Miller HF826825 Owner's manual

Miller HF826825 Owner's manual
3 April 1975 FORM: OM-315
Effective with serial No. HF826825
MODEL STOCK NO.
DIALARC HF 901 782
DIALARC HF-P 901 788
MILLER ELECTRIC MFG. CO.
APPLETON, WISCONSIN, USA 54811
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TOM
NWSA CODE NO. 4579
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WARRANTY
MILLER Electric Mfg. Co., Appleton, Wisconsin, warrants all new equipment to be free from defects in
material and factory workmanship for the periods indicated below, provided the equipment is installed and
operated according to manufacturer's instructions.
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MILLER Electric Mfg. Co.'s obligation, under this warranty, is limited to replacing or repairing any defective
part or correcting any manufacturing defect without charge during the warranty period if MILLER’S inspec-
tion confirms the existence of such defects. MILLER'S option of repair or replacement will be f.o.b. factory at
Appleton, Wisconsin or f.o.b. a MILLER authorized service facility, and therefore no compensation for trans-
portation costs of any kind will be allowed.
The warranty period, beginning on the date of sale to the original purchaser-user of the equipment, will be as
A O O PD E E E LWW ULL
follows:
1, Arc welders, power sources, and components — 1 year
2. Original main power rectifiers — 3 years (unconditionally)
3. MHFC-L1 Feeder, MHG-35C1, 20E, 20K,
and all guns and torches — 90 days
4. All other Millermatic Feeders — 1 year
5. Mag-Diesel engine on DEL-200 — 6 months
6. All other engines — 1 year
Engine Warranties are covered by the engine manufacturers, subject to their procedures and to be handled
through their authorized local Service Stations or agencies. No warranty will be made in respect to trade
accessories, such being subject to the warranties of their respective manufacturers.
MILLER Electric Mfg. Co. will not be liable for any loss or consequential damage or expense accruing
directly or indirectly from the use of equipment covered in this warranty.
This warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or
warranties expressed or implied.
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OPTIONAL ACCESSORIES means
No. 2 WA Welding Accessories (Stock No. 040 039)
Consists of 35 feet of No. 2 electrode cable with insulated electrode holder, 30 feet of No. 2 ground cable, ground
clamp, welding helmet, wire scratch brush. Jack plugs are fumished with the welder.
No. 2B {Stock No. 040 014)
Four 8” solid rubber tired wheels with towing handle.
No. 1BCR (Stock No. 040 010)
Same as No. 1B, but with provisions for carrying two gas cylinders,
No. 2BCR (Stock No. 040 015)
Same as No. 2B, but with provisions for carrying two gas cylinders.
RHC-3 {Stock No. 040 056)
Remote hand amperage control. Supplied with 20° cable and plug.
RFC-3A (Stock No. 040 068)
Remote foot amperage control. Supplied with 20° cable and plug.
RFC-23AG (Stock No. 041 161)
Remote foot control for amperage and contactor. Supplied with 20” cable and plug.
RHS-2G (Stock No. 041 157)
Momentary contact {normally open) hand switch for remote contactor control. Fastens to TIG torch handle.
CERTIFICATE
NAME OF EQUIPMENT: MODEL NO.
SERIAL NO. DATE
This equipment has been type-tested under standardized field test conditions as recommended
by the Joint Industry Committee on High Frequency Stabilized Arc Welding Machines found to rad-
¡ote less than 10 microvolts per meter at a distance of one mile, the maximum allowable limit
established by the Federal Communications Commission for equipment of this type.
Installations using this equipment on the basis of these tests, may reasonably be expected to
meet the radiation limitations established by the Federal Communications Commission, only when in-
stalled, operated and maintained as specified in the instruction book provided.
USER'S CERTIFICATION
The welding equipment identified above has been installed in accordance with the specific in-
structions applicable to this model as outlined in the instruction book furnished, It is being used
only for the purpose for which it was intended and is being maintained and operated in accord-
ance with the manufacturer's instructions.
Date Installed Signed
ED TAB | E OF CONTENTS SA
Paragraph No. Page No.
SECTION 1 — SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
Introduction .....222 4224414 42 4 4 4 4 4 4 a 4 xadudreoraroararernrdanerneoa
General! Precautions........12010 444044 4 4 4e 4 4 a 4 ee a 4 4 8 a a 4 ee a ee 6
Arc Welding........2022002 04424444 ea 1e ee 14 41 4e 0 ae a a 1 eee»
Standards Booklet Index . ..... 200100010444 1 24 1 aa 2 a a a 8 ea a eue»
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SECTION 2 — INTRODUCTION
General eee НИЕ
Receiving-Handling ........._.c_e-eoreanerarare ene ar2eonerecere. |
Description ..........eeeeereearanaveróreravcracanvenanenemera
Safety .....eecrereremrrreremderererononenaenamanaooneari arena
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SECTION 3 — INSTALLATION
Location st tt ee ee ee eae ee eee
Electrical Inpüt Connections ........._eerecarereo rr inane eens
Secondary Welding Connections ........e—.—.ewe.eororzerervereovec.
Remote Amperage Control Connections .........e_._eee.eeeeraacoa
Contactor Control Connections. ........e.eeceeevaeneereraaroe one.
Coolant Valve Connections ..........eeeeenegeonerenanoare vere.
Shielding Gas Valve Connections ...........—ee_e.errecrrorrereecoa.
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SECTION 4 — FUNCTION OF CONTROLS
Power Switch oc ti ee ee ee eee 4 a a a 0 0
Range Selector Switch... co oi eee
Amperage Adjustment Control .... ee
Amperage Control Receptacle & Switch... ........... oat.
Control Circuit Overload Breaker ..... iii eee tees
Weld Selector Switch . «o.oo i re ee eae
Contactor Control Receptacle & Switch .............. oo...
High Frequency Switch ... Li iit eae
Post-Flow Timer ....... cc. inate 4 a 0 a 0 ee eee
115 Volts AC Receptacle RR 4 4 4 a 1 ea 0 a +
Duty Cycle 1.221021 ee i ere ea Ran
Volt-Ampere Curve ... 1.122210 0 01244 144 482 440 4 44 4 KEG
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SECTION 5 — SEQUENCE OF OPERATION
5-1, Shielded Metal-Arc {Stick Electrode) Welding ....................... 10
5-2. Gas Tungsten-Arc (TIG) Welding. .... oc. oii ei iin 10
5 - 3. Shuttind Down i ee ee eee eee a ee 0 11
SECTION 6 — MAINTENANCE
6-1. Fan Motor ......22220 222004 ea aa sa ee ae a ae ee ee sa es aan en 0 11
6-2. Transformer ..........e0rree0eneadre na oavereoavacanooaaronó en 11
6-3. Rectifier ...... a ee et ee ee eee ee ea ee 11
6-4, OpPark Сар oo it eee ee eee eae da vera 11
SECTION 7 — TROUBLESHOOTING
Paragraph No. Page No.
SECTION 8 — CERTIFICATION FOR HIGH FREQUENCY ARC WELDING EQUIPMENT
8-1. General ........ RR PA 13
8 - 2. General Information ..L.1.2 2114414 1 ee 4 La 1 a a ea ea aan a 6 13
3-3. Power Service .....1010 20 4 84 0 4 a 4 4 a a 0 a 4 aa ua na ae eee eae 13
8-4, Welding Machine «ie ere te eens 13
8-5, Welding Leads .......2224 4004444 a ee ea a a AV La teen 14
8-6. Wiring in the Vicinity of the Welding Area ............. ccc... ... 14
8- 7. Grounds Li ee eee 14
8-8 Metal Building 0.00 eee etter eta ea, 14
8-9. Individual Installation Certification . . . . ... o.oo ite ieee 15
8-10. Check List... iti te eee ee ee ee eee ee eee 15
PARTS LIST
mem SECTION 1-SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE mum
1-1.
INTRODUCTION
We learn by experience. Learning safety through personal
experience like a child touching a hot stove 1s harmful, waste-
ful, and unwise. Let the experience of others teach you.
Safe practices developed from experience in the use of weld-
ing and cutting are described in this manual. Research, devel-
opment, and field experience have evolved reliable equipment
and safe installation, operation, and servicing practices. Acci-
dents occur when equipment is improperly used or main-
tained. The reason for the safe practices may not always be
given. Some are based on common sense, others may require
technical volumes to explain. It is wiser to follow the rules.
Read and understand these safe practices before attempting
to install, operate, or service the equipment. Comply with
these procedures as applicable to the particular equipment
used and their instruction manuals, for personal safety and
for the safety of others.
Failure to observe these safe practices may cause serious in-
jury or death. When safety becomes a habit, the equipment
can be used with confidence,
Responsibilities of installer, user, and serviceman. Installa-
tion, operation, checking, and repair of this equipment must
be done only by a competent person, experienced with such
equipment.
These safe practices are divided into two Sections: 1 -
General Precautions, common to arc welding and cutting; and
2 - Arc Welding (and Cutting) (only),
Reference standards: Published Standards on safety are also
available for additional and more complete procedures than
those given in this manual. They are listed in the Standards
Index in these safety rules. ANSI 249.1 is the most complete.
The National Electrical Code, Occupation Safety and Health
Administration, local industrial codes, and local inspection -
requirements also provide a basis for equipment installation,
use, and service,
GENERAL PRECAUTIONS
Burn Prevention
Wear protective clothing - leather (or asbestos) gauntlet
gioves, hat, and high safety-toe shoes. Button shirt collar and
pocket flaps, and wear cuffless trousers to avoid entry of
sparks and slag.
Wear helmet with safety goggles or glasses with side shields
underneath, appropriate filter lenses or plates (protected by
clear cover glass). This is a MUST for welding or cutting, {and
chipping) to protect the eyes from radiant energy and flying
metal. Replace cover glass when broken, pitted, or spattered.
See 1-3A.
Avoid oily or greasy clothing. A spark may ignite them,
Hot metal such as electrode stubs and workpieces shoyld
never be handled without gloves.
Medical first aid and eye treatment First aid facilities and a
qualified first aid person should be available for each shift
uniess medical facilities are close by for immediate treatment
of fiash burns of the eyes and skin burns,
Ear plugs should be warn when working on overhead or in a
confined space. A hard hat should be worn when others work
overhead.
Flammable hair preparations should not be used by persons
intending to weld or cut.
Toxic Fume Prevention
Adequate ventilation, Severe discomfort, illness or death can
result from fumes, vapors, heat, or oxygen enrichment or
depletion that welding {or cutting) may produce. Prevent
them with adequate ventilation as described in ANSI Stan-
dard Z49.1 listed 1 in Standards index. NEVER ventilate
with oxygen.
Lead, cadium, zinc, mercury, and beryllium bearing and simi-
tar materials, when welded {or cut) may produce harmful
concentrations of toxic fumes. Adequate local exhaust venti-
lation must be used, or each person in the area as well as the
operator must wear an air-supplied respirator. For beryllium,
both must be used.
Metals coated with or containing materials that emit toxic
fumes should not be heated unless coating is removed from
the work surface, the area is well ventilated, or the operator
wears an air-supplied respirator.
Work in a confined space only while it is being ventilated
and, if necessary, while wearing an air-supplied respirator.
Gas leaks in a confined space should be avoided. Leaked gas
in large quantities can change oxygen concentration danger-
ously. Do not bring gas cylinders into a confined space.
Leaving confined space, shut OFF gas supply at source. The.
space will then be safe to re-enter, if downstream valves have
been accidently opened or left open,
Vapors from chlorinated solvents can be decomposed by the
heat of the arc (or flame) to form PHOSGENE, a highly toxic
gas, and other lung and eye irritating products. The uitra-
violet (radiant) energy of the arc can also decompose tri-
chloroethylene and perchioroethylene vapors to form phos-
gene. DO NOT WELD or cut where solvent vapors can be
drawn into the welding or cutting atmosphere or where the
radiant energy can penetrate to atmosphares containing even
minute amounts of trichlorethylene or perchlorethylene.
Fire and Explosion Prevention
Causes of fire and explosion are: combustibles reached by the
arc, flame, flying sparks, hot slag or heated material; misuse
of compressed gases and cylinders; and short circuits.
Be aware that flying sparks or falling slag can pass through
cracks, along pipes, through windows or doors, and through
wall or floor openings, out of sight of the goggled operator.
Sparks and slag can fiy 35 feet.
To prevent fires and explosion:
Keep equipment clean and operable, free of oil, grease, and
{in electrical parts) of metallic particles that can cause short
Circuits.
M combustibles are in ama, do NOT weld or cut. Move the
work if practicable, to an area free of combustibles. Avoid
paint spray rooms, dip tanks, storage areas, ventilators. If the
work can not be moved, move combustibles at least 35 feet
away out of reach of sparks and heat; or protect against
ignition with suitable and snug-fitting, fire-resistant covers or
shields.
Walls touching combustibles on opposite sides should not be
welded on {or cut). Walls, ceilings, and floor near work
should be protected by heat-resistant covers or shields.
Fire watcher must be standing by with suitable fire ex-
tinquishing equipment during and for some time after weld-
ing or cutting if:
a. appreciable combustibles (including building construc-
tion) are within 35 feet
Ь. appreciable combustibles are further-than 35 feet but can
be ¡gnited by sparks
e. openings (concealed or visible) in floors or wails within 35
feet may expose combustibles to sparks
d. combustibles adjacent to walls, ceilings, roofs, or metal
partitions can be ignited by radiant or conducted heat.
Hot work permit should be obtained before operation to
ensure supervisor's approval that adequate precautions have
been taken.
After work is done, check that area is free of sparks, glowing
embers, and flames.
An empty container that held combustibles, or that can pro-
duce flammable or toxic vapors when heated, must never be
welded on or cut, unless container has first been cleaned as
described in AWS Standard AB.0, listed 3 in Standards index.
OM-315 Page 1
Page 2
This includes: a thorough steam” or caustic cleaning (or: a
solvent or water washing, depending on the combustible's
solubitity) followed by purging and inerting with nitrogen or
carbon dioxide, and. using protective equipment as: recom-
mended in AB8.0. Waterfilling just below working level may
substitute for inerting.
A container with unknown contents should be cleaned (see
paragraph above). Do NOT depend: on sense of smell or r sight
to determine if itis safe to weld or cut.
Hollow castings or containers must be vented befare welding
or cutting. They can explode.
Explosive atmospheres. Never weld or cut where the air may
con tain flammable dust, gas, or liquid vapors (such as gaso-
itne
Compressed Gas Equipment
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-1, PRECAU-
TIONS FOR SAFE HANDLING OF COMPRESSED GASES
IN CYLINDERS, listed 6 in Standards index.
1. Pressure Regulators
Regulator relief valve is designed to protect only the regula
tor from overpressure; it is not intended. to protect any
downstream equipment. Provide such protection with one or
more relief devices. - . a
Never connect a regulator to a cylinder containing vas ‚other
than that for which the regulatory was designed. | :
Remove faul ty regulator from service immediately forrepair
(first close cylinder valve! The following symptoms jr indicate
a faulty regulator: at ae
Leaks - if gas leaks externally.
Excessive. Creep - if delivery pressure continues to rise with
downstream valve closed.
Faulty Gauge - if gauge pointer does not move off: stop pin
when pressurized, nor returns to stop pin, after pressure
release. "
Repair. Do NOT emt son Son faulty regulators for
repair to manufacturer's designated repair center, where
special techniques and tools are used by trained personnel.
2. Cylinders | |
Cylinders must be handled carefully to prevent leaks and
damage to their walls, valves, or safety devices:
Avoid electrical circuit contact with cylinders including third
. rails, electrical wires, or welding circuits. They can produce
short circu ares that may lead to a serious accident. (See
1-3C
ICC or DOT marking must be on each. cylinder. It is. an
assurance of safety when the cylinder is properly handled.
Identifying gas content. Use only cylinders with name of gas
marked on them; do not rely on color to identify gas con-
tent. Notify supplier if unmarked. NEVER DEFACE or alter
name, number, or other markings on a cylinder. Et is illegal
and hazard ous.
-Empties: Keep valves closed, replace caps securely; mark MT;
keep thém separate from FULLS and. return promptly.
Prohibited use. Never use a cylinder. or. its contents for other
than its intended use, NEVER a.a support or, roller.
Secure from faliing. Chain or secure cylinders upright when a
regulator {and hose). are connected toit.
Passageways and work areas. Keep cylinders clear of areas
where they may be struck. - , |
Transporting cylinders. With a crane, use a secure support
such as a platform. or cradle. Po NOT lift cylinders. off the
ground by their valves or caps, or oy chains, slings, or mag-
nets.
Do NOT expose cylinders to excessive heat, sparks, slag, and
flame, etc. that may cause rupture. Do not allow contents to
exceed 130°F. Cool with water spray where such exposure
exists.
Protect. cylinders particulary valves from bumps, falls, falling
objects, and weather. Replace caps securely when moving
cylinders, `
Stuck valve. Do NOT use a hammer or metal wrench to open
a cylinder valve that can not be opened by hand. Notify your
supplier.
Mixing gases. Never ty to mix any gases ina cylinder.
; Never refill any cylinder.
Cylinder fi fittings should never be modified or exchanged.
3 Hose - | В
Prohibited -use. Never use hose other than that designed for
the specified gas. A general hose identification rule is: red for
fuel 93s, green for oxygen, and black fori inert gases.
Use ferrules or. clamps designed for the hose (not ordinary
wire or other substitute). asa binding to connect hoses to
| fetings.
‘No copper tubing spices. Use only standard brass fittings to
splice hose,
Avoid long runs 16 prevent Kinks and abuse. Suspend hose off
* ground to kesp it from being run over, stepped on, or other-
— wise damaged.
Coil excess hose to prevent kinks and tangles.
Protect hose “from damage. by sharp edges, ‘and by sparks,
siag, and open flame.
Examine ‘hose regulary’ for leaks, wear, and loose соппес-
tions. Immerse pressured” hose in. water; bubbles indicate
leaks. a
Repair leaky or worn’ hose: by cutting area out and spli icing
(1:23). Do NOT use tape. -
4. ‘Proper Connections
Clean eylinder vaive outlet of impurities that may clog
orifices and damage seats before connecting regulator. Except.
for hydrogen, crack valve momentarily, pointing outlet away
from people and sources of ignition. Wipe with a clean lint
less cloth: -
"Match regulator. 1 to cylinder. Before connecting, check that
the regulator label and cylinder marking agree, and that the
‘reguiator inlet and cylinder outlet match. NEVER CON-
NECT a regulator designed for a particular gas or gases to a
cylinder containing any other gas.
"Tighten connections. When assembling threaded connections,
clean and. smooth. seats where necessary. Tighten, If connec-
‘tion leaks, disassemble, clean, and retighten, For metal-to-
metal seating, use correct wrenches, available from your
supplier. For O-ring connections, hand tighten,
_ Adapters. Use a-CGA adapter (available from your supplier)
between cylinder and regulator, if one is required. Use two
wrenches to tighten adapter marked RIGHT and LEFT
HAND threads.
‘Regulator outlet (or hose) connections may be identified by
right hand threads for oxygen and left hand threads (with
grooved hex on nut or shank) for fuel gas.
5. Pressurizing Steps:
- Drain regulator of residual gas through suitable vent before
opening cylinder: {or manifold valve) by turning adjusting
screw in (clockwise). Draining prevents excessive compression
heat at.high pressure seat by allowing seat to open on pressur-
ization. Leave adjusting screw engaged slightly on single-stage
regulators.
Before opening cylinder valve, check that hoses are con-
nected and that downstream valves are closed. -
“Stand to sidé of regulator while opéning eytinder valve.
Open. cylinder” valve siowiy so that regulator pressure in-
creases slowly. When gauge 1s pressurized (gauge reaches regu-
lator maximum} leave cylinder valve in following position:
For oxygen, and inert gases, open fully to seal stem against
1-3.
possible teak. For fuel gas, open to less than one turn to
permit quick emergency shutoff.
Use pressure charts (available from your supplier) for safe
and efficient, recommended pressure settings on regulators. !:
will reduce backfiring and chance of flashbacks.
Check for leaks on first pressurization and regularly there-
after. Brush with soap solution (capful of lvory Liquid* or
equivalent per gallon of water}. Bubbles indicate leak, Ciean
off soapy water after test; dried soap is combustible.
User Responsibilities
Remove leaky or defective equipment from service immed-
tatety and repair them only if recommended in equipment
instruction manual. Send others for repair to manufacturer's
designated repair center where special techniques and tools
are used by trained personnel. Refer to User Responsibilities
statement in equipment manual.
Leaving Equipment Unattended
Close gas supply at source and drain gas.
Rope Staging-Support
Rope staging-support shouid not be used for welding or cut-
ting operation; rope may burn.
ARC WELDING
Comply with precautions in 1-2 and this section. Arc Weld-
ing, properly done, is a safe process, but a careless operator
invites trouble. The equipment carries high currents ai signifi-
cant voltages, The arc is very bright and hot. Sparks fly,
fumes rise, ultraviolet and infrared energy radiates, weld-
ments are hot, and compressed gases may be used. The wise
operator avoids unnecessary risks and protects himself and
others from accidents. Precautions are described hers and in
standards referenced in index.
Burn Protection
Comply with precautions in 1-2.
The welding arc is intense and visibly bright. 1s radiation can
damage eyes, penetrate lightweight clothing, refiect from
light-colored surfaces, and burn the skin and eyes. Skin burns
resemble acute sunburn, those from gas-shielded arcs are
more severe and painful. DON'T GET BURNED; COMPLY
WITH PRECAUTIONS,
1. Protective Clothing
Wear longsleeve clothing {particularly for gas-shielded arc) in
addition to gloves, hat, and shoes (1-2A). As necessary, use
additional protective clothing such æ teather jacket or
sleeves, flame-proof apron, and fire-resistant leggings. Avoid
outergarments of untreated cotton.
Bare skin protection. Wear dark, substantial clothing. Button
collar to protect chest and neck and button pockets to pre-
vent entry of sparks.
2. Eye and Head Protection
Protect eyes from exposure to arc. NEVER look at an elec-
tric arc without protection.
Welding helmet or shield containing a filter plate shade no. 9
or denser must be used when welding. Place over face before
striking arc.
Protect filter plate with a clear cover plate.
Cracked or broken helmet or shield shouid NOT be worn;
radiation can pass through to cause burns,
Cracked, broken, or {oose filter plates must be replaced IM-
MEDIATELY. Replace clear cover plate when broken, pitted,
or spattered.
Fiash goggles with side shields MUST be worn under the
helmet to give some protection to the eyes should the helmet
not be lowered over the face before an arc is struck. Looking
at an arc momentarily with unprotected eyes (particularly a
high intensity gas-shieided arc) can cause a retinal burn that
may leave a permanent dark area in the fieid of vision.
- *Trademark of Proctor & Gamble.
3. Protection of Nearby Personnel
Enclosed welding area. For production welding, a separate
room ar enclosed bay is best. In open areas, surround the
“operation with low-reflective, non-combustible screens or
panels. Allow for free air circulation, particularly at floor
level.
Viewing the weld. Provide face shields for all persons who
will be looking directly at the weld.
- Others working in area. See that al! persons are wearing flash
goggles.
Before starting to weld, make sure that screen flaps or bay
doors are closed.
Toxic Fume Prevention
Comply with precautions in 1-2B.
Generator engine exhaust must be vented to the outside air.
Carbon monoxide can kill. 7
Fire and Explosion Prevention
Comply with precautions in 1-2C.
Equipments rated capacity. Do not overload arc welding
equipment. It may overheat cables and cause a fire.
: Loose cable connections may overheat or flash and cause a
fire.
Never strike an arc on a cylinder or other pressure vessel. Ft
creates a brittle area that can cause a violent rupture or lead
to such a rupture later under rough handling.
Compressed Gas Equipment
Comply with precautions in 1-2D.
Shock Prevention
Exposed hot conductors or other bare metal in the welding
circuit, or in ungrounded, electrically-HOT equipment can
fatally shock a person whose body becomes a conductor. DO
NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wet sur-
face when welding, without suitable protection.
To protect against shock:
Keep body and clothing dry. Never work in damp area with-
out adequate insulation against electrical shock. Stay on a
dry duckboard, or rubber mat when dampness or sweat can
not be avoided. Sweat, sea water, or moisture between body
and an electrically HOT part - or grounded metal - reduces
the body surface electrical resistance, enabling dangerous and
possibly lethal currents to flow through the body.
1. Grounding the Equipment
When installing, connect the frames of each unit such as
welding power source, control, work table, and water circula-
tor to the building ground. Conductors must be adequate to
carry ground currents safely. Equipment made electrically
HOT by stray current may shock, possibly fatally. Do NOT
GROUND to electrical conduit, or to a pipe carrying ANY
gas or a flammable liquid such as oil or fuel.
Three-phase connection. Check phase requirement of equip-
ment before installing. If only 3-phase power ls available,
connect single-phase equipment to only two wires of the
3-phase tine. Do NOT connect the equipment ground lead to
the third (live) wire, or the equipment will become electri-
cally HOT - a dangerous condition that can shock, possibly
fatally.
Before welding, check ground for continuity. Be sure conduc-
tors are touching bare metal of equipment frames at connec-
tions. y
If a line cord with a ground lead is provided with the equip-
ment for connection to aswitehbox, connect the ground lead
to the grounded switchbox. If a three-prong plug is added for
connection to a grounded mating receptacle, the ground lead
must be connected to the ground prong only. If the line cord
comes with a three-prong plug, connect to a grounded mating
receptacle. Never remove the ground prong from a plug, or
use a plug with a broken off ground prong.
OM-315 Page 3
Page 4
2. Electrode Holders
Fully insulated electrode holders should be used. Do NOT
use holders with protruding screws.
3. Connectors
Fully insulated lock-type connectors should be used to join
welding cable lengths.
4. Cables
Frequently inspect cables for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn or
damaged insulation to avoid possibly - lethal shock from
bared cable. Cables with damaged areas may be taped to give
resistance equivalent to original cable. Keep cable dry, free of
oil and grease, and protected from hot metal and sparks.
bh. Terminals
Terminals and other exposed parts of electrical units should
have insulating covers secured before operation,
6. Electrode Wire
Electrode wire becomes electrically HOT when the power
switch of gas metal-arc welding equipment is ON and welding
gun trigger is pressed. Keep hands and body clear of wire and
other HOT parts,
7. Safety Devices
Safety devices such as interlocks and circuit breakers should
not be disconnected or shunted out.
Before installation, inspection, or service, of equipment, shut
OFF all power and remove line fuses (or lock or red-tag
switches) to prevent accidental turning ON of power. Discon-
nect all cables from welding power source, and pull ali 115
volts fine-cord plugs.
1-4.
Do not open power circuit or change polarity while welding.
If, in an emergency, it must be disconnected, guard against
shock burns, or flash from switch arcing.
Leaving equipment unattended. Always shut OFF and dis-
connect all power to equipment.
‘Power disconnect switch must be available near the welding
power source.
STANDARDS BOOKLET INDEX
For more information, refer to the following standards or
their latest revisions and comply as applicable:
1. ANSI Standard 248.1, SAFETY IN WELDING AND
CUTTING obtainable from the American Welding
- Society, 2501 NW 7th St., Miami, Fla. 33125.
2. ANSI Standard Z87.1, SAFE PRACTICE FOR OCCUPA-
TION AND EDUCATIONAL EYE AND FACE PROTEC-
TION, obtainable from American National Standards
Institute, 1430 Broadway, New York, N.Y, 10018.
3. American Welding Society Standard A6.0, WELDING
AND CUTTING CONTAINERS WHICH HAVE HELD
COMBUSTIBLES, obtainable same as item 1.
4. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING AND CUTTING, obtainable from the
National Firs Protection Association, 470 Atlantic
Avenue, Boston, Mass. 02210.
5. NFPA Standard 51B, CUTTING AND WELDING PRO-
CESSES, obtainable same as item 4,
6. CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES iN CYLINDERS, obtaineble from the
Compressed Gas Association, 500 Fifth Avenue, New
York, N, Y. 10036,
7. OSHA Standard 29 CFR, Part 1910, Subpart Q, WELD-
ING, CUTTING AND BRAZING.
————]——.0 2 SECTION 2 - INTRODUCTION ———e—mmmmemmesmeenmnennÜnmnnnn
Rated ;
Welding Welding
Rated Current Current Amperes Input
Welding Weiding Amperes Ranges At Rated Load Output
Current Current (Gas (Gas Max. __60/Hiz Single Phase 0 {| Weigh
Amperes Ranges Tungsten- Tungsten- Qoen- | (208) vera eight
{Shielded | (Shielded . Are) Arc) Circuit] 200 | 230 | 460 Dimensions (Pounds)
Model | Metal-Arc) | Metal-Arc) (TIG) (T1G) Voltage; Volts | Volts | Volts | KVA | KW (Inches) Net | Ship
AC AC AC AC
250 amps LOW 10-45 200 amps | LOW 10-45 75
Without at MED 35-160 at MED 40-165
Power 30 volts HIGH 85-295 | 40% Duty | KIGH 140-310 99 30 45 20.6 | 12.8 476 | 486
Factor | 40% Duty Cycle Height-26-5/8
Cycle 125 amps
at Width -19
100% Duty
Cycle Depth -33
DC DC oc | co | | -
200 amps | LOW 10-50 250 amps | LOW 10-55 76 | &
With at MED 35-150 at MED 40-190 84 | 76 | 38 | 17.5 | 128 486 | 496
Power | 40volts | HIGH 80-270 | 40% Duty | HIGH 125-310
Factor | 60% Duty Cycle
Cycle
Figure 2-1. Specifications
LINE POWER INPUT MAIN 115 VOLTS À 115 VOLTS CIRCUIT
TERMINALS SWITCH VOLTAGE XFMR SECONDARY "OVERLOAD BREAKER
| —— JUMPER PRIMARY | WI > |
LINKS 30 VOLTS CONTROL 8 1115VOLTSAC
SECONDARY En OAD 3 | ™ RECEPTACLE
WINDING L BR
POWER _SRÉAKER À RELAY CRY CONTACTOR
Me eon] | qe mE)
: ©. GAS
I CONTROL À. OF TIMER VALVE
MAIN SELECTOR MAGNETIC ÿ | CONTACTOR |
RECTIFIERN | swiTCH AMPLIFIER § CONTACTS ‘ СОМТАСТОВ NO CONTACTS |
Comunal] | ra ACUTE THERMOSTAT CONTROL N OF RELAY COOLANT
CONTROL | CR2
В МРЕНАСЕ STANDARD - À : Y
| 2 RECEPTACLE] ‚REMOTE Aita TAC OF RELAY
POST-F LOW
TIMER
TD1
WELD
SELECTOR |
| swiTcH В
SECONDARY | WORK
OUTPUT |
TERMINALS ELECTRODE
|
y ,
| HIGH HIGH- À OFF
RECTIFIER À FREQUENCY SPARK FREQUENCY Ba OE RELAY > CON. | FREQUENCY
В XFMA GAPS XFMR CR? TINUCUS
то SWITCH
T3 START
IN.O. CONTACTS
OF RELAY
CRT
TB-000 510
Figure 2-2. Block Diagram
When requesting information concerning this equipment, it is
essential that Model Description and/or Stock Number and
Serial (or Style) Numbers of the equipment be supplied.
2-3. DESCRIPTION
This unit is a single-phase welding power source which pro-
duces ac and dc welding current, This welding power source
is designed to be used in conjunction with the Shielded
Metal-Arc (Stick Electrode) and Gas Tungsten-Arc {TIG)
Welding processes.
. SAFETY
Before the equipment is put into operation, the safety sec-
tion at the front of this manual should be read completely.
This will help avoid possible injury due to misuse or improper
welding applications.
2-1. GENERAL
This manual has been prepared especially for use in famitiar-
izing personnel with the design, installation, operation, main-
tenance, and troubleshooting of this equipment. All informa-
tion presented herein should be given careful consideration to
assure optimum performance of this equipment.
. RECEIVING-HANDLING
Prior to installing this equipment, clean all packing material
from around the unit and carefully inspect for any damage
that may have occurred during shipment. Any claims for loss
or damage that may have occurred in transit must be filed by
the purchaser with the carrier. A copy of the bill of tading
and freight bili will be furnished by the carrier on request if
occasion to file claim arises.
The following definitions apply to CAUTION, IMPORTANT,
and NOTE blocks found throughout this manual:
OM-315 Page 5
Under this heading, installation, operating, and main-
tenance procedures or practices will be found that if
not carefully followed may create a safety hazard to
| personnel. 1
IMPORTANT
Under this heading, installation, operating, and main-
tenance procedures or practices will be found that if
not carefully followed may result in damage to equip-
I ment. - I
LOCATION (Figure 3-1}
A proper installation site should be selected for the welding
power source if the unit is to provide dependable service, and
remain relatively maintenance free.
A proper installation site permits freedom of air movement
into and out of the welding power source, and also least
subjects the unit to dust, dirt, moisture, and corrosive vapors.
A minimum of 18 inches of unrestricted space must be main-
tained between the welding power source front and rear
panels and the nearest obstruction. Also, the underside of the
welding power source must be kept completely free of
obstructions. The installation site should also permit easy
removal of the welding power source outer enclosure for
maintenance functions.
IMPORTANT
Do not place any filtering device over the intake air
passages of the welding power source as this would
restrict the volume of intake air and thereby subject
the welding power source internal components to an
overheating condition and subsequent failure. War-
L ranty is void if any type of filtering device is used. 1
Holes are provided in the welding power source base for
mounting purposes. Figure 3-1 gives overall dimensions and
the base mounting hole layout.
3"
23-5/8"
7/6”
Dia.
4 Holes
1-1/2"
TC-000 321
Page 6
Figure 3-1. Dimensional Drawing
On most welding power sources a lifting device is provided
for moving the unit. However, if a fork lift vehicle is used for
lifting the unit, be sure that the lift forks are long enough to
extend completely under the base.
Under this heading, explanatory statements will be
found that need special emphasis to obtain the most
efficient operation of the equipment,
SECTION 3 - INSTALLATION === === ==—=——— o
IMPORTANT
The use of lift forks too short to extend out of the
opposite side of the base will expose internal com-
ponents to damage should the tips of the lift forks
I penetrate the bottom of the unit. ;
3-2. ELECTRICAL INPUT CONNECTIONS
It is recommended that a Line Disconnect Switch be’
installed in the input circuit to the welding power
source. This would provide a safe and convenient
means to completely remove all electrical power from
the welding power source whenever it is necessary to
: I perform any internal function on the unit. N
Before making electrical input connections to the
welding power source, ‘machinery lockout proce-
dures’ should be employed. If the connection is to be
made from a line disconnect switch, the switch should
be padlocked in the open position. If the connection is
made from a fuse box, remove the fuses from the box
and padlock the cover in the closed position. If lock-
ing facilities are not available, attach a red tag to the
line disconnect switch {or fuse box} to warn others
i that the circuit is being worked on. 1
Input Electrical Requirements
This welding power source is designed to be operated from a
single-phase, 60 Hertz, ac power supply which has a line volt-
age rating that corresponds with one of the primary voltages
shown on the welding power source nameplate. Consult the
loca! electric utility if there is any question about the type of
electrical system available at the installation site or how pro-
per connections to the welding power source are to be made.
Input Conductor Connections
Do not connect the input conductors to the single-
phase power supply until all input electrical connec-
I tions have been made to the welding power source. I
It is recommended that the input conductors be of the heavy
rubber covered type or be installed in solid or flexible con-
duit. Select the proper size input conductors and fuse from
Table 3-1.
Table 3-1. Input Conductor and Fuse Size is lower than the highest voltage for which the unit was de-
signed, the jumper links will have to be moved to the proper
Input Conductor Size (AWG) Cuse Size In Amperes position before operation of the welding power source com-
Model 200V [230V [460V | 575V 200V | 230V] 460V 575V mences. Figure 3-3 shows the various positions for which the
Without P.F.C. | No. 31No. 3 (No. 8 | No. 8 150 | 150 | 70 | 60 jumper links may be set on the standard welding power
With P.F.C. No. 4 1No. 41No. & |М№о. 10 125 7014 60 60 source. If the input voltages on the welding power source
(8) (8) (8) (10) nameplate differ from those shown in Figure 3-3, the input
voltage jumper links must be positioned as shown on the in-
*Numbers in { } indicate ground conductor size. put voltage label.
Insert the two input conductors plus one ground conductor
through the access hole on the rear panel. The hole wiil
accept standard conduit fittings: See Figure 3-2 for hole loca-
tion and size.
If only one jumper link is required on each of the
grouped terminals, it is recommended that the unused
jumper links be placed across the terminals which are
10 be used. This will prevent losing the jumper links
It is recommended that a terminal lug of adequate | which are not required for this connection. 1
amperage capacity be attached to the ends of the
input and ground conductors. The hole diameter in 200 (208) VOLTS 230 VOLTS 460 VOLTS
the terminal lug must be of proper size to accommo- а ее (Ла o AER © ooo
date the ling and ground terminal studs on the primary
es © © c © © o © D
| terminal board. й GH, Ly La GR Ly La GR. La La
TA-010 586-A
Connect the two input conductors to the terminals on the Figure 3-3. Input Voltage Jumper Link Arrangement
primary terminal board labeled LO a Canes: the
round conductor to the terminal labele ee Figure
32). The remaining end of the ground conductor should be 3-3. SECONDARY WELDING CONNECTIONS
connected to a proper ground, Use whatever grounding
method that is acceptable to the local electrical inspection It is recommended that the welding cables be kept as short as
authority. a possible, placed close together, and be of adequate current
CC carrying capacity. The resistance of the welding cables and
connections cause a voltage drop which is added to the volt-
age of the arc. Excessive cable resistance may result in over-
loading as well as reducing the maximum current output of
which the welding power source 15 capable. The proper opera-
tion of any arc welding power source is to a great extent
CAUTION |
The terminal labeled GRD is connected to the welding
power source chassis and is for grounding purposes dependent on the use of weiding cables and connections that
only. Do not connect a conductor from the terminal are in good condition and of adequate size. An insulated
labeled GRD to any one of the L. or LINE terminals as electrode holder must be used to ensure the operator's safety.
this will result in an electrically hot welding power
i source chassis. a Table 3-2, Secondary Weld Cable Size
WELDINGL TOTAL LENGTH OF CABLE { COPPER) IN WELD CIRCUIT
AMPERESÍ *50 | 100 | 150 | 200 | 250 | 200 {| 350 | 400
100 a 4 4 3 2 1 1/0 | 1/0
input Voltage 150 3 3 2 1 1/0 |-2/0 3/0 3/0
Jumper Links 200 2 2 1 |10 |2/0 |3/0 | 4/0 | 4/0
250 1 1 10 |270 |3/0 lazo | 4/0 | 22/0
300 170 | 2% |3/0 |4/0 | 4/0 2-2/0 | 2-3/0
A-002 624
NOTE: *A. 50 FEET OR LESS.
*B. CABLE SIZE IS BASED ON DIRECT CURRENT (DC),
60% DUTY CYCLE ANC EITHER A 4 VOLTS OR LESS
DROP OR A CURRENT DENSITY OF NOT OVER 300
CIRCULAR MILS PER AMP.
*C. WELD CABLE INSULATION WITH A VOLTAGE
RATING TO WITHSTAND THE OPEN-CIRCUIT VOLT-
AGE (OCV) OF THE WELDING POWER SOURCE MUST
BE USED. WHILE MOST WELDING POWER SOURCES
=
`
fe “| o HAVE AN OPEN-CIRCUIT VOLTAGE OF LESS THAN
f 1-3/4" 100 VOLTS, SOME WELDING POWER SOURCES OF
/ Access Hole SPECIAL DESIGN MAY HAVE HIGHER OPEN-CIRCUIT
Ground VOLTAGE.
Terminal
Use Table 3-2 as a guide for selecting the correct welding
Line cable size for the anticipated maximum weld current that will
Terminals be used. Table 3-2 takes into account the total cable length
for the weld circuit. This means the length of the Electrode
Input Voltage
Label cable that connects the Electrode Holder to the welding
power source and the Work or ground cable between the
TC-000 321 welding power source and the work piece. For example: If
the Electrode cable is 75 feet long and the Work or ground
cable is 25 feet long, select the size cable from Table 3-2 that
is recommended for 100 feet. In a situation where a maxi-
mum weld current of 150 amperes is anticipated, No. 3 weld
Figure 3-2. Input Conductor Connections
C. Matching The Welding Power Source To The Avail- cable is recommended for both the Electrode and Work
able Input Voltage cables. |
The input voltage jumper links provided on the primary ter- To ensure that the weld current output will be in accordance
minal board permit the welding power source to be operated with the labeling of the positions on the WELD SELECTOR.
from various line voltages. The various voltages from which Switch, connect the electrode holder cable to the ELEC-
this welding power source may be operated are stated on the TRODE terminal and the work cable to the WORK terminal,
welding power source nameplate, and on the input voltage
abel. See Figure 3-2 for location. The input voltage jumper 3 -4, REMOTE AMPERAGE CONTROL CONNECTIONS
links on this welding power source are positioned for the (Figure 4-1)
- highest of the voltages stated on the nameplate. If the weld-
ing power source is to be operated from a line voltage which The AMPERAGE CONTROL Receptacle provides a junction
OM-315 Page 7
Range Selector
point for connecting a Remote Amperage Control to the
amperage control circuitry in the welding power source.
To connect the Remote Amperage Control to the AMPER-
AGE CONTROL Receptacle, insert the three-prong plug
from the Remote Amperage Control into the receptacle and
rotate the plug as far as it will turn in a clockwise direction,
Once fully rotated, the plug will be locked in the receptacle
and will not pull out under stress.
. 44) TACTOR CONTROL CONNECTIONS (Figure
The CONTACTOR CONTROL Receptacie provides a junc-
tion point for connecting a Remote Contactor Control device
to the contactor control circuitry in the welding power
source,
To connect the Remote Contactor Control to the CON-
TACTOR CONTROL Receptacle, insert the three-prong plug
from the Remote Contactor Control device into the CON-
TACTOR CONTROL Receptacle and rotate the plug as far as
it will turn in a clockwise direction. The plug will now be
locked in the receptacle and will not pull out under stress,
. COOLANT VALVE CONNECTIONS (Figure 4-1)
‘A valve is provided in order to control on and off flow of
coolant to the electrode holder. The COOLANT Valve input
Power
Amperage
Adjustment Switch High-Frequency
Control Switch
уу
Switch E |
Weld Selector
и Switch
ha м
Amperage © Contactor
ontro >» —— Control
Switch | „De ‚ © | Switch
Amperage я Contactor
Control | : Control
Receptacle . Receptacle
115 Volts ac— ee. Post- Flow
Receptacle = Timer
… Gas
Coolant q Valve
Valve a Electrode
Secondary
Work .
Secondary | Terminal
Terminal
TB-006 322
Figure 4-1. Front Panel View
4-1. POWER SWITCH (Figure 4-1)
Page 8
Piacing the POWER Switch in the ON position will energize
the welding power source fan and control circuitry and place
the welding power source in a ready-to-weld status. Placing.
the POWER Switch in the OFF position will shut the welding
power source down,
Even though the POWER Switch is in the OFF posi-
tion and the welding power source is apparently elec-
trically shut down, electrical input power is still
present on all circuitry up to the POWER Switch. To
completely cut-off all electrical input power to the
welding power source, it will be necessary to place the
line disconnect switch in the OFF position or remove
I the electrical input fuses. 1
. RANGE SELECTOR SWITCH (Figure 4-1)
The RANGE SELECTOR Switch provides the capability of
selecting from three coarse amperage ranges. The amperage
3-7.
SECTION 4-FUNCTION
4 - 3.
and output connections both have left hand threading. En-
sure that the hose from the coolant source is attached to the
connection on the COOLANT Valve labeled IN, The coolant
hose from the electrode holder must be attached to the con-
nection on the COOLANT Valve labeled QUT,
IMPORTANT
If a Coglant Pump is to be used and the Coolant Pump
is not equipped with a by-pass network, do not make
connections from the Coolant Pump to the COOL-
ANT Valve but rather connect the Coolant Pump
directly to the electrode holder coolant hoses, Failure
to comply may result in damage to the Coolant Pump
due to excessive back pressure when the COOLANT
1 Valve is closed. }
AMIELDING GAS VALVE CONNECTIONS (Figure
A valve is provided in order to control on and off flow of
shielding gas to the electrode holder. The Gas Valve input
and output connections both have right hand threading. En-
sure that the hose from the shielding gas source is attached to
the connection on the GAS Valve labeled IN. The shielding
gas hose from the electrode holder must be attached to the
connection on the GAS Valve labeled QUT.
range of each switch position is displayed on the welding
power source nameplate. If the amperage desired falls in the
overlapping area of two ranges, use the lower of the two
ranges, as better fine amperage adjustment is obtained in the
lower of the two ranges,
IMPORTANT
Do not change the position of the RANGE SE-
LECTOR Switch while welding or under load as this
will cause the contacts of the switch to arc. Arcing
across the contacts will cause the contacts to become
pitted and thereby eventually to become inoperative,
AMPERAGE ADJUSTMENT CONTROL (Figure 4-1)
The AMPERAGE ADJUSTMENT Control, located on the
upper center portion of the front panel, provides a means of
selecting the exact amperage desired within the range being
used, Rotating the control in a clockwise direction will in-
crease the amperage output.
The contacts of the AMPERAGE ADJUSTMENT Con-
trol are of the continuous contact type, thereby
making it possible to adjust the amperage output while
| welding. | J
The scale surrounding the AMPERAGE ADJUSTMENT Con-
trol is calibrated in percentage and should not be miscon-
strued as an amperage or voltage reading.
. AMPERAGE CONTROL RECEPTACLE & SWITCH
(Figure 4-1)
if a Remote Amperage Control is to be used, make connec-
tions from the Remote Amperage Control to the
AMPERAGE CONTROL Receptacle as instructed in item
34.
When remote control of the amperage is desired, it is essential
that the AMPERAGE CONTROL Switch be placed in the
REMOTE position. Likewise, if a Remote Amperage Control
is not to be utilized, the switch must be in the STANDARD
position. When in the STANDARD position, only the AM-
PERAGE ADJUSTMENT Control on the front panel will
control the amperage.
When a Remote Amperage Control is being used, it should be
noted that the Remote Amperage Control is functioning as a
fine amperage adjustment for the AMPERAGE ADJUST
MENT Control setting on the welding power source. For
example: H the AMPERAGE ADJUSTMENT Control on the
welding power source is set at the mid-range position, the
Remote Amperage Control will provide {from the min. to
max. positions) fine amperage adjustment on one half of the
welding power source output for the current range selected
by means of the RANGE SELECTOR Switch. If full adjust-
ment thru use of the Remote Amperage Control of the cur-
rent range selected is desired, the AMPERAGE ADJUST-
MENT Control on the welding power source must be set at
the maximum position,
. CONTROL CIRCUIT OVERLOAD BREAKER (Fig
ure 4-1)
The CONTROL CIRCUIT OVERLOAD BREAKER is sup-
plied in order to provide protection to the control circuit
components. Should a short occur in the amperage adjust
ment control circuit, this breaker would open and thereby
cause the weld output to drop to the minimum of the range
in use. When this occurs, neither the AMPERAGE ADJUST-
MENT Control or Remote Amperage Control will have any
Steve on Varying whe weld SuUpU. To place the welding
power source in a ready-to-weld status should this circuit
breaker trip, the circuit breaker must be manually depressed.
Should the circuit breaker continue to trip after each reset,
an internal problem in the control circuitry is most probabiy
present. Do not attempt any further welding until the trouble
has been remedied.
. WELD SELECTOR SWITCH (Figure 4-1)
The WELD SELECTOR Switch provides a means of selecting
either ac, dc straight, or dc reverse polarity without changing
the secondary cable connections.
Placing the WELD SELECTOR Switch fully up will provide
DC STRAIGHT polarity; fully down will provide DC RE-
VERSE polarity; the center position wili provide AC weld
current.
CAUTION \
Do not change the position of the WELD SELECTOR
Switch while welding or under load as this will cause
the contacts of the switch to arc. Arcing across the
contacts will cause the contacts to become pitted and
8 thereby eventually to become inoperative. _
CONTACTOR CONTROL RECEPTACLE
8 SWITCH (Figure 4-1)
if a Remote Contactor Control device is to be used, make
connections to the CONTACTOR CONTROL Receptacle as
instructed in item 3-5,
A prerequisite for remote contro! of the contactor, is to have
the CONTACTOR CONTROL Switch on the welding power
source in the REMOTE position, If this switch is left in the
STANDARD position, the contactor will energize as soon as
the POWER Switch is positioned to ON.
Whenever the CONTACTOR CONTROL Switch is in
the STANDARD position, open-circuit voltage will be
present at the secondary terminals for as long as the
POWER Switch is positioned to ON
Le —————————cd]
The Remote Contactor Control! device will, when closed,
energize the contactor and GAS and COOLANT Valves.
{High-frequency wili also be present when the Remote Con-
tactor Control device is closed if the HIGH-FREQUENCY
Switch is in the START or CONTINUOUS position.) When
the Remote Contactor Control device is opened, the con-
tactor will open and suspend the weld output; also the
POST-FLOW Timer will energize and begin to time out.
. Thermostat Protecti on
This welding power source is protected from damage due to
excessive overload by a thermostat which is physically lo-
cated in the main transformer and electrically connected in
series with the contactor coil. Should this thermostat detect
an overheated condition in the main transformer it will open.
As soon as the thermostat has opened, it will cause the con-
tactor to open and thereby suspend all weld output. The
symptom of an overload condition would be the inability to
cause the contactor to energize by placing the CONTACTOR
CONTROL Switch in the STANDARD position or by placing
the CONTACTOR CONTROL Switch in the REMOTE posi-
tion and then closing the Remote Contactor Control Switch.
Should an overload condition be noted, leave the POWER
Switch in the ON position and allow the welding power
source to idle for approximately 5 minutes. After this 5
minute cooling period, the thermostat will automatically
close and once again permit normal operation,
‚ HIGH-FREQUENCY SWITCH (Figure 4-1)
The HIGH-FREQUENCY Switch, located on the front panel,
provides three positions which determines whether the
high-frequency will be on or off.
. Start Position
When in the START position, high-frequency will be present
at the welding electrode from the time the contactor is closed
until the arc is initiated. Once an arc is established, and even
though the contactor 15 closed, the high-frequency will be
de-energized. High-frequency will be present again only after
the arc is broken and restarted.
. Continuous Position
The CONTINUOUS position will provide high-frequency for
as long as the contactor is closed. The high-frequency and
weld current may be shut off during the weld by opening the
Remote Contactor Control Switch.
. Off Position
High-frequency wiil not be available when in the OFF posi-
tion, even if the contactor is closed. This position must be
used when performing Shielded Metal-Arc {Stick Electrode)
Welding.
Never try to use high-frequency when performing
Shielded Metal-Âre {Stick Electrode) Welding. Failure
to comply may result in the high-frequency arcing
through the electrode holder and seriously injurying
I the operator. |
. POST-FLOW TIMER (Figure 4-1)
An adjustable O to 60 second POST-FLOW Timer is provided
for controlling the period of time shielding gas and coolant
will be allowed to flow after the arc is extinguished.
To select the desired portion of the maximum 60 second
post-flow time period available, rotate the adjustable stop
arm on the timer until the appropriate setting is obtained,
As soon as the arc has been extinguished, the POST-FLLOW
Timer will begin to time out the selected period of post-flow
time. Once the selected post-flow time has elapsed, the GAS
and COOLANT Valves will close and thereby cut-off shieid-
ing gas and coolant flow, The timer will then automatically
reset and be ready for another weld cycle.
or GAS and ©
function when the CON-
the POST-FLOW Timer
COOLANT Valves will
TACTOR CONTROL Switch is in the STANDARD
Neither
position. In order to make these items operational, the
REMOTE position of the CONTACTOR CONTROL
| Switch must be used, }
4-10. 115 VOLTS AC RECEPTACLE {Figure 4-1)
À 115 VOLTS AC Receptacle 1S provided on the lower por-
tion of the front panel for operating accessory equipment
which requires 115 volts, 60 Hertz electrical power. Up to 10
OM-315 Page 9
amperes of 115 volts ac may be obtained from this recep-
tacle.
NOTE
A circuit breaker, located behind the lower front
access door, is supplied in arder to provide protection
to the 115 volts circuitry in the welding power source.
Should the amperage draw from the 115 VOLTS AC
Receptacle exceed 10 amperes, this circuit breaker
‘would open and prevent any output from the recep
tacle, To reset this circuit breaker should it open,
manually depress the red button portion of the circuit
breaker. Should this circuit breaker continue to open
upon reset, an internal trouble is probable and no
further use of the 115 VOLTS AC Receptacle shauld
be attempted until the trouble has been remedied,
hr ——————— |
4-11. DUTY CYCLE (Figure 4-2)
Welding power sources are rated on a percent duty cycle
based on 10 minute intervals. For example: a 40 percent
duty cycle simply means that the welding current is on for 4
minutes, off for 6 minutes, and so on. It must be kept in
mind that time intervals of other than 10 minutes will yield
different test rating results. As the output is reduced or in-
creased, the duty cycle will increase or decrease,
Figure 4-2 enables the operator to determine the safe output
of the welding power source at various duty cycles.
[RATED OUTPUT
300
250
Ac,
rf o <
ui 57 mai
a 200 ae AT
< Shay, ь <
® ^^ u
zZ |
8 150 <
= ><
100
25 130 40 509 60 70 #0 90100
7 DUTY CYCLE 5.002 976
Figure 4-2. Duty Cycle Chart
Never, under any circumstances, operate the welding
power source with any portion of the outer enciosure
removed. In addition to a safety hazard, improper
cooling may result in damage to the welding trans-
former and the welding power source components,
Warranty is void if the welding power source is opera-
ted with any portion of the outer enclosure removed, I
2-1 IELDED METAL-ARC (STICK ELECTRODE)
. SH
WELDING
1. Make secondary welding connections as explained in
item 3-3.
2. Select the properelectrode for the welding application
and insert it into the electrode holder,
3. Place the WELD SELECTOR Switch in the desired
position,
4, Place the RANGE SELECTOR Switch in the desired
position.
5. Rotate the AMPERAGE ADJUSTMENT Control to
the desired setting.
° 6. If a Remote Amperage Control is not to be used, place
the AMPERAGE CONTROL Switch in the STAN-
Page 10
IMPORTANT
Exceeding the indicated duty cycle will cause the
welding. power source to overheat and thereby cause
I damage to the welding power source. ]
4-12. VOLT-AMPERE CURVE (Figure 4-3)
The volt-ampere curve shows the output voltage available at
any given output current within the limits of the minimum
and maximum AMPERAGE ADJUSTMENT Control setting.
Load voltage is predetermined to a large degree by arc charac-
teristics. With the use of the volt-ampere curve, it is possible
to determine the amperage required for a specific load volt-
age. With reference to the volt-ampere curve (Figure 4-3), the
curve shows only the maximum and minimum settings of the
AMPER AGE ADJUSTMENT Control for each of the welding
current ranges available, Curves of other settings will fall be-
tween the maximum and minimum curves shown.
80
70
60
2 50
ll
O
> 40
50 100 150 200 250 300 350 400
AC AMPERES B-002 974
80
70
60
2 so
5
> 40
Wu
a 30
| |
о 50 100 150 200 250 300 350 400 450
DC AMPERES
Figure 4-3. Volt-Ampere Curves
8-002 970
SECTION 5 - SEQUENCE OF OPERATION =
DARD position. if a Remote Amperage Control is to
be used, place the AMPERAGE CONTROL Switch in
the REMOTE position.
7. Place the CONTACTOR CONTROL Switch in the
STANDARD position.
8. Place the HIGH-FREQUENCY Switch in the OFF
position,
Prior to welding, it is imperative that proper protective
clothing (welding coat and gloves) and eye protection
I (glasses and/or welding helmet) be put on. Failure to
comply may result in serious and even permanent
L bodily damage. I
9. Place the POWER Switch in the ON position.
10. Commence weiding.
5-2. GAS TUNGSTEN-ARC (TIG) WELDING
1. Make secondary connections as explained in item 3-3.
2. Select the proper electrode for the welding application
and insert it into the electrode holder.
3. Make shielding gas connections as explained in item
3-7 to the GAS Valve and coolant connections as ex-
plained in item 3-6 to the COOLANT Valve.
4. Connect the plug from the Remote Contactor Control
device to the CONTACTOR CONTROL Receptacle
and place the CONTACTOR CONTROL Switch in the -
REMOTE position.
5, Place the WELD SELECTOR Switch in the desired
position,
6. Place the RANGE SELECTOR Switch in the desired
position.
7. Rotate the AMPERAGE ADJUSTMENT Control to
the desired setting.
8. 1 a Remote Amperage Control is not to be used, place
the AMPERAGE CONTROL Switch in the STAN-
DARD position. If a Remote Amperage Control 15 to
be used, place the AMPERAGE CONTROL Switch in
the REMOTE position,
9. Place the HIGH-FREQUENCY Switch in the desired
position,
10. Rotate the POST-FLOW Timer to the desired time
setting.
11. Turn on the shielding gas at the shielding gas container
and coolant at the coolant source.
12. Place the POWER Switch in the ON position.
Be sure the branch circuit or main disconnect switch is
open or the electrical input circuit fuses are removed
before attempting any inspection or work on the
inside of the welding power source. Placing the
POWER Switch on the welding power source in the
OFF position does not remove voltage from the power
terminals inside of the unit,
6-1. FAN MOTOR
All modets are equipped with an exhaust fan and rely on
forced draft for adequate cooling. The fan motor is manufac-
tured with lifetime-lubricated sealed ball bearings and no
attention should be required.
65-2, TRANSFORMER
Occasional blowing out of the dust and dirt from around the
transformer is recommended, This should be done periodi-
cally depending upon the location of the unit and the
amount of dust and dirt in the atmosphere. The welding
power source outer enclosure should be removed and a clean
dry air stream should be used for this cleaning operation.
. RECTIFIER
lt is recommended that the rectifier be cleaned occasionally
by blowing it out with compressed ar, This cieaning opera-
tion is necessary so that maximum cooling wiii be accom-
plished by the air stream, This should be done periodically,
depending upon the location of the unit and the amount of
dust and dirt in the atmosphere. It is necessary to remove the
outer enclosure for this cleaning operation.
. SPARK GAP (Figure 6-1)
The spark gaps can be readily inspected by opening the access
door on the front of the welding power source.
The spark gaps are normally set at .008" clearance at the
factory. It will be necessary to periodically readjust these
after extended operation. Usually inspection and adjustment
every three or four months will suffice. Readjustment is also
indicated when intermittent operation of the gaps is noted.
Usually this occurs when the setting has increased to .013" or
greater. _
13. Commence welding.
RIL k
TT
Prior to welding, it is imperative that proper protective
clothing {welding coat and gloves) and eye protection
{glasses and/or welding helmet) be put on. Failure to
comply may resuit in serious and even permanent
bodily damage.
5.3. SHUTTING DOWN
1. Break the arc,
2, Allow the welding power source to idle for 3 minutes
with nc load applied.
3, Place the POWER Switch in the OFF position.
4, Turn off the shielding das and coolant ¡fused.
If welding is performed in a confined area, failure to
turn off the shielding gas supply could result in a
buitd-up of gas fumes, thereby endangering personnel
| re-entering the welding area. i
SECTION 6 - MAINTENANCE mme nn
Generally speaking, the high-frequency output varies directly
(up to a certain point) with the spark gap spacing. In extreme
cases where the greatest amount of high-frequency is needed,
it may be necessary to adjust the spark gap setting to .010”
or even .013”, This also increases the high-frequency radia-
tion and it is suggested that the minimum gap setting (.004"
10 008"), consistent with good welding operation, be used.
Cleaning or dressing the points of the spark gaps is not
recommended, as the material at the points is tungsten
and is impossible to file. The entire point should be
replaced when the tungsten section has completely
т disappeared, 1
To Adiust the Spark Gaps, Proceed as Follows:
1. Loosen screw A on both sides.
2. Place feeler gauge of proper thickness between points at
gap C.
Ww
. Apply slight pressure against point B so feeier gauge is
held firmiy in gap. -
4. Tighten screws A,
TA-020 G23-A2
Figure 6-1. Spark Gap Adjustment
OM-315 Page 11
The data collected here, discusses some of the common problems which may occur in this welding power source.
The assumption of this data is that a proper welding condition has been achieved and has been used until trouble developed. In all cases of
equipment malfunction, the manufacturer's recommendations should be strictly adhered to and followed.
If after performing the following procedures the trouble is still not remedied, it is recommended that a serviceman be called.
It is recommended that the circuit diagram be used for reference during troubeshooting.
TROUBLE
PROBABLE CAUSE
REMEDY
No weiding current.
Open line fuse,
Replace fuse.
POWER Switch defective.
Replace switch.
Circuit breaker CB2 open.
Reset CB2. See item 4-10.
Thermostat TP1 open.
Allow welding power source to
idle for 5 minutes, See item 4-7A.
Erratic weld current,
Loose welding connections.
Secure connections.
Bad ordamp electrodes.
Use new dry electrodes.
fan does not run,
POWER Switch defective.
Replace switch,
Fan motor defective.
Replace fan motor,
‘Line fuse open,
Replace fuse.
Welding current low.
CONTROL CIRCUIT OVERLOAD BREAKER open.
Reset breaker, See item 4-5,
AMPERAGE ADJUSTMENT
Control does not control current.
AMPERAGE CONTROL Switch in REMOTE position with
no Remote Amperage Control connected to AMPERAGE
CONTROL Receptacle.
Place AMPERAGE CONTROL
Switch in STANDARD position
or connect a Remote Amperage
Control to AMPERAGE
CONTROL Receptacle.
Tungsten electrode oxidizing and
Loose gas fittings on regulator of gas line.
Secure gas fittings.
not remaining bright after
conclusion of weid.
Insufficient gas flow.
Increase gas flow.
Drafts blowing gas shield away from tungsten.
Shield welding arc area,
Wandering arc, poor control of
direction of arc.
Tungsten used considerably larger than recommended.
Use proper size tungsten.
Lack of high-frequency, difficulty
Spark gap spacing incorrect,
Adjust spark gap (See item 6-4).
in establishing the arc,
Tungsten larger than recommended for weld current
involved,
Use proper size tungsten.
Leakage of high-frequency from electrode holder lead,
Replace lead.
FEWETE CONTROL
ECÉUTIGNAL-EXTASI
"РЛС DHLY
Page 12
POWER FACTOR CORACETI
Circuit Diagram
Circuit Diagram No. CB-901 782-1A
men SECTION 8 - CERTIFICATION FOR HIGH FREQUENCY ARC WELDING EQUIPMENT ===
8-1. GENERAL 3. Direct radiation from welding leads. Direct radiation from
. 2 1 the welding leads, although very pronounced, decreases
This following information is necessary to make a proper rapidly with distance from the welding leads. By keeping
installation of the high frequency arc welding equipment de- the welding leads as short as possible, the operator can do
scribed in this instruction manual. In order to comply with a great deal to minimize interference from the source.
Part 18 of the Rules and Regulations of the Federal Com- :
munications Commission, the certificate in front of this man- The intensity and frequency of the radiation can be
ual must be filled in completely and signed. The certificate altered over wide limits by changing the location and rela-
must be kept WITH THE EQUIPMENT AT ALL TIMES to tive position of the welding leads and work. If possible,
comply with the regulation. loops and suspended sections should be avoided.
The manufacturer of the equipment covered herein has con- 4. Pick-up and reradiation from power lines. Even though
ducted approved field tests and certifies that the radiation welding lead radiation falls off rapidly with distance, the
can reasonably be expected to be within the legal limits if the field strength in the immediate vicinity of the welding
correct installation procedures, as outlined, are followed. area may be extremely high. Unshielded wiring and un-
. . grounded metallic objects in this strong field may pick up
The importance of a correct Installation cannot be over the direct radiation, conduct the energy for some dis-
emphasized since case histories of interference due to high tance, and produce a strong interference field in another
frequency stabllized arc Welding Machines have shown that area.
invariably an inadequate installation was at fault. -
. © This is usually the most troublesome source of interfer-
The user of the equipment must complete the certification ence, but careful adherences to proper installation pro-
by stating that he has installed the equipment and is using it, cedure as outlined in this booklet will minimize this type
according to the manufacturer's instructions. The user must of interference.
sign the certification notice appearing in front of this instruc-
tion booklet indicating that he has complied with the require-
ments. 8 - 3. POWER SERVICE
In the event that interference with authorized services occurs, The specific installation instructions for making the proper
in spite of the fact that the radiation from the welding equip- primary connections to the equipment as outlined in the in-
ment is within the specified fimits, the user is required to struction booklet furnished with the equipment, should be
take suitable steps to clear the situation. The factory person- followed carefully with one exception as notted in the
nel will assist the user by supplying technical information to following paragraph. :
clear the situation.
Frequently installation instructions specify that the primary
in lieu of complying with the installation requirements and power service shall be run in solid or flexible metallic con-
the certification of each individual installation, the user may duit. Ordinary helically wrapped conduit is designed for
elect to certify his entire plant by having a reputable engin- mechanical protection and is not suitable for electrical shield-
eering firm make a plant radiation survey. In such cases, the ing. Only solid metallic conduit or conduit of “equivalent
installation instructions incorporated in this instruction electrical shielding ability” should be used to enclose the
booklet could very well serve as a guide in minimizing inter- primary power service leads.
ference that might be contributed by the high frequency arc
welding equipment. Solid metallic shielding shall enclose the primary power ser-
vice to the equipment from a point 50 feet from the equip-
8-2. GENERAL INFORMATION ment in a unbroken run.
In a high frequency stabilized arc Welding Machine installa- This shielding shall be grounded at the farthest point from
tion, interfering radiation can escape in four distinct ways as the equipment and should make good electrical contact with
outlined below: the casing of the equipment. The ground should be in accor-
dance with the specifications outlined in the section entitled
1. Direct radiation from the welding machine. This is radia- “GROUNDS” and as shown in Figure 8-1. Care should be
tion that escapes directly from the Welding Machine case. taken that paint or corrosion at the junction of conduit and
This is very pronounced if access doors are left open and case, does not interfere with good electrical contact.
unfastened and if the Welding Machine case is not pro- ‚ o
perly grounded. Any opening in the metal Welding Ma- There shall be no gap in this shielding run, This simply means
chine case will allow some radiation to escape. The high that within 50 feet of the equipment, no portion of the
frequency unit of this certified equipment is adeguately power wires serving the equipment shall be unshielded. If
shielded to prevent direct radiation of any consequences there is any question about the electrical efficiency of the
if proper grounding is carried out. joints between individual conduit sections, outiet boxes and
the equipment case, bonding should be carried out by solder-
2. Direct feedback to the power line. High frequency energy ing a copper strap or wire across the joint as shown in Figure
may get on the power line by direct coupling inside the 8-2,
equipment or the high frequency unit, the power line Clean and bolt
then serving as a radiating antenna. Solder [@ Copper Swap e) Solder
By proper shielding and filtering, direct coupling ts pre- > —
vented in this certified equipment.
(a) DemountaSte Bonding Strap for Conduit Joints
La At least 50 feet NU. Solder Copper Wire Solder
Solid Metatlic Conduit |
Line Fuse and
~~ / Switch Box (b) Solid Bonding with Copper Wire for Conduit Joints
o o ana due |" Figure 8-2. Two Recommended Methods For Electrical
High Frequency Stabilized Weld- Bonding Across Poor Conductivity Conduit Joints
Ground ing Machine or Oscillator
8-4. WELDING MACHINE
Good electrical contact.
Clean metal to metal. |
The location of the equipment should be chosen with respect
to nearness to a suitable ground connection. The equipment
case, firmly bonded to the power conduit, should be
grounded to the work terminal of the equipment with a
copper cable or braid with rated current carrying capacity
equal to or greater than that of the power service wires.
OM-315 Page 13
Figure 8-1. Power Service Installation H.F. Stabilized
Arc Welding Machine
This “work” output terminal of the equipment should then
be grounded to a “good electrical ground” (as defined in
section entitled “"GROUNDS”) with a short length of welding
cable of the same capacity as the “work lead”. (See Figure
Welding Machine Case firmly
bonded to Power Conduit
Work Terminal grounded to driven
ground rod or cold water pipe with
heavy braided strap or cable
Source of .
Power .
Case grounded to —
Work Terminal
E
Figure 8-3. Ground Connections At Welding Machine
Page 14
No change in the wiring or the location of parts inside the
equipment, other than power service tap changes or other
adjustments specifically covered shall be made. The equip-
ment shall not be modified in any way since changes in the
equipment can affect the radiation characteristics and may
hol be in accordance with the test data upon which the man-
ufacturer bases his certification.
While the equipment is in operation, all access and service
doors shall be closed and properly fastened.
Spark gap settings shall be maintained at the minimum separ-
ation consistent with satisfactory welding results,
. WELDING LEADS
In order to minimize direct weld lead radiation, the welding
leads {electrode lead and work lead) must be kept as short as
possible. Certification tests on this machine have been made
with leads 25 feet long. Considerable improvement in radia-
tion minimization can be had by shortening the leads as
much as possible.
Keeping the electrode lead and ground or work lead as close
as possible and on the floor serves to reduce the radiation.
(See Figure 841.
Welding Machine
ar Oscillator
Electrode Holder
Keep leads on ground
or boards and
3/4” to 1” apart
+
Figure 8-4. General Rules For Welding Leads
Keep leads as short as possible —
never in excess of 25 feet.
. WIRING IN THE VICINITY OF THE WELDING
AREA
As discussed in the general information section, the most
serious source of interference is reradiation from wires that
are located near the welding area.
Any ungrounded electrical conductor in the strong “directly
radiated” field, produced by the welding leads, serves as a
pick-up device and may conduct the interference for some
distance and reradiate strongly at another location.
For purpose of simplification and standardization, the space
all around the weld zone at a distance of 50 feet in all direc-
tions is referred to as the High Field Intensity (H.F.I.) zone.
{See Figure 8-5).
To minimize radiation of this type all wiring in the H.F.L
zone shall be in rigid metallic conduit, lead covered cable,
copper braid or material of equivalent shielding efficiency.
Ordinary flexible helically wrapped metallic conduit, com-
monly referred to as “B.X.” is not satisfactory for shielding,
and should not be used. The shield on all wiring should be
grounded at intervals of 50 feet and good electrical bonding
between sections shall be maintained.
This shielding requirement applies to all wiring, including tel-
ephone, inter-communication, signal and control and inciden-
tal service.
rte
A „и _
7 Shielded Wires ^^
Groun
ded at
/ 50 foot intervals L
Welding
Maching
KM
ID
ad
ra
a
. Electrode
a Y Holder |
+ = Work
A
Keep ALL unshielded and un-
grounded wires out of this
High Field Intensity Zone.
> —
``
N
Figure 8-5. General Requirements to Minimize Reradiation
Pick-Up In the Vicinity of the Weld Zone
Extreme precaution should be taken to make syre that the
location of the zone is chosen so that none of the conditions
are voided by unshielded wires off the premises but still with-
in the radial dimensions of the H.F.l. zone.
This 50 foot H.F.I. zone is a minimum that is imposed on the
installation. Certification tests by the manufacturer are based
on this limit.
Keeping unshielded wires farther than 50 feet from the weld
zone will materially aid in minimizing interference.
If it is impossible to relocate unshielded wires, that section
within the H.F.l. zone, should be placed in conduit and each
end of the conduit section grounded.
It must be emphasized that all changes in power and
lighting wiring should be made by a qualified electr-
cian and comply with the Nationa! Electrical Code
requirements. Any shielding or relocation of telephone
or signal wires must be done either by the service com-
pany concerned or with the specific permission of said
| company. 1
GROUNDS
Frequent reference is made to a “good ground” in previous
sections. Although there is considerable leeway in the inter-
pretation of this term, for the purpose covered in this
booklet the following specifications apply:
A “ground” connection should be made to a driven rod at
least 8 feet long and driven into moist soil.
A cold water pipe can be used in place of the ground rod
provided it enters the ground within 10 feet of the equip-
ment to be grounded.
All leads connecting the point to be grounded to the ground
rod or pipe should be as short as possible since the ground
lead itself can become an effective radiating antenna.
The effectiveness of a ground in reducing interference de-
pends upon the ground conductivity. In certain locations it
may become necessary to improve the ground conductivity
by treating soil around the ground rod with a salt solution.
. METAL BUILDING
It is frequently through that operating of high frequency
stabilized arc welding equipment in metallic buildings will
completely eliminate troublesome radiation. This, however, 1s
a false assumption.
A metallic building structure, if properly grounded, may
serve to reduce direct radiation from the weld zone but will
have no effect on conducted interference and reradiation. As
a result, all installation requirements necessary for certifica-
tion must be complied with.
8-10.
If the metallic building is not properly grounded, bonding to
several good electrical grounds piaced around the periphery
of the building will give reasonable assurance that the build-
ing itself is not contributing to the radiation.
. INDIVIDUAL INSTALLATION CERTIFICATION
Any or all of the above installation requirements may be
waived by the user if he desires to exercise the option of
making an individual field survey of the particular unit instal-
lation {or the complete installation if more than one unit is
involved), and certifying on that basis.
This survey shall be made by a competent engineer in accord-
ance with the test procedure requirements as set forth in Part
18 of the Rules and Regulations of the Federal Communica-
tions Commission.
Surveys of this nature can cover a single unit or multiple
units or may include the complete plant structure.
CHECK LIST
The following questions may be used by the installer as a
check to see if all installation requirements have been met:
1. Has the equipment been located so that ground leads
can be kept short?
2. Are the power leads, serving the unit, in conduit?
3. Is there good electrical contact between power con-
duit and case?
4. Do the conduit couplings make good electrical con-
tact? (!f in doubt, use bonding}.
5. ls there good electrical contact between conduit and
switch on service boxes?
6. If rigid metallic conduit is not used, is the shielding
used of equivalent shielding efficiency? (Copper sleev-
ing, lead covered cable, etc., is satisfactory. Spirally
wound flexible metallic conduit is not suitable).
7. Is the conduit system grounded at a point at least 50
feet from the equipment?
8. Is the conduit run complete (without any gap) in the
H.F.l. zone?
9. Is the equipment case connected to the work terminal
of the secondary?
10. ls the wire used for this connection of sufficient size?
11. Is the work terminal connected to a good electrical
ground?
12, Is the cable or copperbraid used for this connection
equal to or greater in current carrying capacity than
the welding lead?
13. ls this cable as short as possible?
14. Are the spark-gaps set at .008” or less?
15. Are all service and access doors closed and bolted?
16. Are the welding leads less than 25 feet long?
17. Are they as short as possible?
18. Are the welding leads on the floor or placed on a
suitable board?
19. Are the welding leads approximately 3/4” to 1” apart?
20. Have you visualized the H.F.l. zone, a sphere with a 50
foot radious centered on the weld zone?
21. Have the unshielded power and light wires originally in
this H.F.I. zone been placed in grounded shields or
been relocated outside the zone?
22. Have all large metallic objects and any long guy or
supporting wires in the H.F.I. zone been grounded?
23. Have you checked so that no external power or tele-
phone lines off the premises are within the zone?
24, Are the grounds driven ground rods?
25. Is a cold water pipe used as ground?
26. If so, does it enter the ground 10 feet or less from the
connection?
27. Are the connections to the ground clean and tight?
28. If operated within a metal building, is the building
property grounded?
If your answer is “yes” to the above questions, you can certi-
fy the installation by signing the certificate.
OM-315 Page 15
April 1975 FORM: OM-315
Effective with serial No. HF826825
MODEL STOCK NO.
DIALARC HF 901 782
DIALARC HF-P 901788
IMODEL/STOCK NO, SERIAL/STYLE NO, DATE PURCHASED
PARTS LIST
O
MILLER ELECTRIC MFG. CO.
APPLETON, WISCONSIN, USA 54911
NWSA CODE NO. 4579
Quantity
Mode!
Item Dia. Factory | Without | With
No. Mkgs. Part No. Description PFC PFC
Figure A Main Assembly
1 W 032786 CONTACTOR, 60 amp 3 pole 600 volts (See Fig. G Page 6) ...... 1 1
2 000 382 LINK, jumper - contactor ........re.eeeosa0orerewrenrvare 2 2
3 SR3 037568 RECTIFIER, with mounting brackets {consistingof} ........... 1 1
4 601 242 INSULATOR, washer ..........e-eaeanvanvenoaranoreneo 2 2
5 102 363 .BRACKET, mounting - rectifier......... e. cemeraor rre eo. 2 2
6 CR2 034615 RELAY, 115 volts ac 2PDT ............... seemed iiem. 1 1
7 .CR1 034601 RELAY, 24 volts de 2PDT .............. a. ererrerecreene. 1 1
8 R3 030617 RESISTOR, WW adj 25 watt 20000hm ...........eereereren. 1 1
9 039 220 BRACKET, mounting - contactor ........._.eorcerérerorer. 1 1
10 SR2 037601 RECTIFIER, selenium-control ......... oi... 1 1
11 000 072 PANEL, side RR RER a 4e 44 es 1 a 1 a 1e 0 0 2 2
12 000 073 COVER, top 122144000044 044 a 4 2 4 4 4 4 4 4 4e ee ee a aa 00 6 1 1
13 026 627 GASKET, liftingeye ......... iii iii. 1 1
14 025 141 BRACKET, mounting - capacitOr 0a 1
15 C1 025 317 CAPACITOR, paper oil 40 uf 460voltsac........ cc vue... 2
16 Figure B PANEL, rear - with components (See Page 2) ................. 1 1
17 TEl 034587 TERMINAL ASSEMBLY, primary (See Fig. C Page 3) ........ 1 1
18 MA1 039234 AMPLIFIER, magnetic (See Fig. E Page 4) ................... 1 1
19 Z 027 218 STABILIZER ie ee ee eee Le 1 1
20 T1 039232 TRANSFORMER, power - main (See Fig. D Page 3) ............ 1
20 T1 000 080 TRANSFORMER, power - main (See Fig. D Page 3) ............ 1
TP1 020520 THERMOSTAT, normally closed. ........... coon. 1 i
21 027212 BAR, steel 1/4 x 1-1/2 х 18 ..........e—.0m00rercrreaor rea. 2 2
22 039221 BASE .......—r...eemearorararercarveaorededróeoceco, 1 1
23 000 076 HF PANEL (See Fig. F Page 5) ...........oememorrererere.. 1 1
24 000 683 PIPE, black 1/8 х 3 ......rcerererearra cr rarearnararcoerne 2 2
25 Figure H PANEL, front - with components (See Page 7) ................ 1 1
13 14 15 16— Fig B
Fig H—25 7 24 23-FigF 22 11 TD-000 891
Figure A — Main Assembly |
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-315 Page 1
item Dia. Factory
No. Mkgs. Part No. Description Quantity
Figure B Panel, Rear - With Components {See Fig. A Page 1 Item 16)
36 SAT 039391 RECTIFIER, silicon diode (consistingof) ............c... ...... i
37 000 601 . SUPPRESSOR, rectifier {consistingof) .......... ivi. 1
38 R2 030 726 .. RESISTOR, WW fixed 5 watt 1000 ohm ............ cc... 1
39 VST 024471 ..SUPPRESSOR, 1uf2.70hm ..... iii 1
40 037 306 .DIODE, 150 amp 300 volts reverse polarity ........._.eeeeeeceera. 2
41 C4-7 031689 .CAPACITOR, ceramic 0.01 uf 500 volts with 3/16 & 1/4 terminals . . .. 4
42 037 305 .DIODE, 150 amp 300 volts straight polarity ..................... 2
43 038 315 JUNCTION BOARD, diode ...............es20a0rearerec deere, 2
44 010489 TURBING, steel .275 ID x .060 wall x 3/4 111224 вкл кк... 1
45 038243 WINDTUNNEL 1110104244 4444 4 ea a 44 4e a 4 a 8 4 4 a 4 4 4 4 ea ea ea 4 0 1
46 032 604 BLADE, fan 60 Hz 14 inch 3 wing 19 degree .........e_eeoreenvacvo i
47 000 074 PANEL, rear ........... ea a 1
35 215074 STRIP, adapter .......... RK a a aa sa 6 1
49 FM 032603 MOTOR, fan 230 volts (consisting of) ..........eee.esanve dere». 1
024 601 .BEARING ........ .....maagedacaaiaroaida roneaeevvanraroaa 2
36
40
includes
(Нет 37-39
_
a Wu CACA E
ón
НАНОСЯ
à PSS
т
he
E e eE
, ies NA oe
кл
г
са Te o €
О
Figure B — Panel, Rear - With Components
TD-000 887
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-315 Page 2
Item Factory
No. Part No. Description Quantity
Figure C 034 587 Terminal Assembly, Primary (See Fig. A Page 1 Item 17)
61 034 588 TERMINAL BOARD ee eee eee eee en 1
62 038618 LINK, jumper -terminal board . ...... 2 a a ea a a a 1 ane 2
63 038887 STUD, brass 10-32x 1-3/8 with hex collar . .......... ua... 6
64 010913 WASHER, flat - brass 3/16 .........ee_esemeroreoraerarerere vero 6
65 601 835 NUT, brass - hex 10-32 ..................ereredacarervareceereo. 12
66 601 836 NUT, brass - hex jam 1/4-20 ................ 222220 0e0r acia. 4
67 038 888 STUD, brass 1/4-20 x 1-1/2 with hex collar .......... 2.0 nm. smesraca 2
68 INSULATION, stud barfier 11.202144 14 4 04 4 4 4 44 0 4 4 4 4 4e 0 a 0 a ee ue 6
026 631
Figure C — Terminal Assembly, Primary
TA-034 587
ПИ
“
7
N
EC
E
{y
tE
>
TC-032 904
) Figure D — Transformer, Power - Main
Quantity
Model
Item Factory | Without With
No. Part No. Description PFC PFC
=: 3
Figure D Transformer, Power - Main (See Fig. À Page 1 [tem 20) а e
E
«< =
81 **039 233 TRANSFORMER SUBASSEMBLY (consisting of) ......... 1 1
82 026 188 .STRIP, glastic 1/16 x 1.666 x5 ......... cui... 4 4
83 026 966 . WEDGE, hardwood -single bevel 1/4 x 1Tx6............. 2 2
84 **039 174 COIL, primary/secondary ........eem_orrenedode done, 1
84 **039 173 COIL, primary/secondary ..........eeeeeemecoarizeo. 1
**Replace At Factory or Authorized Service Station. |
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 3
Item Factory
No. Part No. Description Quantity
Figure E 039 234 Amplifier, Magnetic {See Fig. A Page 1 Нет 18)
96 **039 235 AMPLIFIER SUBASSEMBLY „2 ........... 2.5.5.5... к... .. 1
97 023 363 .WEDGE, glastic - single bevel 5/8 х 1/4 х 5 .................. 2
98 039 236 .STRIP, phenolic 3/8 x 2 x 4-1/2 1.111100 4 41414110 aa ta ee 1
99 010400 . WEDGE, hardwood - single bevel 1/4 x 1/2x6 ....... ane 8
100 034 322 .STRIP, glastic 1/16 x 1.666 X 3 .........ereeareredredeero. 8
101 034 323 .STRIP, fiber 1/32 x 2-3/8x 10........ PE ene 2
102 **039 175 COIL, controlac........... 2... er00ñamneeenerercene nn. 4
103 **039 176 COIL, contra de ......... 2... e00edrea ar aarcara., 1
| ; 96
‘97 98 99 100 101 | -
103
TC-000 889
100 96
Figure E — Amplifier, Magnetic
**Replace At Factory or Authorized Service Station.
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-315 Page 4
Item Dia. Factory
No. Mkgs. Part No. Description Quantity
Figure F 000 076 HF Panel {See Fig. A Page 1 Item 23)
111 014 159 CLAMP, mounting - capacitor .........oreerecveraaroneenrado. 1
112 Rb 030 603 RESISTOR, WW fixed 10watt 10K ohm ....................... 1
113 C3 031 601 CAPACITOR, paper oil 10 uf 600 volts de ........... e... .e.... 1
114 RE 030 965 RESISTOR, WW fixed 100 watt 100 ohm «ovo vive iii iia. 1
115 T2 036 865 TRANSFORMER, 11Bvolts.............e_e ee eee eee eens 1
116 000 681 STRIP, mounting - Col KR 2
117 T3 039177 COIL, coupling - alt 00 i i te ee ee etre ieee 0 ee 1
118 000 682 TUBING, fiber 1/4 ID x 5/16 x 3/4 ........... i iia. 2
119. R4 030 602 RESISTOR, WW fixed 100 watt 10ohm .........e ee. m0d0ra ae 1
120 000 684 MOUNTING BOARD ..........o e... neacasoonvenenenane 1
121 020 623 SPARK GAP ASSEMBLY (consisting of) ............eeeecreeaaos 1
122 020 621 .BASE .......... 2. earerireraveneenavenanenareCrndendoa arar, 1
123 G *020 603 POINT Le ee ce nnena 4
124 020622 . HOLDER, point ........e..eezxenecrorroredareverarare neo a 4
125 010888 .CONNECTOR, holder ......... e... .ararvarenseveroonora 1
126 000 914 LINK, connecting ........ —_—resxesxverdrdodrearócaranoronaaaro ea 1
127 C2 031 602 CAPACITOR, mica 0.002 uf 5000 volts de ...........e... 2. .... 1
a
118 117
TC-000 890
1125 124 123 122,
121
120 119
- Fiqure F — HF Panel
*Recommended Spare Parts.
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 5
Item Factory
No. Part No.
Description Quantity
Figure G 032 786 Contactor {See Fig. A Page 1 Item 1)
136 035 837 COIL, contactor 115 volts ...............e.ceedcierr reo 1
137 *035 836 KIT, point - contact ......... e... ..rrrarerceed0nieonrerer. 1
Figure G — Contactor
*Recommended Spare Parts | |
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-315 Page 6
Fig H2
162
157 161
178 176 175 178 177 166 174 176 175 174
TD-000 888
179
180
Figure H — Panel, Front - With Components
Page 7
[tem Dia. Factory
No. © Mkags. Part No. Description - Quantity
Figure H Panel, Front - With Components (See Fig. A Page 1 Item 25)
151 NAMEPLATE (order by stock, model 8: serial numbers) .......... 1
152 CB1,2 011972 CIRCUIT BREAKER, 10 amp 250 volts ..........ee eeeenererao 2
153 RC3 039 622 RECEPTACLE, grounded - straight 2P3W ..................... | 1
154 RC1 039 607 RECEPTACLE, twistlock 3P3W . _ ..... .... iii. 1
155 S4 000 071 SWITCH, range (See Fig. H1 Page 9)... ....... ci iii... 1
156 000075 PANEL, front .........._e.eer0esorara,eervercreccaaorcerroerr 1
157 52,3 011 609 SWITCH, toggle SPST 10 amp 125 volts ..........—._—.—reeerreeco.. 2
158 S1 025 865 SWITCH, toggle DPDT 60 amp 575 volts ...................... 1
159 R1 030 6563 RHEOSTAT, WW 150 watt T5 ohm ...........eé. Le 4 a 4 a a ae à 1
160 56 011610 SWITCH, toggle SPDT 10 amp 125 volts center off .............. 1
161 RC2 035 493 RECEPTACLE, grounded - twistlock 3P3W .................... - 1
162 55 000 070 SWITCH, selector (See Fig. H2 Page 10) ............ .eeeecex0rs 1
163 014 206 BRACKET, mounting- timer iii. 2
164 TD1 034 836 TIMER, 0-60 seconds 120 volts .... iii iin 1
165 000 383 BUSBAR, terminal Output . o.oo RR к веке. i
166 038 630 TERMINAL, power output (consistingof) ................ ..... 2
167 601 840 NUT, brass- hex jam 1/2-13 i ie een 2
168 602 217 .WASHER, lock - steel external tooth 1/2 ......... vv... 1
169 602 247 WASHER, flat-steel SAE 1/2 1..2... 2..2... к.кв zero, 1
170 038603 .TERMINAL BOARD eK RR 1
171 010912 . PIN, spring 1/8 X 3/8 «oot ee nara 1
172 038 982 .STUD, brass 1/2-13 x 2-5/8 centered drilled ................... 1
173 601 839 . NUT, brass - hex full 1/2-13 ........ RR La a 4e 3
174 010 296 ELBOW, brass - pipe street 90 degree 1/4MPT 5/8-18RH .......... 2
175 014028 ANGLE, mounting - solenoid ...........o_eeexreerarererene e 2
176 GS1,WS1 035601 SOLENOID, 115 volts ac 2 way 1/4IPS port 1/8 orifice
(consisting of) .. 1.212202 200 004444 11 40 a 10 4 4 4 ea 4 a 4 10 4 a ee 00 2
033050 .COIL.............. a RR RR RR 4 a a a a ae 1
177 057 084 BUSHING, snap 1/4 1D 3/8 mounting hole ............ereeceero 2
178 010295 ELBOW, brass - pipe street 90 degree 1/4MPT 5/8-18LH .......... 2
179 000 077 DOOR, access - lower front .........._.eñe ee. 0 RR ee a 1
180 605 583 CATCH, springloaded-door ........... ccc... 1
181 035494 CAP, grounded - twistlock 3P3W...........—.. ro recxsererereraa 1
182 KNOB, ball { included with S5 - See Fig. H2)
183 019627 KNOB, pointer «otter ee eee ee et teeters een 1
184 KNOB, ball (included with 54 - See Fig. H1)-
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. |
OM-315 Page 8
Item Factory
No. Part No, Description Quantity
Figure H1 000 071 Switch, Range (See Fig. H Page 8 Нет 155)
196 011839 BRACKET, mounting - support | 4410004444 4444 ea a aa ae 4e 1
197 011 840 BRACKET, mounting - switch (consisting of) ..................... 1
198 010671 SPRING oe es eet re ter te tea 1
199 000530 CONTACT BOARD ASSEMBLY (consistingof) ................... 1
200 011 968 .CONTACT BOARD, stationary ....... eeeerecudooeorerera ao 1
201 011969 .CONTACT BOARD, movable. .......... iii. 1
202 011644 . CONTACT, stationary - switch .........o..e.eeoredooodaoarao 3
203 011645 . CONTACT ASSEMBLY, movable (consistingof) .................. 1
204 011953 ..CONTACT, switch .... i ee eee ieee en 2
205 011074 ..SPRING, pressure ........ .. .e..0nvrenererenmeernare mreno na 1
206 011075 .. SPRING, pressure . ue eee ete ee eee ieee 1
207 100 622 SHIM, guide ni i i i ie eee 3
208 100 623 GUIDE, contact «oo ite eee ee te eee eee ea 5
209 011 841 HANDLE, switch 110022020044 4 14444 4 4 4 4 8 a 4 44 4 0 4 8 0 0 a 4 a 4 0 1 10 0 4 0 1
210 019603 KNOB, ball ı ee ee ee eee Ven à 1
211 014 203 BAR, mounting -supportswitch .......e.eceerrervearoredendcane 1
197
Figure H1 — Switch, Range
200)
201
202
203
39 Includes
Item 206
› 199
TE-000 961
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 9
[tem Factory
No. Part No. Description Quantity
Figure H2 000 070 Switch, Selector (See Fig. H Page 8 Item 162)
221 000531 CONTACT BOARD ASSEMBLY (consistingof) ................... 1
222 011968 .CONTACT BOARD, stationary er RR 1
223 100623 .GUIDE, contact oot te ie eet te eee ee ee teen as 5
224 100 622 .SHIM, guide . i ee ee eee 3
225 011969 . CONTACT BOARD, movable... ..... cin. 1
226 011645 . CONTACT ASSEMBLY, movable {consistingof) .................. 2
227 011075 ..SPRING, pressure .......e.e _eoesuaarere o aracereroondena. 1
228 011 953 ..CONTACT, switeh ........e eee serve rararendeorarerarerCan e 2
229 011074 ..SPRING, pressure .........._... em m0nvdari a rnnaco reroanarm, 1
230 011 644 CONTACT, stationary - switch .. 122220200444 21 aa ea вене. 6
231 100621 . LINK, connecting- switeh ....120220 00000104 V4 i ieee ieee. 2
232 011841 HANDLE, switen .. 1.220444 4 4 4 14 4 4 4 44 4 4 4 4 4 VA 4 4 4 4 4 4 4 a dae nana 1
233 011840 BRACKET, mounting - switch (consisting of) ..................... 1
234 010671 .SPRING ........ eee ae ea 1
235 014 203 BAR, mounting- support switch 110222040204 14 64 4 4 a ee a ea a 4 ae 6 1
236 011 839 BRACKET, mounting - SUPport .........eeverecverereenrecoenea 1
237 019603 KNOB, ball ............... re ....e0r0seaevencereoverermerenorea 1
229
226 228
Includes
221 4 Item 227
Ro
236 TD-000 962
Figure H2 — Switch, Selector
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-315 Page 10
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