- Thread starter shenion
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shenion
Tool Pack Rat
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That would be great:
Airco 300AMP AC/DC Heliwelder
Model: 3A/DDR-224HPA/B-D
Stock #: 1341-0118
Serial #: HD677507
Hmm, if the serial # is from Miller then it was built in 1973.
shenion
Tool Pack Rat
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They were oil-filled caps. The oil is oozing out. Nasty stuff anyway. I think the first thing I will do is get some brake cleaner and hose this whole thing down.
Want to replace the caps before I even try to power this thing up. They are part of the spark gap circuit (looks like the HF start is a Tesla coil setup.) These were Bakelite-cased caps, the rest are metal can and look good. From looking it over, the only other thing that I see that dies of old age is the selenium rectifier. Will ohm that out before powering it up.
Probably someone did not hook the ground clamp and boiled the caps. Looks like they have been bad a long time.
I seem to have figured out the sequence:
1973 - bought Heliarc, wire feeder, spoolgun and TIG gun.
1979 - Bought Miller and moved the wire feeder to the Miller.
At some point they blew the fuse in the Miller for the wire feed power. Must have been short in feeder.
1988 - Bought the Lincoln and LN7 wire feeder.
I did not even know TIG was readily available in '73 or even MIG (wire feeder was probably a later add-on).
Want to replace the caps before I even try to power this thing up. They are part of the spark gap circuit (looks like the HF start is a Tesla coil setup.) These were Bakelite-cased caps, the rest are metal can and look good. From looking it over, the only other thing that I see that dies of old age is the selenium rectifier. Will ohm that out before powering it up.
Probably someone did not hook the ground clamp and boiled the caps. Looks like they have been bad a long time.
I seem to have figured out the sequence:
1973 - bought Heliarc, wire feeder, spoolgun and TIG gun.
1979 - Bought Miller and moved the wire feeder to the Miller.
At some point they blew the fuse in the Miller for the wire feed power. Must have been short in feeder.
1988 - Bought the Lincoln and LN7 wire feeder.
I did not even know TIG was readily available in '73 or even MIG (wire feeder was probably a later add-on).
mishka
Is it me?
- Messages
- 247
Nasty stuff indeed. Given the age of the machines (70s) I'd read this first, and take suitable precautions:
http://en.wikipedia.org/wiki/Polychlorinated_biphenyl
shenion
Tool Pack Rat
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- 7,586
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- Stone Mountain, GA USA
Yes, I have read that.
Not sure if this is PCB, the article talks of it being clear and can soluble in isopropanol or mineral oil . This is dark brown and I cant get it dissolve with anything less than acetone (another nasty chemical.) I get the feeling it is dried-out mineral oil.
The other wiki article on mineral oil says PCB's use were basically stopped in the 1960's.
Miller has stopped making these caps. I have seen similar ones available (using modern technology) for $100 each.
I have found a solution though. Picked up a dozen of 0.002uf 10kv caps relatively cheap ($30). The original is 4kv. I will make a bank of caps in a serial/parallel to increase heat dissipation and then encase them in potting epoxy to prevent any surface arcing and further improve heat dissipation.
shenion
Tool Pack Rat
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- 7,586
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- Stone Mountain, GA USA
Yes it will as it covers this model.
I will pay to have a copy mailed unless you can scan it. PM me and we can work out details.
Thanks!
Drains
Yeah, nah.
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Just to butt in quickly on this thread. I work with acetone and xylene a fair bit. Neither are reckoned to be carcinogenic (though benzine is), and there are no long term effects with acetone. Xylene can, amongst other things affect the central nervous system. But exposure has to be pretty high, over a period, for long term effect. In the short term, both will make you dizzy/ sick in high enough concentrations.
I rather like the smell of acetone, myself...
Si
shenion
Tool Pack Rat
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Si, thanks, i was told acetone would make you sick. I also heard it accumulates in your system like arsenic and does not go away. I looked up a MSDS sheet. looks like it is mostly an irritant.
Update:
Thanks to arc-products dot com, they sent me exploded views, schematic and parts list. The schematic is barely readable, but helps.
They do not have the caps. I found Miller has a new part # with higher voltage.
Looking at the schematic, the only thing that would probably fail is the selenium rectifier. I can replace that with modern diodes (and some resistors as silicon diodes have far less resistance the the old relics.)
Looks like I can get it going. There is a remote current control. I will probably have to put in a different connector as it is odd. The remote sets the current from min to the value set on the panel. Looks good for a tig footpedal.
However, it shows a 15 ohm, 150watt rheostat! I'll have to design a footpedal with a regular pot and an amplifier to drive it. Sounds like a future project.
Have been using the Miller and the old Arico wire feed. Works ok. I can only get about 150A out of it. This is because of single phase so get 100% ripple (like any other single phase MIG) so the RMS value is lower. Picked up some .9mm wire, should be plenty then. I have built a dolly for the Airco with it.
Amron, if you have the user manual it would help (need to know what all these switches do
)
Update:
Thanks to arc-products dot com, they sent me exploded views, schematic and parts list. The schematic is barely readable, but helps.
They do not have the caps. I found Miller has a new part # with higher voltage.
Looking at the schematic, the only thing that would probably fail is the selenium rectifier. I can replace that with modern diodes (and some resistors as silicon diodes have far less resistance the the old relics.)
Looks like I can get it going. There is a remote current control. I will probably have to put in a different connector as it is odd. The remote sets the current from min to the value set on the panel. Looks good for a tig footpedal.
However, it shows a 15 ohm, 150watt rheostat! I'll have to design a footpedal with a regular pot and an amplifier to drive it. Sounds like a future project.
Have been using the Miller and the old Arico wire feed. Works ok. I can only get about 150A out of it. This is because of single phase so get 100% ripple (like any other single phase MIG) so the RMS value is lower. Picked up some .9mm wire, should be plenty then. I have built a dolly for the Airco with it.
Amron, if you have the user manual it would help (need to know what all these switches do
)
Ratty
Putting the She in Sheds
- Messages
- 1,775
...but wear gloves! Like all solvents (including white spirit) it gets into the entire system through the skin which is worse than breathing it (tho that's not good either)
shenion
Tool Pack Rat
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- 7,586
- Location
- Stone Mountain, GA USA
Everything works.
Just to close out this thread.
Everything works. The Miller just needs a coat of paint. The Lincoln is the same. Both have been tested and will go on ebay/craigs list.
I have everything working on the Airco. Well, the start circuit for arc is not optimal, but all I need is a new resistor.
Did a quick paint job on the Airco. Just Rustolium from a can using my HVLP sprayer. Hardest part is it takes several days before the paint gets hard enough to do anything.
Did not care for the pumpkin-orange. So it is now close to a Miller blue. Have the lower front cover painted, but it is a pain to put back in, had to beat on it to get it out. Will let paint dry a week before trying to wedge it back in.
Still waiting for a buddy of mine to make a 0.030 roller for the wire-feed unit. Once that is done, will have arc, TIG and MIG all in one.
Total cost: just over $600 (including $260 for all 3 welders). Big items were the TIG torch and accessories and 50' of 0-gauge wire and ground clamp (the ground cable cost more than the torch. Copper is expensive
) When I sell the other two, I should still come out ahead. May even sell my little Clarke MIG, but I love the small, light torch and the portability.
I have cables that will reach over entire 2-car garage. Will build a cart for the MIG feeder. It has a 25' cable and 15' torch. Just picked up some Tweco 1/0-gauge quick disconnects. Surprise, only $10/pair at the local welding supply. Will allow plugging in the MIG and arc electrode without having to unbolt cables.
Been lots of fun, still happy as a clam with my big toys
Just to close out this thread.
Everything works. The Miller just needs a coat of paint. The Lincoln is the same. Both have been tested and will go on ebay/craigs list.
I have everything working on the Airco. Well, the start circuit for arc is not optimal, but all I need is a new resistor.
Did a quick paint job on the Airco. Just Rustolium from a can using my HVLP sprayer. Hardest part is it takes several days before the paint gets hard enough to do anything.
Did not care for the pumpkin-orange. So it is now close to a Miller blue. Have the lower front cover painted, but it is a pain to put back in, had to beat on it to get it out. Will let paint dry a week before trying to wedge it back in.
Still waiting for a buddy of mine to make a 0.030 roller for the wire-feed unit. Once that is done, will have arc, TIG and MIG all in one.
Total cost: just over $600 (including $260 for all 3 welders). Big items were the TIG torch and accessories and 50' of 0-gauge wire and ground clamp (the ground cable cost more than the torch. Copper is expensive
) When I sell the other two, I should still come out ahead. May even sell my little Clarke MIG, but I love the small, light torch and the portability.I have cables that will reach over entire 2-car garage. Will build a cart for the MIG feeder. It has a 25' cable and 15' torch. Just picked up some Tweco 1/0-gauge quick disconnects. Surprise, only $10/pair at the local welding supply. Will allow plugging in the MIG and arc electrode without having to unbolt cables.
Been lots of fun, still happy as a clam with my big toys
shenion
Tool Pack Rat
- Messages
- 7,586
- Location
- Stone Mountain, GA USA
Miller is ready for ebay.
Before:
After:
New coat of paint, new Miller logos. Inside clean up and oil gears/sliders for controls. Only repair was blown fuse. Font panel is a pain, anything I try to clean it with takes off the lettering.
There are several of these listed for $299 on ebay. This is an older model that does not support a 24 volt contactor. Don't expect much, but I have about $20 in parts/paint in it.
http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=140133183561
Before:
After:
New coat of paint, new Miller logos. Inside clean up and oil gears/sliders for controls. Only repair was blown fuse. Font panel is a pain, anything I try to clean it with takes off the lettering.
There are several of these listed for $299 on ebay. This is an older model that does not support a 24 volt contactor. Don't expect much, but I have about $20 in parts/paint in it.
http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=140133183561
