductors in a cable or raceway
(Table 310-16 of NEC).
3 Maximum length is to prevent more than a 3% voltage drop between service entrance and input terminals of the welding power source (Articles
210-19(a) and 215-2(b) of NEC).
4 The grounding conductor shall be colored or identified as specified in the NEC. Grounding conductor size for copper wire is not required to be
larger than input conductor (Article 250-95 of NEC). S-0092-G
Deltaweld 300 TM-2203 Page 9
 SECTION 4 – OPERATION

WARNING
ELECTRIC SHOCK can kill. ARC RAYS can burn eyes and skin;
• Always wear dry insulating gloves. NOISE can damage hearing.
• Insulate yourself from work and ground. • Wear welding helmet with correct shade of filter.
• Do not touch live electrical parts. • Wear correct eye, ear, and body protection.
• Keep all panels and covers securely in place.
MOVING PARTS can cause injury.
FUMES AND GASES can be hazardous
to your health. • Keep away from moving parts.
• Keep your head out of the fumes. • Keep all doors, panels, covers, and guards closed
and securely in place.
• Ventilate area, or use breathing device.
• Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used. MAGNETIC FIELDS FROM HIGH CUR-
RENTS can affect pacemaker operation.
WELDING can cause fire or explosion. • Pacemaker wearers keep away.
• Do not weld near flammable material.
• Wearers should consult their doctor before going
• Watch for fire; keep extinguisher nearby. near arc welding, gouging, or spot welding opera-
• Do not locate unit over combustible surfaces. tions.
• Do not weld on closed containers.
See Safety Precautions at beginning of manual for ba-
• Allow work and equipment to cool before handling. sic welding safety information. swarn6.1 10/91

1 2 1 Voltmeter
2 Ammeter
3 Pilot Light
4 Power Switch
5 Voltage Adjustment Control
3
8 6 Remote Voltage Adjustment
Switch
4
7 7 Output (Contactor) Switch
5 8 Inductance Control
6
Ref. ST-155 295

Figure 4-1. Controls

1 2 3 Wear the following while welding:

1 Dry, Insulating Gloves
2 Safety Glasses With Side
Shields
3 Welding Helmet With Correct
Shade Of Filter (See ANSI
Z49.1)

sb3.1 1/94

Figure 4-2. Safety Equipment

1 Work Clamp
1
Connect work clamp to a clean,
Tools Needed:
paint-free location on workpiece,
as close to weld area as possible.
Use wire brush or sandpaper to
clean metal at weld joint area. Use
chipping hammer to remove slag
after welding.
sb4.1 2/93

Figure 4-3. Work Clamp

TM-2203 Page 10 Deltaweld 300
 1 Voltage Adjustment Control
Use control to adjust weld voltage
output. Numbers around control
1 are in volts.
2 Remote Voltage Adjustment
Switch
Use switch to select way of control-
ling voltage adjustment.
For front panel control, place
switch in the Panel position.
For remote control, place switch in
Remote 14 position. See Example
in Figure 4-7.

Ref. SC-141 462-A

Figure 4-4. Voltage Controls

1 Inductance Control
Use control to adjust welding arc
and weld puddle properties.
When set at 0, low inductance re-
sults in a stiff, fast-responding arc,
and small, fast-freezing puddle.
When set at 100, high inductance
1 results in a soft, slower-respond-
ing, low spatter arc, and more fluid
weld puddle.
Select setting best suited for ap-
plication. Numbers around control
are for reference only.

Figure 4-5. Inductance Control

WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Do not touch weld output terminals when contactor is energized.
• Do not touch electrode and work clamp at the same time. swarn7.1 10/91

Weld output terminals are energized when 1 Output (Contactor) Switch

switch is On and Power is On. Use switch to select way of control-
ling unit output.
For weld output, place switch in On
position.
1
For remote output control, place
switch in Remote 14 position (see
Section 3-6).

Figure 4-6. Output (Contactor) Switch

Deltaweld 300 TM-2203 Page 11
 EXAMPLE: Full Remote Voltage Control

REMOTE VOLTAGE

Min Max
(0 V) (32 V)

Set Switches Control setting does Adjust Remote Voltage

not matter control on wire feeder

In Example:
Min = 0 V
Percentage Of Output = 100%
Max = 32 V (100% of 32 V)

Ref. ST-141 462-A

Figure 4-7. Example Of Remote Voltage Control

1 Pilot Light
2 Power Switch
Use switch to turn unit, pilot light
and fans On and Off.
1

Figure 4-8. Power Switch And Pilot Light

TM-2203 Page 12 Deltaweld 300
 1 Voltmeter
Voltmeter displays voltage at the
weld output terminals, but not nec-
1 2 essarily the welding arc due to
cable resistance, poor connec-
tions, etc.
2 Ammeter
Ammeter displays weld amperage
output of unit.

Figure 4-9. Ammeter And Voltmeter

Install & Install & Prepare Put On Turn On Turn On Feeder

Connect Wire Feeding Personal Safety Set Controls Shielding Gas And Welding
Equipment System Equipment Power Source

Begin Welding

ssb6.1 9/92

Figure 4-10. Sequence Of Gas Metal Arc Welding (GMAW)

Install & Install & Prepare Put On Turn On Feeder

Connect Wire Feeding Personal Safety Set Controls And Welding Begin Welding
Equipment System Equipment Power Source
ssb6.1* 9/92

Figure 4-11. Sequence Of Flux Cored Arc Welding (FCAW)

Deltaweld 300 TM-2203 Page 13

 SECTION 5 – THEORY OF OPERATION

1 Input Terminal Board TE1

Provides means for operation on
different input voltages.
2 Power Switch S1, Pilot Light
PL1 3
Provides on/off control of welding Fan Motors
power source. FM
3 Fan Motors FM
Provides cooling of internal compo-
nents when TP1, TP2, or TP3
opens thereby deenergizing CR1. 1 2 4 3φ
4 Main Transformer T1
Input Secondary
Supplies power to weld output cir- Power Main
Three-Phase Terminal Switch S1 Transformer
cuit, control board PC1, other con- Input Power Board TE1 T1
trol circuits, and fan motors FM. 3φ
5 115 VAC Duplex Receptacle Primary
RC2
Connects auxiliary equipment to
welding power source. 1φ 1φ 3φ
Synchronization
6 Remote 14 Receptacle RC1 Signal
2
Connects remote voltage and con-
tactor controls. Pilot
5 Light
7 Circuit Breaker CB1 115 VAC PL1
Provides overload protection for Duplex
115 volts ac portion of Remote 14 Receptacle
RC2
receptacle RC1 and 115 volts ac
duplex receptacle RC2.
8 Circuit Breaker CB2 7
6
Provides overload protection for 24 115 VAC Circuit
volts ac portion of Remote 14 re- Breaker
ceptacle RC1. CB1
9 Contactor Control Relay CR1
8
Provides means for gun trigger
from wire feeder to turn on and off 24 VAC Circuit
weld output. Breaker
CB2
10 Control Board PC1 36 Volts AC
Controls weld output by changing Centered Tapped
the SCR gate pulses (conduction +10 VDC Output 10
times) after comparing voltage Command Voltage
feedback to selected voltage sig-
nal. 11
Uses current feedback signal for
Voltage
foldback circuit to prevent SCR fail- Adjustment
Remote 14
ure caused by sustained short-cir- Receptacle Control R1 Control
cuit conditions. RC1 Board
PC1
11 Voltage Adjustment Control 6♦ 12
R1
Remote Remote
Selects weld output voltage level. Voltage Voltage Control
Control Switch S2
12 Remote Voltage Control
Switch S2
6♦
Selects front panel or remote volt-
age control. Remote
Contactor 24 VAC
13 Thermostats TP1, TP2, TP3 Switch
24 VAC
If unit overheats, TP1, TP2, and/or
TP3 open stopping all weld output. 6♦ 9
14 Output (Contactor) Switch S4 Remote
Contactor 115 VAC Contactor
Selects On or Remote for remote Switch Control
contactor control. 115 VAC Relay CR1

Figure 5-1. Functional Diagram

TM-2203 Page 14 Deltaweld 300
 19 20 15 Main Rectifier SR1
Changes the ac output from T1 to
Ammeter Inductance full-wave rectified dc.
A1 Control R3
16 Capacitor Bank C1, Resistors
R4 and R5
17 18 21 Filters the dc output voltage of SR1.
Protected by resistors R4 and R5.
Electrode (+)
Current High Stablizer
Shunt Stabilizer 17 Current Shunt
Z1 Weld Output
Terminal Provides current feedback signal to
PC1 and ammeter A1.
15 18 Stabilizer Z1
16
Smooths (filters) weld output cur-
21 Electrode
Main Capacitor rent.
Rectifier Bank C1, Electrode (+)
SR1 Low Stablizer 19 Voltmeter V1 And
Resistors
R4 And R5 Weld Output Ammeter A1
Terminal
Display the rectified and filtered val-
ues of the voltage and current pro-
19
vided by this welding power source.
Voltmeter 20 Inductance Control R3
V1 Adjusts the properties of the weld-
Work ing arc to control the weld puddle.
21 Electrode High Stablizer (+),
21 Electrode Low Stablizer (+),
And Work (–) Weld Output
Work (–) Weld Terminals
Output
Terminal Provide weld output and allow
changing of output polarity.

SCR
Gating
Signals

Voltage Current
Feedback Feedback

13
Thermostats AC Or DC Control Circuits
TP1, TP2,
TP3 Weld Current Circuit
14
External Circuits
Output
(Contactor)
Switch S4 3φ Power

♦ Optional
CR1

Deltaweld 300 TM-2203 Page 15

 SECTION 6 – TROUBLESHOOTING

6-1. Troubleshooting Table

WARNING
ELECTRIC SHOCK can kill. MOVING PARTS can cause injury.
• Do not touch live electrical parts. • Keep away from moving parts.
• Turn Off welding power source, and disconnect
input power before inspecting, maintaining, or
servicing.
STATIC ELECTRICITY can damage parts
on circuit boards.
HOT PARTS can cause severe burns. • Put on grounded wrist strap BEFORE handling
boards or parts.
• Allow cooling period before servicing unit.
• Use proper static-proof bags.
Have only qualified persons familiar with and following
standard safety practices perform troubleshooting
procedures. smwarn1.1 2/93

Table 6-1. Troubleshooting

NOTE Use MILLER Testing Booklet (Part No. 150 853) when checking solid-state parts.

Trouble Remedy Section

No weld output; unit completely inop- Place line disconnect device in On position. 3-8
erative; pilot light PL1 off.
Check for open line fuse(s), and replace if open. 3-8
Check for proper input power connections. 3-8
Check for proper jumper link position. 3-8
Check continuity of Power switch S1, and replace if necessary. 6-2,
Figure 7-2

No weld output; unit completely inop- Unit overheated. Allow unit to cool with fans On. 8-2
erative; fan motors FM run.
Check continuity of Power switch S1, and replace if necessary. 6-2,
Figure 7-2
If using remote control, place Output (Contactor) switch S4 in Re- 3-6,
mote 14 position, and connect remote control to Remote 14 re- Figure 4-6
ceptacle RC1. If remote is not being used, place Output (Contac-
tor) switch S4 in On position.
Check, repair, or replace remote control. ––
Check coil voltage and connections of control relay CR1. Check 6-2,
continuity of coil and condition of contacts. Replace CR1 if neces- Figure 7-2
sary.

Check diodes and SCRs in main rectifier SR1, and replace if nec- 6-2,
essary. If any diodes or SCRs are replaced, check capacitors C7 Figure 7-1
through C12 for a short or open, and check for proper connec-
tions. Replace C7 through C12 if necessary.
Check main control board PC1 and connections, and replace if 6-4
necessary.

Unit provides only minimum weld out- If using remote control, place Remote Voltage Adjustment switch 3-6,
put. S2 in Remote 14 position, and connect remote control to Remote Figure 4-4
14 receptacle RC1. If remote is not being used, place Remote
Voltage Adjustment switch S2 in Panel position.
Check continuity of Remote Voltage Adjustment switch S2, and 6-2,
replace if necessary. Figure 7-2

TM-2203 Page 16 Deltaweld 300

 Trouble Remedy Section
Unit provides only minimum weld out- Connect weld output cable to Electrode (+) High Stabilizer weld 3-5
put. (Continued) output terminal.
Check resistance and connections of Voltage Adjustment control 6-2,
R1; R1 is 1000 ohms ±10%. Replace R1 if necessary. Figure 7-2

Check diodes and SCRs in main rectifier SR1, and replace if nec- 6-2,
essary. If any diodes or SCRs are replaced, check capacitors C7 Figure 7-1
through C12 for a short or open, and check for proper connec-
tions. Replace C7 through C12 if necessary.

Check main control board PC1 and connections, and replace if 6-4
necessary.

Limited weld output and low open-cir- Check position of Remote Voltage Adjustment switch S2. Figure 4-4
cuit voltage.
Check for open line fuse(s), and replace if open. 3-8
Check for proper input power connections. 3-8
Check for proper jumper link position. 3-8
Clean and tighten all weld output connections. ––
Check continuity of Remote Voltage Adjustment switch S4, and 6-2,
replace if necessary. Figure 7-2
Check resistance and connections of Remote Voltage Adjust- 6-2,
ment control R1; R1 is 1000 ohms ±10%. Replace R1 if neces- Figure 7-2
sary.

Check diodes and SCRs in main rectifier SR1, and replace if nec- 6-2,
essary. If any diodes or SCRs are replaced, check capacitors C7 Figure 7-1
through C12 for a short or open, and check for proper connec-
tions. Replace C7 through C12 if necessary.

Check main transformer T1 for signs of winding failure. Check 6-2,

continuity across windings, and check for proper connections. Figure 7-1
Check secondary voltages. Replace T1 if necessary.

Check main control board PC1 and connections, and replace if 6-4
necessary.

Erratic or improper weld output. Use proper size and type of weld cable. 3-3
Clean and tighten all input and output connections. ––
Check wire feeder installation according to its owner’s manual. ––
Check resistance and connections of Voltage Adjustment control 6-2,
R1; R1 is 1000 ohms ±10%. Replace R1 if necessary. Figure 7-2

Check diodes and SCRs in main rectifier SR1, and replace if nec- 6-2,
essary. If any diodes or SCRs are replaced, check capacitors C7 Figure 7-1
through C12 for a short or open, and check for proper connec-
tions. Replace C7 through C12 if necessary.

Check main transformer T1 for signs of winding failure. Check 6-2,

continuity across windings, and check for proper connections. Figure 7-1
Check secondary voltages. Replace T1 if necessary.

Check stabilizer Z1 for signs of winding failure. Check continuity 6-2,

across winding, and check for proper connections. Replace Z1 if Figure 7-1
necessary.

Check main control board PC1 and connections, and replace if 6-4
necessary.

Arc conditions do not vary with Induc- Check resistance and connections of Inductance Control R3; R3 6-2,
tance Control R3. is 25 ohms ± 10%. Replace R3 if necessary. Figure 7-2

Deltaweld 300 TM-2203 Page 17

 Trouble Remedy Section
High weld output; Voltage Adjustment Check main control board PC1 and connections, and replace if 6-4
control R1 does not vary output. necessary.

No 115 volts ac output at duplex recep- Reset circuit breaker CB1. 8-2
tacle RC2, or Remote 14 receptacle
RC1.

Check wiring of 115 volts ac duplex receptacle RC2, or Remote 6-2,

14 receptacle RC1. Repair or replace if necessary. Figure 7-2

No 24 volts ac output at Remote 14 re- Reset circuit breaker CB2. 8-2

ceptacle RC1.
Check wiring of Remote 14 receptacle RC1. Repair or replace if 6-2,
necessary. Figure 7-2

Fan motor(s) FM not operating proper- Check and clear blocked fan blade. ––
ly.
Check coil voltage and connections of fan motor(s) FM, and re- 6-2,
place if necessary. Figure 7-1

TM-2203 Page 18 Deltaweld 300

 NOTES

Deltaweld 300 TM-2203 Page 19

6-2. Troubleshooting Circuit Diagram For Welding Power Source

WARNING
ELECTRIC SHOCK can kill. STATIC ELECTRICITY can damage parts
• Do not touch live electrical parts. on circuit boards.
• Turn Off welding power source before making or • Put on grounded wrist strap BEFORE handling
changing meter lead connections and before boards or parts.
disconnecting or connecting any leads. • Use proper static-proof bags.

Have only qualified persons familiar with and following

standard safety practices perform troubleshooting
procedures. smwarn2.1 2/93

R1
R1

V2

V3

V1

V4

V5

Pilot V12
Light PL1

V6

CR1 is energized V7 V8
by gun trigger.
V13

V9

See Section 3-6

V10 V11 for RC1 data

Figure 6-1. Troubleshooting Circuit Diagram For Welding Power Source

TM-2203 Page 20 Deltaweld 300
 Resistance Values
a) Tolerance – ±10% unless specified
b) Turn Off unit and disconnect input
power before checking resistance
R1 All values for T1 are less than 1 ohm
No calibration available for
voltmeter V1 and ammeter A1. R2 Less than 1 ohm

Test Equipment Needed:

R2

R2

V19
D, E, F
V18
See Section 6-3
A, B, C for waveforms
A thru F

Voltage Readings
V17 a) Tolerance – ±10% unless specified
b) Reference – to circuit common
(lead 42) unless noted
c) Wiring Diagram – see Section 10

V1 230 volts ac
V2, V3, V4 17 volts ac
V5, V6, 18 volts ac
V7, V8, V9
See Section 6-4 V10 24 volts ac with remote contactor
for PC1 data closed or wire feeder gun trigger
closed
V11 115 volts ac with wire feeder gun
trigger closed
V12 115 volts ac
V13 24 volts ac
V16
V14 +8 volts dc with S4 in Remote 14
position; 0 volts dc with S4 in On
position
V15 +10 volts dc
V16 0 to 10 volts dc from min to max
of R1 with S2 in Panel position
V17 0 to +38 volts dc equal to arc
voltage
V14 V15 V18 +12.5 millivolts dc/100 amperes
See Section 3-6 V19 38 volts dc open-circuit voltage
for RC1 data
SC-169 393

Deltaweld 300 TM-2203 Page 21

6-3. Waveforms For Section 6-2

WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off welding power source before making or changing any test equipment leads or cable connections.

Have only qualified persons familiar with and following standard safety practices perform troubleshooting procedures.
smwarn3.1 12/93

5 ms 10 V 5 ms 10 V

gnd gnd

A. Electrode Low Stabilizer/Max Open-Cir- B. Electrode Low Stabilizer/Rated Load Out-

cuit Voltage, 38 Volts DC put, 32 Volts DC At 300 Amperes (Resistive
Load)

5 ms 10 V 5 ms 10 V

gnd gnd

C. Electrode Low Stabilizer/Max Open-Circuit D. Electrode High Stabilizer/Max Open-Circuit

Voltage With Capacitor Bank C1 Open Voltage, 38 Volts DC

Figure 6-2. Waveforms For Section 6-2

TM-2203 Page 22 Deltaweld 300
 5 ms 10 V 5 ms 10 V

gnd gnd

E. Electrode High Stabilizer/Rated Load Out- F. Electrode High Stabilizer/Max Open-Cir-

put, 32 Volts DC At 300 Amperes (Resistive cuit Voltage With Capacitor Bank C1 Open
Load)

Test Equipment Needed:

Deltaweld 300 TM-2203 Page 23

6-4. Troubleshooting Main Control Board PC1

WARNING
ELECTRIC SHOCK can kill. STATIC ELECTRICITY can damage parts
• Do not touch live electrical parts. on circuit boards.
• Turn Off welding power source before making or • Put on grounded wrist strap BEFORE handling
changing meter lead connections and before boards or parts.
disconnecting or connecting any leads. • Use proper static-proof bags.

Have only qualified persons familiar with and following

standard safety practices perform troubleshooting
procedures. smwarn2.1 2/93

Be sure plugs are secure before

testing. Use Table 6-2 for specific
values during testing.
Test Equipment Needed: 1 Main Control Board PC1
2 Receptacle RC51
3 Receptacle RC52
4 Receptacle RC55
5 Receptacle RC54

1 2 3 4 5

SB-157 655-B / ST-801 009

Figure 6-3. Main Control Board PC1 Testing Information (Use With Table 6-2)
TM-2203 Page 24 Deltaweld 300
 Table 6-2. Main Control Board PC1 Test Point Values (Use With Figure 6-1 And Figure 6-3)

Voltage Readings:

a) Tolerance – ±10% unless specified b) Reference – to circuit common

(lead 42) unless noted

Receptacle Pin Value

1 Gate pulse to SCR2 with respect to pin 2

2 Reference for gate pulse to SCR2

RC51 3 Gate pulse to SCR1 with respect to pin 6

4 Gate pulse to SCR3 with respect to pin 5

5 Reference for gate pulse to SCR3

6 Reference for gate pulse to SCR1

RC52 1 Not used

2 Not used

3 Not used

4 18 volts ac input

5 18 volts ac input

6 Not used

7 18 volts ac input for synchronization

8 18 volts ac input for synchronization

9 18 volts ac input

10 Circuit common (lead 42)

11 Not used

12 Not used

13 Not used

14 Not used

15 Not used

16 18 volts ac input for synchronization

RC54 1 Command reference 0 to +10 volts dc input from min to max of Voltage Adjustment control R1 with
Remote Voltage Adjustment switch S2 in Panel position or 0 to +10 volts dc input from min to max
of R1 with S2 in Remote 14 position

2 Remote command reference; +10 volts dc output

3 Not used

4 +10 volts dc output

5 Contactor control signal, +8 volts dc input with Output (Contactor) switch S4 in Remote 14 position,
0 volts dc input with S4 in On position

6 Not used

7 Not used

8 Not used

9 Not used

10 Not used

11 Circuit common

12 Not used

RC55 1 Voltage feedback input with respect to pin 6, same as OCV or load voltage

2 Not used

3 Current feedback, 12.5mV per 100 amperes of weld output with respect to pin 5

Deltaweld 300 TM-2203 Page 25

 Receptacle Pin Value
RC55 4 Not used
(Continued)

5 Current feedback, 12.5mV per 100 amperes of weld output with respect to pin 3

6 Voltage feedback input with respect to pin 1, same as OCV or load voltage

7 Not used

8 Not used

9 Not used

10 Not used

TM-2203 Page 26 Deltaweld 300

6-5. Input Voltage Labels And Connection Diagrams

WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off welding power source, and disconnect input power before inspecting or servicing.

Have only qualified persons familiar with and following standard safety practices perform troubleshooting procedures.
smwarn4.1 12/93

1 Input Voltage Label And

Connection Diagram – Only
One Label Is On Unit
2 Terminal Strip TE1
Test Equipment Needed:
If replacing or servicing trans-
former coils, connect coil leads
#001 thru #006 to matching termi-
nals 1 thru 6 on terminal board
TE1.

ST-155 298 / SA-145 095-B / SA-145 094-A

Figure 6-4. Input Voltage Labels And Connection Diagrams

Deltaweld 300 TM-2203 Page 27
 SECTION 7 – LOCATION OF PARTS

8
7

4
5
6

9
3
2
1

10

1 Capacitor Bank C1 5 Resistor R7 8 Main Transformer T1

2 Resistor R4
6 Current Shunt 9 Terminal Strip TE1
3 Resistor R5
4 Stabilizer Z1 7 Fan Motors FM 10 Front Panel (See Figure 7-2)
ST-145 607-A

Figure 7-1. Main Assembly And Component Locations

TM-2203 Page 28 Deltaweld 300
 11
10
9
8
7
6
5

12
4

13
3

14
15
1
2

1 Remote Voltage Adjustment Switch S2 6 Ammeter A1 11 115V 15A Duplex Receptacle RC2
2 Output (Contactor) Switch S4 7 Pilot Light PL1 12 Main Control Board PC1
3 Inductance Control R3 8 Power Switch S1 13 Remote 14 Receptacle RC1
4 Voltage Adjustment Control R1 9 Circuit Breaker CB2 14 Connection Stud 1T
5 Voltmeter V1 10 Circuit Breaker CB1 15 Contactor Control Relay CR1 ST-145 606-C

Figure 7-2. Front Panel And Component Locations

Deltaweld 300 TM-2203 Page 29
 SECTION 8 – MAINTENANCE

WARNING
ELECTRIC SHOCK can kill. MOVING PARTS can cause injury.
• Do not touch live electrical parts. • Keep away from moving parts.
• Turn Off welding power source, and disconnect
input power before inspecting, maintaining, or
servicing.

HOT PARTS can cause severe burns.

• Allow cooling period before maintaining or
servicing.
Maintenance to be performed only by qualified
persons. swarn8.1 2/93

8-1. Routine Maintenance

3 Months Turn Off all power before maintaining. 6 Months

Replace Blow Out

Unreadable OR Or
Labels Vacuum
Inside

Tape Or During Heavy Service,

Replace –– Clean Monthly
Cracked
Cables
––

Clean
And
Tighten
Weld
3-5 Terminals
ST-145 603-A

Figure 8-1. Routine Maintenance

8-2. Overload Protection

WARNING READ SAFETY BLOCKS at start of

Section 8 before proceeding.

A. Overheating

15

minutes

When overheated, thermostats open, output Let fans run for Start welding.
stops, and cooling fans keep running. 15 minutes. ssb10.1* 1/94 – ST-145 603-A

Figure 8-2. Overheating

TM-2203 Page 30 Deltaweld 300
B. Circuit Breakers CB1 And CB2

See Section 3-4 for circuit breaker

location behind access door.
1 Circuit Breaker CB1
CB1 protects the 115 volts ac wind-
ing of transformer T1 from over-
PRESS TO RESET load. If CB1 opens, the 115 volts ac
2 10A 15A output to the Remote 14 receptacle
1
and 115 volts ac duplex receptacle
stops.
2 Circuit Breaker CB2
CB2 protects the 24 volts ac wind-
CB2 CB1 ing of transformer T1 from over-
load. If CB2 opens, the 24 volts ac
output to the Remote 14 receptacle
stops.
Press button to reset a breaker.
Close access door.

Ref. S-142 465-A

Figure 8-3. Circuit Breakers CB1 And CB2

Deltaweld 300 TM-2203 Page 31

 SECTION 9 – SHIPPING AND STORAGE
mod8.1 2/93

WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off welding power source, and disconnect input power before preparing unit for shipping or storage.

1 Welding Power Source

Disconnect unit from power and
accessories.
4 Remove running gear.
2 Wooden Skid
Bolt unit to skid.
3 Plastic
Tape plastic around unit.
3 4 Cardboard
Cover with cardboard.
5 Truck
If sending unit to factory, ship unit
as directed by factory Service
1 Department or Transportation De-
partment.

5
2

S-0670

Figure 9-1. Preparation For Reshipment

1 Welding Power Source

Disconnect unit from power and
accessories.
Clean inside and outside of unit.
4 Apply touch-up paint.
2 Storage Location
No wide temperature changes,
dust, dirt, or corrosive vapors.
2 3 2 x 4’s or 4 x 4’s
1 4 Plastic Or Tarp
Cover unit.

S-0671

Figure 9-2. Preparation For Storage

TM-2203 Page 32 Deltaweld 300
 SECTION 10 – ELECTRICAL DIAGRAMS

Table 10-1. List Of Circuit Diagrams And Wiring Diagrams

NOTE 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, proceed as
follows:
1. Know unit Model and Serial or Style Number.
2. Use List to find diagram number.
3. Include your FAX number or mailing address with your request.
4. FAX the Technical Publications Department at 414-735-4011 or call at 414-735-4356.

Model Serial Or Style Number Circuit Diagram Wiring Diagram

Deltaweld 300 KB058453 thru KB098277 SC-139 159-C D-142 723-F♦♦
KB098278 thru KC203236 C-147 641♦♦ D-147 640♦♦
KC203237 thru KC248745 C-153 515♦♦ D-153 516♦♦
KC248746 thru KE654751 C-154 636♦♦ SD-154 637-B
KE654752 and following SC-169 393 SD-154 637-B

Circuit Board PC1 KB058453 thru KB098277 D-139 166-C♦♦

KB098278 thru KC203236 D-146 821-B♦♦
KC203237 thru KD363140 D-153 513♦♦
KD363141 and following SD-157 657-B

♦♦Not included in this manual

Deltaweld 300 TM-2203 Page 33

 SC-139 159-C
Figure 10-1. Circuit Diagram For Deltaweld 300 Effective With Serial No. KB058453 Thru KB098277
TM-2203 Page 34 Deltaweld 300
 SC-169 393
Figure 10-2. Circuit Diagram For Deltaweld 300 Effective With Serial No. KE654752 And Following
Deltaweld 300 TM-2203 Page 35
 Figure 10-3. Wiring Diagram For Deltaweld 300 Effective With Serial No. KC248746 And Following
TM-2203 Page 36 Deltaweld 300
 SD-154 637-B

Deltaweld 300 TM-2203 Page 37

Figure 10-4. Circuit Diagram For Main Control Board PC1 Effective With Serial No. KD363141 And Following
TM-2203 Page 38 Deltaweld 300
 SD-157 657-B

Deltaweld 300 TM-2203 Page 39

 NOTES

TM-2203 Page 40 Deltaweld 300

 May 1997 Form: TM-2203
Effective With Serial No. KB058453

SECTION 11 – PARTS LIST

Deltaweld 300

Deltaweld 300 TM-2203 Page 41

 2
1 3 Fig 11-3 11

4 5 6

10

7
8
9 13
12
14

20 15

16

19 Fig 11-2 18 17 Fig 11-5

ST-145 607-A

Figure 11-1. Main Assembly

TM-2203 Page 42 Deltaweld 300

 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 11-1. Main Assembly

... 1 .............. 145 164 . . . PANEL, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 .............. 141 238 . . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 109 035 . . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 .............. 142 067 . . . INSULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .............. 141 823 . . . BUS BAR, capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . R4 . . . . . 095 966 . . . RESISTOR, WW fxd 10W 500 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . C1 . . . . . 109 833 . . . CAPACITOR, elctlt 30000uf 50VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
... 8 .............. 142 720 . . . SHEET, prp 100% rag .010 x 3.000 x 10.000 . . . . . . . . . . . . . . . . . . . . . . . . 2
... 9 .............. 108 105 . . . CLAMP, capacitor 2.500dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . R5 . . . . . 119 998 . . . RESISTOR, WW fxd 300W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . Fig 11-3 . . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . T1 . . . . . 141 760 . . . TRANSFORMER, pwr main 200/230/460 (consisting of) . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 141 097 . . . . . COIL, pri/sec LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 141 096 . . . . . COIL, pri/sec center & RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . TP1,2 . . . 026 181 . . . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . T1 . . . . . 144 426 . . . TRANSFORMER, pwr main 230/460/575 (consisting of) . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 144 360 . . . . . COIL, pri/sec LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . 144 361 . . . . . COIL, pri/sec center & RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . TP1,2 . . . 026 181 . . . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . . . . . . . . 146 827 . . . BRACKET, mtg primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . C21-23 . . . 142 351 . . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 17 . . . . . TE1 . . . . 038 138 . . . TERMINAL ASSEMBLY, pri 3ph (Fig 11-5) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 141 335 . . . BASE, (Prior to KB102064) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . 146 961 . . . BASE, (Eff w/KB102064) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . Fig 11-2 . . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . 141 237 . . . PANEL, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

Deltaweld 300 TM-2203 Page 43

 1 2 3 4
TM-2203 Page 44

5
6
7
8

37

36
35

10
34 11
12
13
13
14
13
15

28 27 26 25

18
19
29
20
21
24 23 17 22 16
33 30
Deltaweld 300

32 ST-145 606-B

31
Figure 11-2. Panel, Front w/Components
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 19)

. . . 1 . . . . . R3 . . . . . 030 987 . . . RHEOSTAT, WW 50W 25 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . R1 . . . . . 072 462 . . . POTENTIOMETER, w/shaft lock (consisting of) (Prior to KE725577) . . . . 1
. . . . . . . . . . . . . . . . . . . . 072 590 . . . . . LOCK, shaft pot .375-32 x .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . R1 . . . . . 035 897 . . . POTENTIOMETER, CP std slot 1/T 2W 1K linear (Eff w/KE725577) . . . . 1
. . . 3 . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . 097 922 . . . KNOB, pointer .875dia x .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 097 924 . . . KNOB, pointer 1.625dia x .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . V1 . . . . . 119 006 . . . METER, volt DC 0-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . A1 . . . . . 119 005 . . . METER, amp DC 50MV 0-400 scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . PL1 . . . . 027 645 . . . LIGHT, ind red lens 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . S1 . . . . . 128 756 . . . SWITCH, tgl 3PST 40A 600VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 134 058 . . . STANDOFF SUPPORT, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 11 . . . . . CB2 . . . . 083 432 . . . CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . CB1 . . . . 093 995 . . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . C4,5,7 . . . 128 750 . . . CAPACITOR, cer disc .1uf 500VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 14 . . . . RC2 . . . . 604 176 . . . RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . 010 381 . . . CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 16 . . . . Work . . . . 039 046 . . . TERMINAL, pwr output black (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . Electrode . . 039 047 . . . TERMINAL, pwr output red (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . . . . . . . . . . . 601 976 . . . . . SCREW, cap stl hexhd .500-13 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 039 045 . . . . . TERMINAL BOARD, black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 039 049 . . . . . TERMINAL BOARD, red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . 601 880 . . . . . NUT, stl hex jam .500-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . 039 044 . . . . . BUS BAR, term bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . 601 879 . . . . . NUT, stl hex full fnsh .500-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 141 277 . . . PANEL, front (Prior to KB101160) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 147 639 . . . PANEL, front (Eff w/KB101160) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . PC1 . . . . 154 029 . . . CIRCUIT CARD, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG52 . . . 131 052 . . . HOUSING RECEPTACLE & SOCKETS, (consisting of) . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 113 746 . . . . . TERMINAL, female 1skt 24-18 wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . PLG54 . . . 130 203 . . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 113 746 . . . . . TERMINAL, female 1skt 24-18 wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . . . . . . . PLG55 . . . 115 091 . . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 113 746 . . . . . TERMINAL, female 1skt 24-18 wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . 25 . . . . . . . . . . . . . . 141 278 . . . BRACKET, mtg receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . RC1 . . . . 086 022 . . . RECEPTACLE, 14skt 97-3102A-20-27S (Prior to KC202047) . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 094 481 . . . PLUG, 14 pin MS-3106A-20-27P Amphenol
. . . 26 . . . . RC1 . . . . 143 976 . . . RECEPTACLE w/SOCKETS, (Eff w/KC202047) (consisting of) . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 079 534 . . . . . TERMINAL, female 1skt 18-14 wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . 134 734 . . . PLUG, term plstc 14cont 213571-2 Amp
. . . . . . . . . . . . . . . . . . . . 134 731 . . . TERMINAL, male 1 pin 18-14 wire 213603-1 Amp
. . . . . . . . . . . . . . . . . . . . 079 739 . . . CLAMP, cable strain relief sz 17 206322-2 Amp
. . . 27 . . . C2,3,6 . . . 136 493 . . . CAPACITOR, (Prior to KC202047) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 27 . . . . . C2 . . . . . 152 108 . . . LEAD ASSEMBLY, elect (Eff w/KC202047) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . C3 . . . . . 152 106 . . . LEAD ASSEMBLY, elect (Eff w/KC202047) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . C6 . . . . . 152 107 . . . LEAD ASSEMBLY, elect (Eff w/KC202047) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . 1T . . . . . 072 253 . . . STUD, connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . R6 . . . . . 114 050 . . . RESISTOR, WW fxd 10W 1K ohm (Prior to KB101160) . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 142 664 . . . COVER, PC card (Prior to KC202047) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . 151 871 . . . COVER, PC card (Eff w/KC202047) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . +141 330 . . . DOOR, access front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . 127 363 . . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 605 583 . . . CATCH, spr loaded door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . 134 327 . . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . 093 838 . . . WEATHERSTRIPPING, adh (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2ft
. . . 35 . . . . CR1 . . . . 006 393 . . . RELAY, encl 24VAC DPDT (Prior to KB101160) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . CR1 . . . . 134 163 . . . RELAY, encl 24/120VAC DPDT (Eff w/KB101160) . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . 145 203 . . . TUBING, corrugated plstc slit 1.000dia x 3.000 . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . S2,4 . . . . 011 609 . . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Deltaweld 300 TM-2203 Page 45
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 11-3. Panel, Rear w/Components (Fig 11-1 Item 11)

. . . 1 . . . . . . . . . . . . . . 141 241 . . . BAFFLE, air vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . FM1,2 . . . 142 401 . . . MOTOR, fan 230V 50/60Hz 1550RPM .250dia shaft
(Prior to KB139431) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . . 148 808 . . . MOTOR, fan 230V 50/60Hz 1550RPM .312dia shaft (Eff w/KB139431) . 2
. . . 3 . . . . . . . . . . . . . . 133 118 . . . BLADE, fan 9 in 5wg 34deg .250 bore CCW (Prior to KB139431) . . . . . . 2
. . . 3 . . . . . . . . . . . . . . 148 809 . . . BLADE, fan 9 in 5wg 34deg .309 bore CCW (Eff w/KB139431) . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 146 826 . . . BLADE, hub (Prior to KB139431) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . . 134 209 . . . NUT, speed push-on-type .250 (Prior to KB139431) . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . . 049 399 . . . NUT, speed push-on-type .312 (Eff w/KB139431) . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . 142 434 . . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . Z1 . . . . . 141 262 . . . STABILIZER, (Prior to KC250438) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . Z1 . . . . . 152 493 . . . STABILIZER, (Eff w/KC250438) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 141 239 . . . BAFFLE, air horizontal (Prior to KC250438) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 152 494 . . . BAFFLE, air horizontal (Eff w/KC250438) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . R7 . . . . . 119 998 . . . RESISTOR, WW fxd 300W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 141 567 . . . SHUNT, meter 50MV 300A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 053 816 . . . TERMINAL, al .187 x .875 x 2.500W/.437H . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 133 126 . . . RECTIFIER, (Prior to KC203237) (Fig 11-4) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 153 514 . . . RECTIFIER, (Eff w/KC203237 thru KC248745) (Fig 11-4) . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . 154 635 . . . RECTIFIER, (Eff w/KC248746 and on) (Fig 11-4) . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . 141 774 . . . LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 026 627 . . . GASKET, lifting eye cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 2 3 4 5

13
12
Fig 11-4

11
10

8 7 6 SC-145 605

Figure 11-3. Panel, Rear w/Components

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
TM-2203 Page 46 Deltaweld 300
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 11-4. Rectifier, Si Diode (Fig 11-3 Item 11) 133 126 153 514 154 635

... 1 .............. 026 947 . . . STANDOFF, insul .250-20 x 1.000 lg x .312thd . . . . . . . . . . 7 . . . . . 7 . . . . . 7

. . . 2 . . . SCR1-3 . . 141 388 . . . THYRISTOR, scr 175A 300V . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . 3 . . . . . 3
. . . 3 . . . . C7-12 . . . 031 689 . . . CAPACITOR, rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . 6 . . . . . 6
. . . 4 . . . . D4-6 . . . . 037 305 . . . DIODE, rect 150A 300V SP . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 4 . . . . D4-7 . . . . 037 956 . . . DIODE, rect 275A 300V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 4 . . . . D4-6 . . . . 037 956 . . . DIODE, rect 275A 300V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 5 . . . . D7,8 . . . . 037 157 . . . DIODE, rect 275A 250V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG51 . . . 115 093 . . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . 1 . . . . . 1 . . . . . 1
.................... 113 746 . . . . . TERMINAL, female 1skt 24-18 wire . . . . . . . . . . . . . . . . . 6 . . . . . 6 . . . . . 6
. . . . . . . . . . . TP3 . . . . 604 515 . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
1 2

3
1
5
4
3
SB-145 608-A 2
4 6 4 5 4
1
Figure 11-4. Rectifier, Si Diode

7
8

6 7
SA-138 574

Figure 11-5. Terminal Assembly, Pri

Item Part
No. No. Description Quantity

038 138 Figure 11-5. Terminal Assembly, Pri (Fig 11-1 Item 17)

... 1 .............. 601 835 . . . NUT, brs hex 10-32reg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

... 2 .............. 038 058 . . . TERMINAL BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 038 887 . . . STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
... 4 .............. 010 913 . . . WASHER, flat brs .218 ID x .460 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . . 18
... 5 .............. 038 618 . . . LINK, jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
... 6 .............. 601 836 . . . NUT, brs hex .250-20 jam hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
... 7 .............. 010 915 . . . WASHER, flat brs .250 ID x .625 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . . 6
... 8 .............. 038 888 . . . STUD, pri bd brs .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Deltaweld 300 TM-2203 Page 47