Miller KD358812 Owner's manual

Miller KD358812 Owner's manual
 X
— April 1993 Form: OM-2744
| er. Effective With Serial No. KD358812
OWNER’S -
MANUAL
Pulstar 450®
Constant Voitage Non-Pulsed Or Pulsed DC Arc Welding Power Source
For Pulsed And Non-Pulsed GMAW, And FCAW Welding
450 Amperes, 38 Volts DC At 100% Duty Cycle
Uses Three-Phase Input Power
24/115 VAC, Short Circuit, Incorrect Input, And Overheating Protection
Background Voltage And Peak Amperage Controls
14-Pin And 10-Pin Remote Control Receptacles
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1
Read and follow these instructions and all E ® Give this manual to the operator.
safety blocks carefully. » A
Have only trained and qualified persons
install, operate, or service this unit.
Cali your distributor if you do not understand mor: MILLER ELECTRIC Mfg. Co., Р.О. Вох
the directions. — 1079, Appleton, WI 54912 414-734-9821
E For help, call your distributor
cover 8/92 - ST-085 483-C PRINTED IN USA
NZ
MILLER’S TRUE BLUE™ LIMITED WARRANTY
Effective January 1, 1992
(Equipment with a serial number preface of “KC” or newer)
This limited warranty supersedes all pravicus MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY — Subject to the terms and conditions below, MILLER Electric
Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new
MILLER equipment sold after the effective date of this limited warranty is free of de-
fects in material and workmanship at the time it is shipped by MILLER. THIS WAR-
RANTY 1S EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT-
NESS.
Within the warranty periods listed below, MILLER will repair or replace any war-
ranted parts or components that fail due to such defects in maternal or workmanship.
MILLER must be notified in writing within thirty (30) days of such defect or failure, at
which time MILLER will provide instructions on the warranty claim procedures to be
followed.
MILLER shal! honor warranty claims on warranied equipment listed below in the
event of such a failure within the warranty time periods. All warranty time periods
start on the date that the equipment was delivered to the original retail purchaser,
and are as follows:
1. 5 Years Parts — 3 Years Labor
* Original mai power rectifiers
2. 3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Are Cutting Power Sources
* Semi-Automatic and Automatic Wire Feeders
* Robots
3, 2 Years — Parts and Labor
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the engine manufacturer.)
а, 1 Year — Parts and Labor
* Motor Driven Guns
* Process Controllers
* Water Coolant Systems
* HF Units
* Grids
* Spot Welders
* Load Banks
* SOX Transformers
+ Running Gear/Trailers
* Field Options
(NOTE: Field options are covered under True Blue ™ for the remaining
warranty period of the product they are installed in, or for a minimum of
one year — whichever is greater)
5. 6 Months — Batteries
6. 90 Days — Parts and Labor
* MIG Guns/TIG Torches
* Plasma Cutting Torches
* Accessory Kits
" Replacement Parts
MILLER'S True Blue Limited Warranty shall not apply to;
1. items furnished by MILLER, but manufactured by others, such as engines or
trade accessories. These items are covered by the manufacturer's warranty, if
any.
2. Consumable components; such as contact tips, cutting nozzles, contactors
ang relays.
3. Equipment that has been modified by any party other than MILLER, or equip-
ment that has been improperly installed, improperly operated or misused
based upon industry standards. or equipment which has not had reasonable
and necessary maintenance. or equipment which has been used for operation
outside of the specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER-
CIALANDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT,
in the event of a warranty claim covered by this warranty, the exclusive remedies
shalt be, at MILLER'S option: (1) repair; or (2) replacement; or, where authorized in
writing by MILLER in appropriate cases, (3) the reasonable cost of repair or replace-
ment at an authorized MILLER service station: or (4) payment of or credit for the pur-
chase price (less reasonable depreciation based upon actual use} upon return of the
goods at customer's risk and expense. MILLER'S option of repair or replacement
wilbeF.Q.B., Factory at Appleton, Wisconsin, or F.O.B. ata MILLER authorized ser-
vice facility as determined by MILLER. Therefore no compensation or reimburse-
ment for transportation costs of any kind will De allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES, IN NQ EVENT SHALL MILLER BE
LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CON-
TRACT, TORT OR ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR-
RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL
THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION CF LAW, CUSTOM CF TRADE OR COURSE OF DEALING, IN-
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY ANC ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND CISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an implied warranty
lasts, or the exclusion of incidental, indirect, special or consequential damages, so
the above limitation or exclusion may not apply to you. This warranty provides spe-
cific legal rights, and other rights may be available, but may vary from state to state.
in Canada, legislation in some provinces provides for certain additional warranties
or remedies other than as stated herein, and to the extent that they may not be
waived, the limitations and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be avañable, but may
* Remote Controls vary from province to province,
e
RECEIVING-HANDLING
Before unpacking equipment, check carton for any damage that may have occurred during shipment. File any claims for loss or damage
with the delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment manufacturer's
Transportation Department.
When requesting information about this equipment, always provide Model Designation and Serial or Style Number.
Use the following spaces to record Model Designation and Serial or Style Number of your unit. The information is located on the rating label
Or nameplate.
Model
Serial or Style No.
Date of Purchase
miller 5/92
ARC WELDING SAFETY PRECAUTIONS
A WARNING
ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Satety Standards.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
ELECTRIC SHOCK can kill. 5. Properly install and ground this equipment according to its
Touching live electrical parts can cause fatal shocks Owner's Manual and national, state, and locai codes.
y or severe burns. The electrode and work circuit is 6. When making input connections, attach proper grounding
_ electrically live whenever the output is on. The input conductor first.
power circuit and machine internal circuits are aiso - .
live when power is on. in semiautomatic or automatic 7. Turn off all equipment when not in use.
wire welding, the wire, wire reel, drive roll housing, 8. Do not use worn, damaged, undersized, or poorly spiiced
and all metal parts touching the welding wire are cables.
electrically live. Incorrectly installed or improper
grounded equipment isa Hazard, property 9. Do not wrap cables around your body.
. th |
I Do not touch live electrical parts. 9 a e pe © a good uo (earth) ground
2. Wear dry, hole-free insulating gtoves and body protection. - Donottouche ectro el n contact with the work or ground.
3. insulate yourself from work and ground using dry insulating 12. Use only well-maintained equipment. Repair or replace
mats or covers. damaged parts at once.
4. Disconnect input power or stop engine before instaling or 13. Wear a safety harness if working above floor leve.
servicing this equipment. 14. Keep all panels and covers securely in place.
ARC RAYS can burn eyes and skin; ARC RAYS
NOISE can damage hearing. 2. Wear a welding helmet fitted with a proper shade of filter (see
| ANSI Z49.1 listed in Safety Standards) to protect your face and
AZ rana tono ulravioletrays trat can Dum eyes eyes when welding or watching.
lr Y 1 .
a and skin. Noise from some processes can damage 3. Wear approved safety glasses. Side shields recommended.
hearing. 4. Use protective screens or barriers to protect others from flash
NOISE and glare; warn others not to watch the arc.
5. Wear protective clothing made from durable, flame-resistant
1. Use approved ear plugs or ear muffs if noise level is high. material (wool and leather} and foot protection.
re 9: FUMES AND GASES can be hazardous 5. Work in a confined space only if it is well ventilated, or while
“ E to your health. wearing an air-supplied respirator. Shielding gases used for
, Welding produces fumes and gases. Breathing these welding can displace air causing injury or death. Be sure the
# fumes and gases can be hazardous to your health. breathing air is safe.
— 6. Donotweldin locations near degreasing, cleaning, or spraying
operations. The heat and rays ofthe arc can react with vapors to
1. Keep your head out of the fumes. Do not breathe the fumes. form highiy toxic and irritating gases.
if inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases. 7. Do not weld on coated metals, such as galvanized, lead, or
3. If ventilation is poor, use an approved air-supplied respirator. cadmium plated steel, unless the coating is removed from the
4, Read the Material Safety Data Sheets (MSDSs) and the weld area, the area is wel! ventilated, and if necessary, while
manufacturer's instruction for metals, consumables, coatings, wearing an air-supplied respirator. The coatings and any metals
and cleaners. containing these elements can give off toxic fumes if welded.
WELDING can cause fire or explosion. 5. Watch for fire, and keep a fire extinguisher nearby.
(RP r= Sparks and spatter fly off from the welding arc. The 6. Be aware that welding on a ceiling, floor, bulkhead, or partition
flying sparks у hot metal, weld spatter, hot can cause fire on the hidden side.
workpiece, and hot equipment can cause fires an .
burns. Accidental contact of electrode or welding wire 7. Do not weld on closed containers such as tanks or drums.
to metal objects can cause sparks, overheating, or 8. Connect work cable to the work as close to the welding area as
fire. practical to prevent welding current from traveling long, possibly
k ing electric sh nd fire h ds.
1. Protect yourself and others from flying sparks and hot metal. unknown paths and causi ; elec пе shock and fire hazar
2. Do not weld where fiying sparks can strike flammable material. 9. Do not use welder to thaw frozen pipes. a
3. Removeall flammables within 35 ft (10.7 m) ofthe welding arc. If 10. Remove stick electrode from holder or cut off welding wire at
this is not possible, tightly cover them with approved covers. contact tip when not in use.
4. Be alert that weiding sparks and hot materials from welding can 11. Wear oil-free protective garments such as leather gloves, heavy
easily go through small cracks and openings to adjacent areas. shirt, cuffless trousers, high shoes, and a cap.
FLYING SPARKS AND HOT METAL can 1. Wear approved face shield or safety goggles. Side shields
cause injury. recommended.
2. Wear proper body protection to protect skin.
sr1 9/92
CYLINDERS can explode if damaged.
~#__| Shieiding gas cylinders contain gas under high
ÿ | pressure. If damaged, a cylinder can explode. Since
process, be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining
them to a stationary support or equipment cylinder rack to
prevent falling or tipping.
{gas cylinders are normally part of the welding
3. Keep cylinders away from any welding or other electrical
circuits.
4. Never allow a weiding electrode to touch any cylinder.
5. Useonly correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is
in use or connected for use.
8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards. |
A WARNING
ENGINES can be hazardous.
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and
away from any building air intakes.
ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable.
—
ra
Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or
open flames.
3. Allow engine to cool before fueling. if possible, check and add
fuel to cold engine before beginning job.
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before starting
engine.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can
cut fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and
securely in place.
2. Stop engine before instailing or connecting unit.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
4, To prevent accidental starting during servicing, disconnect
negative (—) battery cabie from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
| burn eyes and skin.
Batteries contain acid and generate explosive
gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery
cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5.
Observe correct polarity {+ and —) on batteries.
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
The coolant in the radiator can be very hot and
under pressure.
nl
-
Do not remove radiator cap when engine is hot. Aliow engine
to cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard 248.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Ameri-
can Welding Society Standard AWS F4.1, frorn American Welding So-
ciety, 550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Pro-
tection Association, Batterymarch Park, Quincy, МА 02269.
sr 9/92
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis High-
way, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou-
levard, Rexdale, Ontario, Canada MW 1R3.
Safe Practices For Occupation And Educational Eye And Face Protec-
tion, ANSI Standard 287.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MÁ 02269.
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
MISE EN GARDE
LE SOUDAGE À L'ARC est dangereux.
respectez toutes ces normes.
PROTÉGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OÙ LA MORT. NE LAISSEZ PAS LES
ENFANTS S'APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU'ILS N'AIENT CONSULTÉ UN MÉDECIN).
Le soudage, comme la plupart des activités industrielles, expose à certains risques. Le soudage n'est pas dangereux lorsqu'on prend des
précautions. Les consignes de sécurité suivantes ne font que résumer l'information contenue dans les normes énumérées ci-après. Lisez et
SEULES DES PERSONNES QUALIFIÉES DOIVENT FAIRE DES TRAVAUX D'INSTALLATION, DE RÉPARATION, D'ENTRETIEN ET
10,7 mètres autour de l'arc, ou couvrez-les soigneusement avec
des bâches approuvées.
4. Méfiez-vous des étincelles et des éclats brûlants, susceptibles
de pénétrer dans des aires adjacentes par de petites ouvertures
ou fissures.
D'ESSAI.
= L'ÉLECTROCUTION peut étre morteile. 5. Veileza installer ces matériels et a les mettre a la terre selon le
Une décharge électrique peut vous tuer ou vous manuel d'utilisation et les codes nationaux, provinciaux et
brûler gravement. L'électrode etle circuit de soudage locaux applicables. o
sont sous tension au démarrage. Le circuit d'entrée et 6. Arrétez tous les materiels apres utilisation. Ш
les circuits internes des matériels sont aussi sous 7. N utilisez pas de câbles usés, endommagés, mai épissés ou de
tension dès la mise en marche. En soudage calibre trop petits. —
automatique ou semi-automatique avec fil, ce dernier, fe support de 8. N'enroulez pas de cables autour de votre corps. |
roquette, le logement des galets d'entrainement et toutes les piéces 9. Mettez à la terre ia tôle à souder au moyen d'une bonne prise de
métalliques en contact avec le fil de soudage sont sous tension. Des terre. a |
matériels mal installés ou mal mis à la terre sont dangereux. 10. Ne touchez pas à l'électrode si vous êtes en contact avec ie
1. Ne touchez pas à des pièces sous tension. circuit de soudage (terre).
2. Portez des gants et des vêtements isolants, secs et non troués. 11. N'utilisez que des matériels en bon état. Réparez ou remplacez
3. |solez-vous de la tôle à souder et de la mise à la terre au moyen sur-le-champ les pièces endommagées.
de petits tapis isolants ou autres. 12. Portez un harnais de sécurité si vous travaillez en hauteur.
4. Déconnectez la prise d'entrée des matériels ou arrêtez leur 13. Fermez solidement tous les panneaux et les capots.
moteur avant de les instalier ou d'en faire l'entretien.
Le RAYONNEMENT DE L'ARC peut que vous observez l'exécution d'une soudure.
brûler les yeux et la peau; le BRUIT peut 2. Portezdesl!unettes de sécurité approuvées. Des écrans iatéraux
= 7 d Рош > sont recommandées.
— en ommager quie. 3. Entourez l’aire de soudage de rideaux ou de cloisons de
—— L'arc de soudage produit une chaleur et des rayons protection contre les coups d'arc ou l’ébiouissement: avertissez
ultraviolets intenses, susceptibles de brûler les yeux et la peau. Le les observateurs de ne pas regarder l'arc.
bruit causé par certains procédés peut endommager l'ouie. 4. Portez des vêtements en tissus ignifuge durabie (laine et cuir)
1. Portez un casque de soudeur avec écran fittrant de teinte et des chaussures de sécurité.
appropriée (consultez la norme ANSI Z49 indiquée ci-apres), 5, Portez un casque antibruit ou des bouchons d'oreille approuvés
pour vous protéger le visage et les yeux lorsque vous soudez ou si le niveau de bruit est élevé.
Les VAPEURS ET LES FUMÉES sont 5. Ne travaillez dans un espace confiné que s'il est bien ventilé;
dangereuses pour la santé sinon, portez un respirateur à adduction d'air. Les gaz protecteurs
Le soudage dégage des vapeurs et des fumées qu'il de soudage peuvent déplacer l'oxygène de l'air et causer des
est dangereux de respirer blessures ou la mort. Assurez-vous que l'air est propre à la
2 , unos respiration.
. rl . RA ema A.
| Cone le visage pour eviter de respirer les 6. Ne soudez pas à proximité d'opérations de dégraissage, de
2 À l'intérieur. assurez-vous que l'aire de soudage est bien nettoyage ou de pulvérisation. La chaleur et les rayons de l'arc
ventilée ou que les fumées et les vapeurs sont aspirées à l'arc. pouver але des vapeurs et former des gaz hautement
3. Si la ventilation est mauvaise, portez un respirateur à adduction OxXIques El imitarts. |
d'air approuvé. 7. Ne soudez pas de tôles galvanisées ou plaquées en plomb ou
4. Lisez les fiches signalétiques et les consignes du fabricant en cadmium sans les avoir grattées à fond, car ces métaux, et
relatives aux métaux, aux produits consummables, aux tout revêtement qui en contient, peuvent alors dégager des
revêtements et aux produits nettoyants fumées toxiques. Assurez-vous d'une bonne ventilation et portez
- un respirateur a adduction d'air si c'est nécessaire.
= п Le SOUDAGE peut causer un incendie 5. Méfiez-vous des incendies et gardez un extincteur à portée de
(PA) où une explosion. а таг. |
L'arc produit des étincelles et des projections. Avec la 6. N oubliez pas qu une soudure sur un plafond, un plancher, une
chaleur intense dégagée par ia tôle et les matériels, cloison ou une parol peut en enflammer autre cote. .
elles peuvent causer un incendie et des brûlures. Le 7. Ne soudez pas un récipient fermé, comme un réservoir ou un
; o tonneau.
contact accidentel de I'électrode avec un objet А >
métallique peut provoquer des étincelles, un échauffement ou un 8. Connectez le cable de soudage le plus pres possible de ‘a tôle
incendie. de soudage pour empêcher le courant de suivre un parcours
1. Protégez-vous, ainsi que les autres, contre les étincelles et les io et prévenir ainsi les risques d'électrocution et
projections. 9. Nefai
ne . . Ne faites pas dégeler des tuyaux avec un chalumeau.
. n n , |
2 Ne soudez pas dans ит © a des étincelles peuvent 10. Videz votre carquois porte-électrodes ou coupez le fil au tube-
no contact après le soudage.
3. Enlevez toutes les matières inflammables dans un rayon de 11. Portez des vêtements protecteurs non huileux, tels des gants en
cuir, une chemise épaisse, un pantalon sans revers, des
chaussures montantes et un Casque.
=
LES ÉTINCELLES ET LES
PROJECTIONS BRULANTES peuvent
causer des blessures.
Le piquage et le meulage produisent des éclats de
métai. En refroidissant, là soudure peut projeter du laitier.
1. Portez un écran facial ou des lunettes à coques approuvées.
Des écrans latéraux sont recommandés.
2. Portez des vêtements de protection individuelle appropriés.
Les BOUTEILLES endommagées peuvent
exploser.
Les bouteilles contiennent des gaz protecteurs sous
haute pression. Des bouteilles endommagées peuvent
exploser. Comme les bouteilles font normalement
partie du procédé de soudage, traitez-les avec soin.
1. Les bouteilles doivent être protégées contre les sources de
chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou à Un
cadre fixe pour les empêcher de tomber ou d' être renversées.
3. Éloignez les bouteilles de tout circuit électrique ou de soudage.
MISE EN GARDE
4. Empéchez tout contact entre une bouteille et une électrode.
5. N'utilisez que des bouteilles de gaz protecteur, des détendeurs,
des flexibies et des raccords conçus pour chaque application
spécifique; ces matériels et les pièces connexes doivent être en
bon état.
6. Ne mettez pas le visage devant le robinet de bouteille en
l'ouvrant.
7. Remettez le chapeau de bouteille après utilisation.
8. Lisez etrespectez les consignes relatives aux bouteilles de gaz
comprimé et aux matériels connexes, ainsi que la publication
P-1 de la CGA, énumérées dans les normes ci-dessous.
Les MOTEURS peuvent être dangereux.
Les GAZ D'ÉCHAPPEMENT DES MOTEURS
PEUVENT ÊTRE MORTELS.
Les moteurs produisent des gaz d'échappement
nocifs.
1. Utilisez des machines à l'extérieur dans des aires ouvertes et
bien ventilées.
2. Si vous utilisez des machines dans un endroit confiné, les
fumées d'échappement doivent être envoyées à l'extérieur, loin
des prises d'air du bâtiment.
Le CARBURANT peut causer un incendie ou
une expiosion.
Le carburant est hautement inflammable.
1. Arrêtez le moteur avant de vérifier le niveau de
carburant ou de faire le plein.
Ne faites pas le plein en fumant ou proche d'une source
d’étincelles ou d'une flamme nue.
3. Sic'est possible, laissez le moteur refroidir avant de faire ie plein
de carburant ou d'en vérifier le niveau au début du soudage.
4. Ne faites pas le plein de carburant à ras bord : prévoyez de
l’espace pour son expansion.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout
carburant renversé avant de faire démarrer le moteur.
Des PIÈCES EN MOUVEMENT peuvent
causer des blessures.
Des pièces en mouvement, telles des ventilateurs,
des rotors et des courroies peuvent couper les doigts
et les mains, ou accrocher des vêtements amples.
№
. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs sont bien fermés.
2. Avant d'installer ou de connecter un système, arrêtez-en le
moteur.
3. Seules des personnes qualifiées doivent démonter des
protecteurs ou des capots pour faire l'entretien ou le dépannage
nécessaire.
4. Pourempêcherun démarrage accidentel d’un système pendant
l'entretien, débranchez le câble d'accumulateur à la borne
négative.
5. N'approchez pas les mains ou les cheveux de pièces en
mouvement; elles peuvent aussi accrocher des vêtements
amples et des outils.
6. Réinstallez ies capots ou les protecteurs et fermez les portes
aprés des travaux d'entretien et avant de faire démarrer le
moteur.
Des ETINCELLES peuvent FAIRE EXPLOSER
UN ACCUMULATEUR; L’ÉLECTROLYTE D'UN
ACCUMULATEUR peut brûler la peau et les
yeux.
Les accumulateurs contiennent de l'électrolyte et
dégagent des vapeurs explosives.
1. Portez toujours un écran facial en travaillant sur
un accumulateur.
2. Arrétez le moteur avant de connecter ou de déconnecter des
câbles d'accumulateur.
3. N'utilisez que des outils anti-étincelles pour travailler sur un
accumulateur.
4. N'utilisez pas un poste de soudage pour charger un accumulateur
où connecter provisoirement un véhicule.
5, Utilisez la polarité correcte (+ et -) de l'accumulateur.
La VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT BRÛLANT SOUS
PRESSION peuvent brûler la peau et les
yeux.
Le liquide de refroidissement d'un radiateur peut être
brûlant et sous pression.
1. N'ôtez pas le bouchon de radiateur tant que le moteur n’a pas
refroidi.
2. Mettez des gants et posez un torchon sur le bouchon pour l'ôter.
3. Laissez la pression s'échapper avant d'ôter complètement le
bouchon.
PRINCIPALES NORMES DE SÉCURITÉ
Safety in Welding and Cutting, norme ANSI Z49.1, American Welding
Society, 550, N.W. LeJeune Rd., Miami FL 33128.
f Heal , OSHA 29 CFR 1810, Superintendent
of Documents, U.S. Government Printing Office, Washington D.C.
20402.
For lon
В nded Safe Praci he P For Weid |
Cuning of Containers That Have Held azarosa sienes norme
AWS F4.1, American Welding Society, 550, NW. LeJeune Rd.,
Miami FL 33128.
National Electrical Code, norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MÁ 02269.
srif 9/91
Safe Handling of Compressed Gases in Cylinders, document P-1,
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, Va 22202.
Code for Safety in Welding and Cutting, norrme CSA W117.2, Asso-
ciation canadienne de normalisation, Standards Sales, 176 Rexdale
Boulevard, Rexdale, Ontario, Canada MSW 1R3.
Safe Practices for Occupation and Educational Eye and Face Protec-
tion, norme ANSI Z87.1, American National Standards Institute, 1430
Broadway, New York, NY 10018.
Iding Pr norme 518 NFPA, National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
TABLE OF CONTENTS
JA ES
SECTION 1 — SAFETY INFORMATION .... ai 1
SECTION 2 — SPECIFICATIONS
2-1. Volt-Ampere Curves (Non-Pulsed Mode) .............—r... .erereredererceaaonae 2
2-2. Duty Cycle ........ 000 s0reororer rre secavererereaereeverdered—enarenmo. 2
SECTION 3 — INSTALLATION
3-1. Selecting A Location And Moving Welding PowerSource ......................... 3
3-2. Selecting And Preparing Weld Qutput Cables .......... coi. 4
3-3. Connecting ToWeld Output Terminals . ......... ieee, 4
3-4. Remote 10 Receptacle Information And Connections ............................ 5
3-5. Remote 14 Receptacle Information And Connections .................. .... ...... 5
3-6. 115 Volts AC Duplex Receptacle ....... ci eee 6
3-7. Remote Voltage Sensing Connections ....... iii ea 6
3-8. 0 To +10 Volts DC Command Modification . ......... i... 8
3-9. Connecting Input Power ...... SEE 9
SECTION 4 — OPERATION eK RR RR RR RK à 11
SECTION 5 — MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance ............... 2. n.rerxrererxacercarecvoderecaervanendaonona 18
5-2, Overload Protection .......... 2... .—....nrerdeocrarererereorcerconoanadearo 18
5-3. Troubleshooting ........._—.n..reeeereeareerrerrieverererenrecenerveradocreero 20
SECTION 6 — ELECTRICAL DIAGRAMS . is 21
SECTION 7 — PARTS LIST
Figure 7-1. Main Assembiy LL. ee a a a a 26
Figure 7-2. Terminal Assembly, Pri L...112 212 LL LL ALL ea 4e ee de ee a 4e 44 a ee ea a a a a nan 0 29
Figure 7-3. Panel, Rear w/Components ........._.o_eeeecrerecererareroonooeroouaronoaoa 29
Figure 7-4. Panel, Front w Components ............eo.2cw_eeeec:ererecoodroeroerovenroveno 30
Figure 7-5. Switch, Push Button . «LL. RK KR a ea nee 32
Figure 7-6. Switch, Mode 3 Position ee a ee 32
Figure 7-7. Rectifier, SCR Main .......... eee co: aaa aorananranraduororvaoooadaroro. 33
OM-274J — 4/93
SECTION 1 — SAFETY INFORMATION
mod1.1 2/93
’ я > a . ® Read all safety messages throughout this manual.
^^ y - B Obey all safety messages to avoid injury.
ON
“| M Learn the meaning of WARNING and CAUTION.
1
A WARNING
LY
2
4% * Do not touch live electrical parts.
> E CAUTION
ELECTRIC SHOCK can kill.”
— 4
| * Disconnect input power before | |
installing or servicing. |
pl
2
A MOVING PARTS can injure.
_ ® Keep away from moving parts.
ab" # Keep all panels and covers closed
when operating.
1 Safety Alert Symbol
2 Signal Word
WARNING means possible death
or serious injury can happen.
CAUTION means possible minor
injury or equipment damage can
happen.
3 Statement Of Hazard And
Result
| / 4 Safety Instructions To Avoid
5 Hazard
5 Hazard Symbol (If Available)
6 Safety Banner
Read safety blocks for each sym-
bol shown.
7 NOTE
Turn Off switch when using high frequency. Special instructions for best oper-
` ation — not related to safety.
READ SAFETY BLOCKS at start of |
. Section 3-1 before proceeding. —
Figure 1-1. Safety Information
SECTION 2 — SPECIFICATIONS
Table 2-1. Welding Power Source
Specification Description
Type Of Output Constant Voltage Non-Pulsed Or Pulsed DC
Rated Weld Output 450 Amperes, 38 Volts DC At 100% Duty Cycle (See Section 2-2)
Type Of Input Power Three-Phase; 200, 230, 460, Or 575 Volts AC; 60 Hz
Input Amperes At Rated Output 81 A At 200 Y, 70 A At 230 Y, 35 A At 460 Y, 28 A At 575 V
KVA/KW Used At Rated Output 28 kKVA/23 kW
Max. Open-Circuit Voltage 80 Volts DC
Welding Processes Gas Metal Arc (GMAW), Flux Cored Arc (FCAW), Gas Metal Arc Welding-Pulsed (GMAW-P)
Overall Dimensions See Figure 3-2
Weight Net: 590 Ib (268 kg); Ship: 605 Ib (274 kg)
Options See Rear Cover
OM-274 Page 1
2-1. Volt-Ampere Curves (Non-Pulsed Mode)
The volt-ampere curves show the
minimum and maximum voltage
100
| 90 Г
70
60 |
50 |
DC VOLTS
and amperage output capabilities
of the welding power source.
Curves of other settings fall be-
tween the curves shown.
MAX. BACKGROUND
30 FE
20 |
10 +
MIN.
100
200 300 400 500 600
DC AMPERES
ssb1.1 10/91 — 5B-091 499.4
Figure 2-1. Volt-Ampere Curves
2-2. Duty Cycle
4 CAUTION
‚| EXCEEDING DUTY CYCLE RATINGS will damage unit.
~® Do not exceed indicated duty cycles.
warn7,1 2/92
Duty cycle is how long the unit can
RATED OUTPUT —; operate within a ten minute period
| 1000 without causing overheating or
damage.
This unit is rated at 100% duty
| cycle allowing continuous opera-
tion at rated load. |
y 800
Ш
CC
« 700
=
<.
A 600
|
z ~~
400 :
40 50 60 70 80 90 100
OM-274 Page 2
% DUTY CYCLE
sb1.1 2/92 - Ref. SB-081 693-C
Figure 2-2. Duty Cycle Chart
SECTION 3 — INSTALLATION
3-1. Selecting À Location And Moving Welding Power Source
A WARNING
ELECTRIC SHOCK can Kill.
e Do nottouch live electrical parts.
power source.
¢ Disconnect input power conductors
deenergized supply line BEFORE moving welding :
from
combustible surfaces.
® Do not locate unit on, over, or near combustible
FIRE OR EXPLOSION can result from.
placing unit on, over, or near:
surfaces.
| # Do not install unit near flammables. |
: BLOCKED AIRFLOW causes:
overheating and possible damage to
unit.
Warranty is void if any type of filter is used.
FUMES can be hazardous; LACK OF
FRESH AIR AND PROPER
VENTILATION can be harmful.
* Do not breathe welding fumes.
® Place unit only where there is a good fresh air |
supply and proper ventilation.
FALLING EQUIPMENT can cause
serious personal injury and equipment
damage. |
* Uselifting eye to Hit unit only, NOT running gear, gas
cylinders, or any other accessories. |
® Use equipment of adequate capacity to lift the unit. |
swamn11.12/92 —
|
| .
| —e Do not block or filter airflow.
|
a — Te
~ >
. 1
7 NN
/ _ Rear y
< 05
Dan
a. :
pr) UT : |
= . 1 |
= г. !
“=.
1
. i
e
\ KE 7 ;
RY
1 18 in (460 mm) Open Space
On Front And Rear Sides For
Good Airflow
2 Lifting Eye
Use lifting eye to move unit.
3 Rating Label
Locate unit near correct input pow-
er supply.
4 Lifting Forks
If using lifting forks, extend forks
out opposite side of unit.
ST-161 259
Figure 3-1. Location and Movement Of Welding Power Source
—
IN Inches | Millimeters :
— A | 30-14 768 |
RD ed \ т | В | 22-1/4 565 |
O] ST | i —
a я SON 10 с 40 1016
AUS > Zu D | 22-14 565
NN LS, c / E 20 508
>< D E |
| NN DA | | F 1106 28.6
_ G' 37 840
| !
Front NS H i 40 1016
| | - J 1-4 38
| _ с y | К | 716Dia | 11Dia
: 4 Holes 4 Holes
F k H
ST-161 261
Figure 3-2. Overall Dimensions And Base Mounting Hole Layout
OM-274 Page 3
3-2. Selecting And Preparing Weld Output Cabies
05 | . 1 Weld Output Cable '
Determine total cable length in
weld circuit and maximum welding
amperes. Use Table 3-1 to select
proper cable size.
Use shortest cables possible.
Do not use damaged cables.
2 Terminal Lug
Use lugs of proper amperage
capacity and hole size for connect-
ing to work clamp, wire feeder, and
weld output terminals.
3 Wire Feeder
Install according to manufacturer's
т instructions.
| тт A — For Example,
[| | N Total Cable 4 Work Clamp
IL ZE ddr Se Length In Weld install onto work cable.
ATA ~~ Circuit = 20 ft (6 m)
| OT 10 ft (3 m} I > sb6.5* 11/92 - §-0752
Figure 3-3. Selecting And Preparing Weld Output Cables
Tabie 3-1. Weld Cable Size*
Total Cable (Copper) Length in Weld Circuit Not Exceeding
1 ft 2 300 ft 4
100 ft (30 m) Or Less (45 m) (60 m) 70 m) ©0 m) i 05 m) (1 20 m)
Weldin T % Thr %
Am peros Duty Cycle Duty Cycle. 10 Thru 100% Duty Cycle
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 3/0 4/0 4/0
250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0
400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0
500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0
600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0
“Weld cable size (AWG) is based on either a 4 voits or less drop or a current density of not more than 300 circular mils per ampere. S-0007-C
3-3. Connecting To Weld Output Terminals
Á WARNING
— e» ELECTRIC SHOCK can kill.
e Do not touch live electrical parts.
1. Turn Off welding power source, and disconnect input power before making any weld output connections.
| swam12.1 2/93
_ Open lower panel access door.
3 ¥ à 7 ES 1 Positive (+) Weld Output
Terminal
2 Negative (-) Weld Output
E E © © о Terminal Ш
For Electrode Positive (ОСЕР),
f 1 connect work cable to negative (—)
Toois Needed: | | terminal and wire teeder cable to
positive (+) terminal.
= For Electrode Negative (DCEN), !
se . 1 2 reverse cable connections.
— 5 3/4 In
+11
EST
ET
РЗ
Close door. Ref. ST-085 482-C
Figure 3-4. Weld Output Connections
OM-274 Page 4
3-4. Remote 10 Receptacle Information And Connections
AP PEAK AMPERAGE
Ve BACKGROUND VOLTAGE
Ve BACKGROUND VOLTAGE
AP PEAK AMPERAGE
~~, PANEL
C=
>
Remote 10 Receptacle RC1
Keyway
Plug
4 Threaded Collar
To connect to this receptacle, align
keyway, insert plug, and tighten
threaded coliar.
5 Remote Pendant Control
Ww iv —
Socket Information:
A
5
m
те от
4.8 volts dc peak current reference voltage (factory
set).
Control circuit common (al! circuit voltages refer-
enced ta this point).
0-4.8 volts de peak current remote control command
(100 amperes output per volt of command).
0-3.8 volts de background voltage remote control
command {10 volts output per volt of command).
Actual peak current signal (1 volt per 100 amperes
output current).
Approximate negative weld output terminal potentiai.
In puise mode, G is connected to J.
In puise mode, J is connected to G.
Positive output signal. In pulse mode, His internal
background voltage. In standard mode, H is total
welding power source voltage.
3.8 volts de background voltage reference {factory
set). Ref. ST-130 111-A / Ref. $-0166-A / ST-162 711
Figure 3-5. Remote 10 Connections
3-5. Remote 14 Receptacle Information And Connections
\.
x
OUTPUT
{CONTACTOR
ojo FEEDER
> OUTPUT
{ CONTACTOR ]
AS | on
1 Remote 14 Receptacle RCS
2 Keyway
3 Plug
4
Threaded Collar
To connect to this receptacle, align
keyway, insert plug, and tighten
threaded collar.
Socket Information:
Remote Contactor
A
B
K
24 volts ac. Protected by circuit breaker СВ2.
Contact closure to pin A completes 24 volts ac
contactor control circuit.
115 volts ac. Protected by circuit breaker CB1.
Contact closure to pin | completes 115 volts ac
contactor control circuit.
Circuit common for 24 and 115 volts ac circuits.
Chassis common.
The remaining sockets are not used.
sb7.1* 3/93 — Ref. ST-130 111-À / Ref. 5-0004-A / 5-0750
Figure 3-6. Remote 14 Connections
OM-274 Page 5
3-6. 115 Volts AC Duplex Receptacle
NEUTRAL
BONDED
TO FRAME
NEUTRE
RACCORDE
AU BAT]
15V 15A (\_y AC
An
Nu
\. J
1 115 Volts AC Duplex Recep-
tacle
This welding power source sup-
plies up to 15 amperes of 115 voits
ac power.
This receptacle is protected by cir-
cuit breaker CB1 (see Section 5-2).
Power output is shared between
this receptacle and the Remote 14
receptacle (see Section 3-5).
Ref. ST-130 111-А
Figure 3-7. Connecting To 115 Volts AC Duplex Receptacle
3-7. Remote Voltage Sensing Connections
A WARNING
— ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
* Turn Off welding power source, and disconnect
input power before inspecting or installing.
ee
EXCESSIVELY HIGH WELDING
AMPERAGE can cause electrode wire to
vaporize.
* Be sure jumper links on terminal strip 1T are
properly positioned for type of voltage sensing
desired (see Figure 3-9).
* Be sure remote voltage sensing leads are
connected for proper polarity.
In the absence of a voltage feedback signal, or if the
polarity ofthe feedback signalis incorrect, weld output
goes 10 unit maximum.
A. Selecting And Preparing Voltage Sensing Leads
Tools Needed:
ED
Remote voltage sensing allows for
exact voltage measurement at the
welding arc, and display ofthis volt-
age on the voltmeter. This may be
needed when over 100 feet of weld
cable is used.
1 Terminal Strip 1T
2 18 Gauge Lead
Determine total lead length from
connection diagram.
Obtain and install connectors onto
leads as shown.
No. 6 Spade Lug
1/2 in Ring Terminal
a A ao
Universal 25 Amp Clamp
a
Workpiece
5-0787-A
OM-274 Page 6
Figure 3-8. Selecting And Preparing Voltage Sensing Leads
B. Remote Voltage Sensing Connections
Open tower front access door.
1 Terminal Strip 17T
HL ss = e FT 2 Jumper Links
Move jumper links to remote volt-
O age sensing position.
O o E o © Маке connections to terminai strip
Er 1T for Electrode Positive (DCEP)
as shown. For Electrode Negative
(DCEN), switch lead connections
at 1T.
3 Weld Cable Terminal Of Wire
Feeder
4 Weld Cable
5 Voltage Sensing Lead
Close door.
internal Voltage Feedback Remote Voltage Feedback
Sensing Position Sensing Position
1 Electrode Positive (DCEP} Connections
|
|
|
№
To Workpiece To Wire Feede 3
Tools Needed:
=e I=
Ref. ST-085 482-C / 5-0278-A
Figure 3-9. Remote Voltage Sensing Connections
OM-274 Page 7
3-8. 0To +10 Volts DC Command Modification
A WARNING
— ‚| ELECTRIC SHOCK can kill STATIC ELECTRICITY can damage parts
^^ ; * Do not touch live electrical parts. | on circuit boards.
; « Turn Off welding power source, and disconnect o * Put on grounded wrist strap BEFORE handling
input power before inspecting or installing. Ent > boards or parts.
| e Use proper static-proof bags and boxes.
| swami.1 2/93 / fwarns.1 9/91 |
4
The control circuit is factory set to |
send O (zero) to +4.8 volts de com-
mand signals to the remote output
control (Section 3-4). If the remote
control requires Q to +10 volts de
command signals, proceed as fol-
fows:
Remove cover and left side panel.
1 Circuit Board Cover
2 Control Board PC1
Remove cover, disconnect plugs
from PC1, and remove PCT.
3 Jumpers J2 And J3
Cut jumpers J2 and J3.
Reconnect plugs to PC1. Reinstall
PC1.
,Ç Toois Needed:
| 7€ 3/8in TB
Figure 3-10. Cutting Jumpers On Control Board PC1
ST-16t 360 / Ref. 5B-154 959
Be sure PC1 plugs are secure be-
fore recalibrating. Set meter on 20
volts de scale.
1 Remote 10 Receptacie RC1
2 Control Board PCH
3 Potentiometers R430 And
R435
Remove compound from screws of
R430 and R435.
Connect negative (—) meter lead to
RC1 socket B, and positive (+) lead
to RC1 socket I. Turn on unit.
Adjust R430 until meter displays 10
volts de. Turn off unit.
AP PEAK AMPERAGE
« VB BACKGROUND VOLTAGE |
Reconnect positive (+) lead to RCH
socket A. Turn on unit.
Adjust R435 until meter displays 10
volts dc. Turn off unit.
Disconnect meter, and reinstall
O PC1 cover. Reinstall left side panel
and top cover.
Tools Needed:
Ref. ST-130 111-A / Ref. 3-0166-A / Ret. SB-154 959
Figure 3-11. Recalibrating Control Board PC1
OM-274 Page 8
3-9. Connecting Input Power
4 WARNING
= | ELECTRIC SHOCK can kill.
| _— | ® Do not touch five electrical parts.
| SN Turn Off welding power source, and disconnect input power before inspecting or installing.
; ® Have only qualified persons install unit.
| | ® Installation must meet National Electrical Code and all other codes.
A. Positioning Jumper Links
swarmn3.1 2/93
Jumperlinks allow operation on dif-
ferent input voltages and are facto-
ry set for the highest input voltage.
Check input voltage available at
site.
Open rear access panel to check
jumper iinks.
1 Input Voltage Label — Only
One Is On Unit
Look at jumper links and compare
link position with unit label.
2 input Voltage Jumper Links
Move links to match input voltage.
For example, use 230 volts posi- |
tion when 230 volts input power is
available.
Close rear panel or go on to
Figure 3-13.
460 VOLTS —_
8-072 135-8
230 VOLTS 460 VOLTS 575 VOLTS I
ЫЮ о о НЮ с о БВ ЯВ о ©! |е о со olidooo clidooo |looookid oooold co 000 lg |
0.0.0, ©.,0.0., 0.9.0,
| S-021 154-A |
Tools Needed:
| 3/8in
ssb5.1 2/92 — ST-161 260
Figure 3-12. Input Voltage Jumper Links Location
OM-274 Page 9
B. Connecting Input Power
||
O
©
Эс
—=
_
O
42
(0
Tools Needed:
pr ще
—
——— —“ 3/8, 716, 1/2 In
ANNE
Figure 3-13. Input Power Connections
Table 3-2. Electrical Service Requirements*
Have only qualified persons make '
this installation.
Open rear panel access door.
1 Line Disconnect Device Of
Proper Rating
2 Input Conductors
3 Grounding Conductor
Select size and length using
Table 3-2. Conductor rating must
comply with national, state, and lo- |
cal electrical codes. Use lugs of .
properamperage capacity and cor- ;
rect hole size.
4 Strain Relief Connector
Insert conductors through strain ;
relief.
5 Input Terminal Board
6 Line Terminals
7 Ground Terminal
Connect grounding conductor and
input conductors to line terminals
and to ground terminal.
Install and connect grounding
conductor and input conductors in
conduit or equivalent to deener-
gized line disconnect device.
Be sure grounding conductor goes
to an earth ground. i
Close rear panel access door.
8 Overcurrent Protection
Select type and size using |
Table 3-2. Install into deenergized
line disconnect device (fused dis-
connect switch shown).
5552.4" 3/93 — ST-048 933-D
Input Voltage 200 230 460 575
Input Amperes At Rated Output 81 70 35 28
or ee naar Eee Or Creu as но o ©
Input Conductor Size In AWG/Kemil” 4 4. 8 10
Max Input Conductor Length in Feet (Meters)? 128 (39) 170 (52) 290 (88) 300 (92)
Grounding Conductor Size In AWG/Kcmil* 6 6 10 10
“ These values are calculated from the 1990 edition of the National Electrical Code (NEC).
1 Recommended fuse or circuit breaker size is that closest to 150% of rated input amperage of the welding power source. Article 630-1 2(a) of NEC
allows fuse or circuit breaker sizing up to 200% of rated input amperage.
2 Input conductor size is for insulated copper wire with 75°C rating with not more than three single current-carrying conductors in a cable or raceway
(Table 310-16 of NEC).
3 Maximum length is to prevent more than a 3% voltage drop between service entrance and input terminals of the welding power source (Articles
210-19(a) and 215-2(b) of NEC).
4 The grounding conductor shall be colored oridentified as specified inthe NEC. Grounding conductor size for copper wire is not required to be larger
OM-274 Page 10
than input conductor (Article 250-95 of NEC).
S-0092-F
SECTION 4 — OPERATION
A WARNING
st
ELECTRIC SHOCK can kill.
Always wear dry insulating gloves.
* insulate yourself from work and ground.
* Do not touch live electrical parts.
# Keep all panels and covers securely in place.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
* Wear welding helmet with correct shade of filter.
* Wear correct eye, ear, and body protection.
FUMES AND GASES can be hazardous
to your health.
* Keep your head cut of the fumes.
* Ventilate area, or use breathing device.
# Read Material Safety Data Sheets (MSDSs) and
manufacturer's instructions for material used.
MOVING PARTS can cause injury.
# Keep away from moving parts.
* Keep all doors, panels, covers, and guards closed
and securely in place.
WELDING can cause fire or explosion.
* Do not weld near flammable material.
e Watch for fire; keep extinguisher nearby.
® Do not iocate untt over combustible surfaces.
* Do not weld on closed containers.
* Allow work and equipment to cool before handling.
MAGNETIC FIELDS FROM HIGH CUR-
RENTS can affect pacemaker operation.
e Pacemaker wearers keep away.
* Wearers should consult their doctor before going
near arc weiding, gouging, or spot welding opera-
tions,
See Safety Precautions at beginning of manual for ba-
sic welding safety information. swarné.1 10/91
\
Voltmeter
Ammeter
Weld Amperage Switch
Mode Selector Switch
Power On Push Button
(fe
“BE,
Power Off Push Button
Background Voltage Adjust-
ment Control
=> © AM bh © N =
8 Peak Amperage Adjustment
Control
9 Vg Background Voltage/Ap
Peak Amperage Swiich
10 Qutput{Contactor) Switch
10 9 8 7
Ret. 37-085 482-C
Figure 4-1. Controls
{a (a
Insuiating Gloves
2 Safety Glasses With Side
Shields
3 Welding Helmet
Wear dry insulating gloves, safety
glasses with side shields, and a
welding helmet with a correct
shade of filter (see ANSI Z48.1).
563.1 10/91
Figure 4-2. Safety Equipment
OM-274 Page 11
ня
po
CT Tools Needed:
— ity
—
1 Work Clamp
Connect work clamp to a clean,
paint-free location on workpiece,
as close to weid area as possible.
Use wire brush or sandpaper to
clean metal at weld joint area. Use
chipping hammer to remove siag
after welding.
sb4.1 2/93
4 CAUTION
ARCING can damage switch.
* Do not change Mode Selector switch position while welding. damage unit.
Arcing inside switch can damage contacts, causing switch to fail.
Figure 4-3. Work Clamp
dard mode operation.
tacts.
INCOMPLETE SWITCH LEVER MOVEMENT can
e Place switch lever fully to left or right positions for 120 PPS or Stan-
Partial switch engagement may overload and damage switch con-
warns. 1* 2/93
120 PPS
60 PPS STANDARD
1 Mode Selector Switch
Use switch to select pulsed weld
output or standard weld output.
60 PPS position provides 60
pulses of peak current per second.
120 PPS position provides 120
pulses of peak current per second
output. 120 PPS position provides
hotter weld puddle than 60 PPS po-
sition.
Built-in arc sustainer senses am-
perage output in pulsed mode and
supplies minimum amperage level
to sustain welding arc.
In Standard position, weld output
set by Background Voltage Adjust-
ment control (see Figure 4-5).
Ref. ST-130 111.4
Figure 4-4. Mode Selector Switch
200
150
300
250
И
100 Ap
\_ PEAK AMPERAGE ADJUSTMENT / \ BACKGROUND VOLTAGE ADJUSTMENT J
1
/
350
400
450
MIN VB 38
1 Peak Amperage Adjustment
Control
This control only works when Mode
selector switch is in a PPS position
(see Figure 4-4),
Use control to select peak current
level during pulsed welding. The
peak current level is a percentage
of maximum output current of the
welding power source. The scale
around the control is in amperes.
2 Background Voltage Adjust-
ment Control
Use control to select background
voltage level. The background volt-
age is a percentage of maximum
output voltage of the welding pow-
er source. The scale around the
control is in volts.
OM-274 Page 12
Figure 4-5. Peak Amperage And Background Voltage Controls
~\ 1 1 Background Voltage/Peak
. VE BACKGROUND VOLTAGE Y Amperage Control Switch
AP PEAK AMPERAGE Use switch to select way of contro!-
ling background voltage and peak
A о PANEL amperage adjustment.
1
For front panel control. place
switch in Panel position.
For remote control, piace switch in
N 74 METER Remote 10 position. See Example
below.
AP PEAK AMPERAGE
Vv 2 Remote Pendant Control
Ne B BACKGROUND VOLTAGE J
EXAMPLE Of Full Remote Background Voltage/Peak Amperage Control
VE BACKGROUND VOLTAGE
AP PEAK AMPERAGE
ADS
Set Switch — Control Settings Do Not Matter — Adjust Remote
Pendant Control
Ref. ST-120 111-A / ST-162 711
Figure 4-6. Background Voltage/Peak Amperage Control Switch
1 Voltmeter
Voltmeter displays average volt-
age of the background and peak
pulses when in the pulse mode, but
not necessarily voltage atthe weld-
ing arc due to cable resistance,
poor connections, etc.
4 2 2 Ammeter
/ / Ammeter displays weld amperage
A N output of unit.
3 Weld Amperage Switch
When switch is in Average posi-
tion, ammeter displays average
amperage output.
To display peak amperage on am-
meter, hold switch in Peak amper-
age position. Release switch to re-
AN N turn to Average position.
3
© o AV E
WELD
AMPERAGE
\. | py PEAK
Figure 4-7. Ammeter, Voltmeter, And Weld Amperage Switch
OM-274 Page 13
& WARNING
= ELECTRIC SHOCK can kill.
* Do not touch live electrical parts.
i ® Do not touch weld output terminals when contactor is energized.
| * Do not touch electrode and work clamp at the same time. swarn7 1 10/91
/
ojo FEEDER
(>> OUTPUT
(CONTACTOR )
NN
”
1 Output (Contactor) Switch
Use switch to select way of controi-
ling unit output.
For weld output, place switch in On
position.
For remote output control, place
switch in Remote 14 position (see
Section 3-5}.
Weld output terminals are energized
when switch is On and power is On.
( TN
POWER J
-6) ©
ad
|
ON
or
OFF
NN J
1 Pilot Light
4 2 Power On Push Button
7 ; Press button to turn On unit and pi-
lot ight.
3 Power Off Push Button
Press button to turn Off unit, pilot
light, and fan if it is running (see
Section 5-2).
L— 2
L— 3
Figure 4-9. Power Push Button And Pilot Light
OM-274 Page 14
A WARNING
в BUILDUP OF SHIELDING GAS can harm health or kill.
# Shut off shielding gas supply when not in use.
warn! 1 9/91
1 Shielding Gas Cylinder
2 Valve
3 Gun Trigger
Gpen valve on cylinder just before
welding.
Gun trigger turns weld output and
gas flow on and off.
Close valve on cylinder when fin-
ished welding.
565.1 6/92 - 5-0621-C
Figure 4-10. Shielding Gas
See Table 4-1 Install & Install & Prepare Put On Turn On
For Suggested Connect Wire Feeding Personal Safety Set Controls Shielding Gas
Parameters Equipment System Equipment
Turn On Feeder
And Welding Begin Welding
Power Source
Figure 4-11. Sequence Of Gas Metal Arc Welding — Puised (GMAW-P)
ESDE.1* 9/07
Install Install & Prepare Put On Turn On Turn On Feeder
Connect Wire Feeding Persona! Safety Set Controls Shielding Gas And Welding
Equipment System Equipment Power Source
) Begin Welding )
Figure 4-12. Sequence Of Gas Metal Arc Welding (GMAW)
5566.1 9/92
Install & install á Prepare Put On Turn On
Connect Wire Feeding Personal Safety Set Controls Welding Power Begin Welding
Equipment System Equipment Source
Figure 4-13. Sequence Of Flux Cored Arc Welding (GMAW)
OM-274 Page 15
Table 4-1. Suggested Weld Parameters For Gas Metal Arc Welding — Pulsed (GMAW-P)
NOTE 7. All joints are T-fillets. Values represent starting parameters; adjust according to
joint design and alloy type. |
. Meter Reading
Thickness In | Gauge Gas CFH ue Wire Size Frog. Shoe E eed Voltage о Amperage Average
Inches Type PPS Setting Setting” | Volts | Amps
ALUMINUM
1/16 Horiz Argon 25 ‚030 4043 60 208 18.7 200 41 18.7
1/8 НО? Argon 25 ‚030 4043 60 576 24.6 195 137 24.6
1/4 Horiz Argon 25 ‚030 4043 120 747 25 210 192 25
3/8 Horiz Argon 25 ‚030 4043 120 801 27.3 250 217 27.3
1/8 Horiz Argon 25 .030 5356 60 576 20 190 117 22
316 Horiz Argon 25 030 5356 69 807 24 190 160 24
1/16 Fioriz Argon 25 .030 5356 120 384 17.5 190 69 17.5
1/4 Horiz Argon 25 030 5356 120 1104 24.3 300 188 24.3
1/16 Horiz Argon 25 035 4043 60 168 17.5 220 44 17.5
1/8 VertUp Argon 25 ‚035 4043 60 330 20.5 260 107 20.5
3/16 VertUp Argon 25 ‚035 4043 60 330 20.5 260 107 20.5
1/4 Horiz Argon 25 035 4043 60 408 22.4 315 135 22.4
1/2 VertUp Argon 25 ‚035 4043 60 438 23.7 235 146 23.7
1/8 VertUp Argon 25 ‚035 4043 120 300 20.8 285 94 20.8
3/16 Horiz Argon 25 ‚035 4043 120 423 21.1 365 125 21.1
1/4 Horiz Argon 30 3/64 4043 60 258 23 255 158 23
1/8 Ноя: Argon 30 3/64 4043 120 186 20.5 315 94 20.5
3/16 VertUp Argon 30 3/64 4043 120 210 20 340 102 20
1/16 Horiz Argon 30 3/64 5356 60 133.5 16.8 290 53 16.8
1/8 Horiz Argon 30 3/64 5356 60 357 21.8 195 170 21.8
1/16 Horiz Argon 30 3/64 5356 120 186 17 240 70 17
1/4 Horiz Argon 30 3/64 5356 120 333.5 23.4 280 145 23.4
1/8 Horiz Argon 35 1/16 4043 60 115 18.2 255 106 18.2
1/8 Horiz Argon 35 1/16 4043 60 135 19.4 190 130 19.4
1/4 Horiz Argon 35 1/16 4043 60 175 21.6 190 191 21.6
1/18 Horiz Argon 35 1/16 4043 120 100 17.5 285 84 17.5
1/4 VertUp Argon 35 1/16 4043 120 125 20.2 250 123 20.2
1/4 Horiz Argon 35 1/16 4043 120 140 20.6 190 142 20.6
1/4 Horiz Argon 35 1/16 4043 120 - 155 21.6 180 154 21.6
STEEL
3/64 VertUp 18 ЭВАг20х 25 ‚030 60 88 14.6 225 37 14.6
1/16 Horiz 16 SBAr20x 25 030 60 125 16.1 245 54 16.1
1/8 VertUp 10 98Ar20X 25 .030 60 250 19.3 270 38 19.3
3/54 Horiz 18 ЭВАг20х 25 030 120 160 16.4 235 59 16.4
116 VertUp 16 ЭВАг20х 25 .030 120 210 18 260 77 18
3/8 VertUp SBAr20x 25 030 120 320 21 330 120 21
3/64 Horiz 18 ЭВАг20х 25 ‚035 60 100 17.2 310 52 17.2
1/8 vVertUp 10 98Ar20x 25 .035 60 145 18.8 375 80 18.8
1/4 VertUp ЭВАг20х 25 ‚035 60 200 20.6 400 112 20.6
3/8 VertUp SBAr20x 25 035 60 270 21.9 305 146 21.9
1/16 Horiz 16 98Ar20x 25 035 120 125 19 260 7 19
1/8 Horiz 10 ЭВАг20х 25 035 120 135 18.2 260 79 18.2
3/8 VertUp 98Ar20x 25 035 120 170 19.2 300 95 19.2
1/2 VertUp ЭВАг20х 25 035 120 260 21.6 315 128 21.6
1/8 Horiz 10 ЭВАг20х 25 ‚045 120 130 19.7 385 126 19.7
3/8 Horiz 98Ar20x 25 045 120 195 22.3 260 183 22.3
1+ VertUp ЭВАг20х 25 ‚045 120 150 20.7 390 145 20.7
OM-274 Page 16
. Meter Readin
Thickness In | Gauge Gas CFH que Wire Size Fro Speed e Voltage Amperage Average 9
Inches Type PP Setting Setting* | vans Amps
STAINLESS STEEL
3/64 VertUp | 18 9BAr20x | 25 .030 308L 60 120 15.8 230 42 15.8
1/8 Horiz 98Ar20x | 25 .030 308L 60 230 18.2 325 66 | 18.2
1/4 Horiz 98Ar20x | 25 030 308L 60 330 20.9 410 90 | 208
1/2 VertUp 9BAr20x | 25 .030 308L 60 380 23 425 107 23
3/64 Horiz 18 98Ar20x | 25 030 308L 120 160 16.9 185 57 16.9
1/8 VertUp 98Ar20x | 25 030 308L 120 200 17.8 210 69 17.8
1/4 VertUp 98Ar20x | 25 030 308L 120 250 18.8 235 88 18.8
1/16 Horiz 16 98Ar20x | 25 ‚035 3081. 60 125 17.6 270 57 17.6
7/64 Vertup 98Ar20x | 25 ‚035 308L 60 150 19 310 71 19
7/64 Horiz 98Ar20x | 25 ‚035 3081. 60 175 19.6 340 80 19.6
1/4 VertUp 98Ar20x | 25 .035 308L 60 225 22 340 117 22
1/16 Horiz 16 98Ar20x | 25 035 308L 120 135 19.5 240 66 19.5
1/4 VertUp 98Ar20x | 25 ‚035 3081. 120 170 19.3 250 79 19.3
1/4 Horiz 98Ar20x | 25 | .035 308L 120 275 22.1 215 123 | 22.1
1/8 Horiz 10 98Ar20x | 25 | .045 308L 60 185 22.5 230 162 | 22.5
1/4 VertUp 98Ar20x | 25 045 | 3081 60 185 22.5 230 162 | 225
3/8 VertUp 98Ar20x | 25 | .045 308L 120 190 21 390 141 21
1/4 Ной 98Ar20x | 25 | .045 3081. 120 255 23 430 177 23
STAINLESS STEEL Base. NICKEL Wire
1/4 VertDn Argon 35 | .045 | ERNI-3 60 161 22.2 200 159 | 22.2
1/4 Horiz Argon 35 .045 | ERNI-3 60 161 22.2 200 162 | 22.2
STAINLESS STEEL Base, ALUMINUM BRONZE Wire
1/8 VertUp | 10 | Argon | 40 | 1/16 | | 66 | 100 | 228 | 300 | 1431 228
MILD STEEL Base, SILICON BRONZE Wire, SQUARE BUTT JOINT {not T-filiet)
Horiz | 20 | Argon | 45 | .035 | | 60 | 338 | 205 | $60 | 107 | 205
*Forbestarc characteristics: Use as much background voltage as possible with no more peak amperage than necessary. These settings will produce
an intermittent spray transfer at a low average heat.
NOTE “ > Electrode extension and travel speeds are sometimes critical; experimentation will
be necessary. (Average electrode extension 5/8 in; travel speeds vary extensively.)
OM-274 Page 17
SECTION 5 — MAINTENANCE & TROUBLESHOOTING
7 WARNING
— ELECTRIC SHOCK can kill.
= А e Do not touch live electrical parts.
„7 e Turn Off welding power source, and disconnect
MOVING PARTS can cause injury.
# Keep away from moving parts.
input power before inspecting, maintaining, or
servicing.
HOT PARTS can cause severe burns.
» Allow cooling period before maintaining or
servicing.
| Ц Maintenance to be performed only by qualified
| persons. swarnB.1 2/93
5-1. Routine Maintenance
Ad 3 Months A Turn Off all power before maintaining. I 6 Months
Tape Or
Replace
Cracked
ZA Cables
Replace
Unreadable
Labels
Clean
6 And
Tighten
Weld
Terminals
ST-085 483-C
Figure 5-1. Maintenance Schedule
5-2. Overload Protection
READ SAFETY BLOCKS at start of
4 WARNING Section 5 before proceeding.
A. Overheating
Thermostat TP1 protects the unit from damage due to overheating. if main rectifier SR1 gets too hot, TP1 opens and
weld output stops. Wait approximately 15 minutes before trying to weld.
B. Fan Control
When the Output (Contactor) switch and Power switch are in the On position, fan runs all the time.
When Output (Contactor) switch is in Remote 14 position and Power switch is in On position, fan runs while welding and
for 15 seconds after welding stops.
If main transformer T1 or main rectifier SR1 get too hot, thermostats TP4 and TPS close and the fan runs until TP4 and
TP5 open, or the unit is turned Off.
C. Short Circuit Shutdown
If contact tube is shorted and sticks to workpiece, the unit output decreases. To regain full output, release gun trigger,
turn Off unit, and remove contact tube from workpiece. Check contact tube and replace if damaged. Turn On unit to
continue operation.
OM-274 Page 18
D. Circuit Breakers CB1 And CB2
1 Circuit Breaker CB1
CB1 protects the 115 volts ac wind-
ing of main transformer T1.
IFCB1 opens, the 115 volts ac out-
р NEUTRAL put to the Remote 14 receptacle
BONDED
| | | TO FRAME sio ! 15 volts ac duplex receptacle
xo RACCORDE [7] REMOTE 14 2 Circuit Breaker CB2
AU CB2 protects the 24 volts ac wind-
45V 15 AC ing of main transformer T1.
If CB2 opens, the 24 volts ac output
tc Remote 14 receptacle stops.
=);
7
Press button to reset a breaker.
>
OUTPUT
{ CONTACTOR ]
olo FEEDER
@ (CONTACTOR |
Ns J FCO) | on
N J
Figure 5-2. Circuit Breakers CB1 And CB2
Ref. ST-130 111-A
E. Fuse Link F1
4 CAUTION
STATIC ELECTRICITY can damage parts on circuit boards.
¢ Put on grounded wrist strap BEFORE handling boards or parts.
fwam5.1* 9/91
Turn Off welding power source and
disconnectinput power.
Remove right side panel.
1 Rectifier SR1 Bracket
2 Fuse Mounting Strip
3 Fuse Link F1 (See Parts List
For Rating)
Remove F1 from mounting strip. To
reinstall, mount with hardware as
shown.
Reinstall side panel.
ST-161 352
Figure 5-3. Fuse Link F1 Location
OM-274 Page 19
5-3. Troubleshooting
A WARNING
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
J
servicing.
e Tur Off welding power source, and disconnect
input power before inspecting, maintaining, or
iman
HOT PARTS can cause severe burns.
* Allow cooling period before servicing.
MOVING PARTS can cause injury.
* Keep away from moving parts.
Troubleshooting to be performed only by qualified
mode.
check hall device HD1 and control board PCH.
persons.
swarn9.1 2/93
Table 5-1. Welding Trouble
Trouble Remedy Section
No weid output, unit does not work; pilot ¡— — »l Place line disconnect device in On position. — — 3-98
light PLT not on.
Check and replace line fuse(s) or reset circuit breaker(s). — — = 3-98
Check for proper input power connections. —— 0 3-98
Check for proper jumper link position. — — = 3-9A
Unit overheated. Allow fifteen minute cooling period. — — - 5-2A
Have Factory Authorized Service Station/Service Distributor |— — -= -—
check contactor W.
No weld output; unit does not work; pilot |-— — | Place Qutput (Contactor) switch in On position, or move switch to — — » 3-5,
light PLí is on, Remote 14 position and connect remote contactor to Remote 14 Figure 4-8
receptacie.
Have Factory Authorized Service Station/Service Distributor — — -» ——
check controi board PCT.
Limited output and low open-circuit volt- |-— — -#i Check and replace line fuse(s) or reset circuit breaker(s). —— 3-98
age.
Check for proper input power connections. ——. 3-98
Check for proper jumper link position. — — > 3-GA
Erratic weid current. — — | Increase setting of Background Voltage Adjustment control. —— -#| Figure 4-5
Use proper size and type of weld cable. —— 5e 3-2
Clean and tighten weld connections. — 3-3
Check wire feeder installation according to its owner's manual. |— — -» ——
Check and replace fuse link F1, if necessary. — — 5-2E
Have Factory Authorized Service Station/Service Distributor |— — — - =
check control board PCT and main rectifier SR1.
Excessively high weld current in pulsed — — -e| Have Factory Authorized Service Station/Service Distributor — — —
OM-274 Page 20
Trouble Remedy Section
| Low weld current in pulsed mode. — — -»= Check and replace line fuse(s) or reset circuit breaker(s). —— 3-98
Be sure Mode Selector switch is not piaced between positions. |—— -= ——
Have Factory Authorized Service Station/Service Distributor [— — — ——
check hall device HD1 and control board PCH.
High weld output: voltage control does
not vary output.
— —-» Have Factory Authorized Service Station/Service Distributor
check control board PC1.
5-2D
LÀ
No 115 volts acoutputat 115 volts acdu- ¡— — —#l Reset circuit breaker CBt. ——.
plex receptacle or Remote 14 recep-
tacle.
No 24 volts ac output at Remote 14 re- [— — -»| Reset circuit breaker CB2. — — -= 5-20
ceptacle. |
SECTION 6 — ELECTRICAL DIAGRAMS
PLGI
те AN
Te,
A < CEN _ с
<
WHT 5» 7 Pa
с ES e 38
> A BO
8 RS
CW Ss
AJ
+.
3 ce ELA
Tw,
о «#0
SA-091 010-A
Figure 6-1. Circuit Diagram For Remote Pendant Control RPC-2A (Optional)
OM-274 Page 21
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54
CONTACTO >
[OUTPUT CONTROL
> TT [I
. Figure 6-2. Circuit Diagram For Welding Power Source
OM-274 Page 22
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OM-274 Page 23
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Figure 6-3. Wiring Diagram For Welding Power Source
OM-274 Page 24
TH{COIL |-3&Y BEG)
36 916
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5 I512| CRES
1613
BAFFLE
END.
50-161 448
OM-274 Page 25
SECTION 7 — PARTS LIST
(tem 31
29
32 A0 Includes
28 — Fig 7-2
25 — Fig 7-3
27
|
A
OM-274 Page 26
ST-087 089-J
Figure 7-1. Main Assembly
Replace Coils at Factory or Factory Authorized Service Station
item Dia. Part
No. Mkgs. No. Description Quantity
Figure 7-1. Main Assembly
e LL ee san 005 194 .. COVER, top ...........eoéererecvrverererverecrenrorecva mera 1
. 2. SR1 . 140120... RECTIFIER, SCR main (Fig 7-7) ........... 2.2.2... erre, 1
E 11222200 091 055.. FRAME, upright base front ...............—... 00:00 eaoo. 1
As 026 627 .. GASKET, lifting eye ......120 10110 enera. 1
‚5. R13 ‚ 091805 .. RESISTOR, WW fxd 50W 100 Ohm ............................ 1
. 6 ... CR2,6 ... 039498.. RELAY, encl 120VAC 3PDT 20000 e. 00srereca e en. 1
7. VR2 .... 047 183 .. VARISTOR, 50 joule 232V ..... 0.000.000 aaa 1
. 8... SR23 ... 035704,. RECTIFIER, integ 40A 800V ..........—..—..r00000rera ae ane 2
‚ 9. HD1 ..... 086 115... SENSOR, current RR 1
C10. 128063 .. COVER, circuit card ......... iii. 1
. 11. PCI 154 958 .. CIRCUIT CARD, control ......... 2... 000, ea aan 1
PLG62 ... 141642.. CONNECTOR & SOCKETS, (consistingof) . ..................... 1
Cea 081378 .... CONNECTOR, rect skt 22-18ga Amp 102100-6 ................ 16
aa PLGO1 ... 090469 .. CONNECTOR, rect 10skt plug Amp1-87159-0.................... 1
aan 081 378 .. CONNECTOR, rect skt 22-18ga Amp 102100-6 ................. 10
12 ............. 080 509 .. GROMMET, ser No. 8-10 .......... 2..5. .5 esa aoaaonanan a 9
13... CR3,5 ... 059266... RELAY, encl 120VAC DPDT ........ 2... a ae. 2
14... D2,12 109068... DIODE .... eneredaererenaanom 2
15 . CRA . 106462 .. RELAY, encl 24VDC DPD .. 0er ea aa 1
16 . TD1 ..... 114494 .. TIMER, delay ...... a aa a aa 1
17 . R16 032819... RESISTOR, C.5W380Kohm ........... i... 1
18..... 2T ..... 038601 .. BLOCK, term B0A OP eden nena. 1
19... D10,11 ... 082456 .. DIODE ASSEMBLY .... 90000000000 oneneao neon 1
20..... W..... 137 900... KIT, contactor ..............2. e. 8 4 4 4 4 4 A ea RL 4 A La a ae à 1
.21..... R7..... 026 520... RESISTOR, grid ...11100 0004104144 da 4 a A AA A ae a aa ae 1
C22 a 130779... PANEL, migcomponents ........... iin, 1
23 . CR1 . 000 770 .. RELAY, encl2aVDC 3PDT ......... 0000. 1
.24.... CR6 .... 134163 .. RELAY, encl 24/120VAC DPDT ...... iii, 1
‚ 25 .............. Fig 7-3.. PANEL, rear w/eomponents ............_e._—eovrervererararevee. 1
26 . C23 137 771 .. CAPACITOR ........ 2... 0000 rea aaacranoeneoooror 1
27 C21,22 ... 137674 .. CAPACITOR .... ee 2
28 . TE? . 038145 .. TERMINAL ASSEMBLY, pri (dual voltage) (Fig 7-2) ................ 1
28 .... TE1 . 038138 .. TERMINAL ASSEMBLY, pri (triple voitage) (Fig 7-2) ............... 1
. 29... T1..... 134 025.. TRANSFORMER, pwr main (200/230/460) (consisting of) ........... 1
BO a 087 404 .... COIL, pri/sec center A RH ............. .—r.0d0000rie.r avere 2
DB naaa 134 031 .... COIL, prissec LH ........... RK 1
. 29... T1..... 134027 .. TRANSFORMER, pwr main (230/460/575) (consistingof) ........... 1
‚ 30 ............. 087627 .... COIL, prifseccenter & RH . ........ iin, 2
RC ............. 134033 .... COIL, prifsec LH... i eee 1
Ce TP5 . 0846860.. THERMOSTAT, NO 1.111101 4 112 LL LL LL Le a aa aa e ue À
‚ 32 ............. 086 191... BUS BAR, jumper ...........omeerervcoreererenererec ar erea.. 1
33..... R9..... 074121 .. RESISTOR, C2W 3.3Kohm ........... iii. 1
34 ..... 22 ..... 086189 .. CHOKE, current peak .... oo. iii ee eee 1
35..... 7A 132038 .. STABILIZER ........ 22 vereis vere cereereoeenaecarcenaa. 1
36 ............. 131 374 .. PANEL, fuse (consisting of) ........ ci iii. 1
‚ 37 ..... F1..... *027 267 .... FUSE, link 300A 250V .. ... iii i eee ee 1
‚ 38 ............. 092 724 .... STRIP, mtg fuse .........e.e.ee0eroeacororeduevrvaenodooeav e, 1
39 139786 .. BASE .........—reressieresrerederearercrrereredarvenaerarcadea 1
‚40 ............. 138378 .. BRACKET, mtgrectifier ............ iin, 2
Ale 2 0 085527 .. BUS BAR, connecting capacitors ............ oon... 2
42 ..... Cé..... 085273 .. CAPACITOR, elctit 16000uf 6OVDG ............. 2.9.0... 6
‚ 43 .............. Fig 7-4 .. PANEL, frontw/components ............c iii iin. 1
AA enana. 005 195... PANEL, side .............emererererverevoereredrarervereeres 2
OM-274 Page 27
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 7-1. Main Assembly (Continued)
041 798 RPC-2A (Optional)
Ce nen 086 181 .. COVER, controlbox .......... i
ee 086 182 .. CASE SECTION . 7
aras PLGT1 ... 038716.. CONNECTOR, circ 10 pin plug Amphenol MS-3106A-18-1P . . ....... 1
ee 052 246 .. CABLE, power 5/c (order by ft) ............................... 20ft
ana aaa 073332 .. CONNECTOR, circ clamp str rif sz 18 Amphenol AN-3057-10 ....... 1
aaa. R1,2.... 035 897 .. POTENTIOMETER,C1T2W 1000ohm ........................ 2
Ce 097 924 .. KNOB, pointer .......... iii 2
aaa, R3..... 005208... RESISTOR, C.5W 2700hm ......... 1
adds H4..... 030033... RESISTOR, C.5 470 0hm .................................1
aran ana aa. 019663 .. MOUNT, 1516 0DXx3/8 ................ A
ee 010476 .. BUSHING, strain relief 625ID x .570mtg hole ....................1
Ce ee anacic., NAMEPLATE (order by model and serialnumber) ................. 1
Ce 604 311 .. GROMMET, rbr 250 ID x .375mtghole ..... .. .. .. ..............1
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-274 Page 28
[tem Part |
No. No. Description Quantity
.Figure 7-2. Terminal Assembly, Pri (Fig 7-1 Item 28) 038 145 | 038 138
. 1 .... 601 835 .. NUT, brs hex regular 10-32 ............ 0... 24 36
. 2 .... 038058... TERMINAL BOARD .. ae a aaaeren—ier 1... 1
. 3.... 038887 .. STUD, pri bd brs 10-32 x 1.375... a 12 . 18
‚ 4 .... 010913... WASHER, flatbrs .218 ID x 4600D ..................... 12 . 18
‚ 5 .... 038 618 .. LINK iumper .......112111 1100 LL LA aa a A a a ea a aa LL LL LA LL 6..... 6
‚ 6 .... 601836... NUT, brs hex .250-20 ....... ea enananaae, 6..... 6
. 7 .... 010815... WASHER, flat brs .250 10 х 625 ОД ............... 2..5... к... 6..... 6
. 8 .... 038888... STUD, pri bd brs .250-20 x 1.500 .......... i, 3..... 3
A
2 Se
6 SA-038 145-E
Figure 7-2. Terminai Assembly, Pri
SC-087 081-C
Figure 7-3. Panel, Rear w/Components
item Dia. Part
No. Mkgs. No. Description Quantity
Figure 7-3. Panel, Rear w/Components (Fig 7-1 Item 25)
Ps веке... 132 259... CHAMBER, plenum 14in L...020 00004014 444 a se 4 a La a aa ea a aa ee 1
C2 605 799 .. BLADE, fan14inSwing30deg .............. i... 1
1 BG LL 11111010 018144 .. PANEL,rear ........1122000 00001144 aa aa LA LA AL aa a 1
.. 4... R6,11 ... 126 409 .. RESISTOR, WW fxd 300W 5 0hM ............................. 1
.5..... FM .... 032605... MOTOR, 1/4hp 230VAC 1625RPM . ........................... 1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-274 Page 29
14—Fig 7-5
or
с бо O M A
32
ST-087 090-G
Fiqure 7-4. Panel, Front w/Components
OM-274 Page 30
item Dia. Part
No. Mkgs No. Description Quantity
Figure 7-4. Panel, Front w/Components (Fig 7-1 Item 43)
$ La La La Aa aa 0 NAMEPLATE (order by model and serial number) ................. 1
.2..... S24 ..... 011 611 .. SWITCH, tgiDPDT 156A 125V i ies, 2
. 3... RC6 . 143976 .. CONNECTOR w/SOCKETS, (consisting of) ..................... 1
Danone ad aa raca 079534 .... CONNECTOR, circ skt push-in 14-18ga Amp 66358-6 ........... 14
Ce 134 734 .. CONNECTOR, circ 14skt rept Amp 213571-2
Ce 134731 .. CONNECTOR, circ pin push-in 14-18ga Amp 213603-1
ee 079739 .. CONNECTOR, circ clamp str rif sz 17-20 Amp 206322-2 (or)
Ce 143922 .. CONNECTOR, circ clamp str rif sz 17-20 Amp 206070-3
A 158 295 .. PANEL, front . _—...e0es0rare 0er 0 anoeceaorserdrerenaorna 1
.5..... CB2 . 083432... CIRCUIT BREAKER, manreset1P10A250V .................... 1
.6..... RC1 . 039718 .. CONNECTOR, circ 10skt rept Amphenol M-3102A-18-15 ........... 1
aaa ea 038716 .. CONNECTOR, circ 10 pin plug Amphenol MS-3106A-18-1P
Ce eee 073 332 .. CONNECTOR, circ clamp str rif sz 18 Amphenol AN-3057-10
7. C15-17,20,24 . 129764 .. CAPACITOR 1112101024 4444 04 4 44 AA 4 44 ee 4 V4 ee 4 eV aa ae 5
. 8....C18,19 . 140 814... CAPACITOR ........ 2.2.0 r00redereaaarerarerenarena rana 2
.9..... 56 ...... 118681 .. SWITCH, tgl DPDT 15A 125VAC ..........oerecrereecenene rem. 1
10..... SI ...... 111 905 .. SWITCH, mode 3posn (Fig 7-6) ............ 2.022, aa 120 1
11.... R5,10 . 035897... POTENTIOMETER, C 1T 2W 1000 ohm ........................ 2
.12..... R14 .. 005208... RESISTOR, C BW 2700hm ......... iii. 1
.13..... R15 . 030033... RESISTOR, C.5W 470 ohm ........... iin. 1
14..... PB1 .. 046 746... ЗУМТСН, РВ (Ак 7-5) .......... 2... eee eee eae 1
‚ 15..... RC4 . 604176 .. RECEPTACLE, strdx grd 2P3W 115A 125V ...................... 1
Cee 073690 .. PLUG, str grd armd 2P3W 15A 125V Arrow Hart 5965V
.16..... CB1 .. 020 278 .. SWITCH, circuit breaker 15A . . ....... i. 1
.017..... C4.,5 . 087 337 .. CAPACITOR ee 2
18... e... 039 046 .. TERMINAL, pwr output black (consisting of) ..................... 1
18 .............. 039 047 .. TERMINAL, pwr output red (consistingof) ....................... 1
‚19 .............. 601 976 .... SCREW, cap stl hexhd .500-13 x 1.500 ....................... 1
‚ 20 .............. 039045.... TERMINALBOARD, black ............. ii... 1
1 .............. 039 049 .... TERMINAL BOARD, red ...............e000seírerírereencevea, 1
C21 .............. 601 880.... NUT, sti hex jam .500-13 ............... i i eee 1
DB 039044 .... BUS BAR . ee 1
Dee 601 879.... NUT, sti hex full fnsh .500-13 ........... i... 1
‚ 24 .............. 025 338 .. BUSHING, nyl 23/32 x 5/8mtg hole ................—.22é.0r.emxe... 1
25..... | ..... 038 772 .. BLOCK, term 20A BP ..... 0000 xrreerearevorerdromo 1
Ce ee eee 601 219 .. LINK, jumpertermblock ............. cc... iii... 2
edo. C13,14 090 974... CAPACITOR ...............s00reseorervereereerereererecarer e
26 .............. 605 583 .. CATCH, spring loaded door .............. oeeeserorereoro re. 1
27 LL 11112100 134 327 .. LABEL, warning general precautionary ...........e—«.—oreceoerecoo. 1
28 ............. +109 449 .. DOOR, access Топ... .......... 2..2... 2... в кк кинка... 1
29..... PL1..... 027645 .. LIGHT, indredlens 125VAC ...... iii i ieee о. 1
‚ 30 .............. 097 922... KNOB, pointer .............e.._eeeerererorecoe:rrorerevrera on 2
„31...... А ...... 118 900 .. METER, Amp DC 50MV 0-600 5са[email protected] ........................... 4
32...... М ...... 119006 .. METER, VoitDCO-100scale .......... ccc. 1
Ce ee 023562 .. CLAMP, hose .312-875diacip ........... 1
+When ordering a component originally displaying a precautionary label, the ¡abel should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-274 Page 31
Item Part I .
No. No. Description Quantity
046 746 Figure 7-5. Switch, Push Button (Fig 7-4 item 14)
. 1 .... 059885 .. BUTTON, push resetred ........... 2.0200 0x0xerererevrereme,neorodraa 1
‚ 2 .... 018 606 .. SPRING, compression ............ 0.0... 08000 errado 4 a a ea ea a 1
. 3 .... 045546 .. PUSHBUTTON SET, w/icable & housing ............ iii... 1
‚ 4 .... 081008 .. BRACKET, mtg switch PB_ ......1201 0110104 444 4 ea 4 ea eins 1
. 5 .... 027 878 .. SWITCH, limitleafactuating .......... ie ie 1
Figure 7-5. Switch, Push Button
ST-080 214-B
ST-087 083-C
Fiqure 7-6. Switch, Mode 3 Position
Item Dia. Part
No. Mkgs No. Description Quantity
111 905 Figure 7-6. Switch, Mode 3 Position (Fig 7-4 item 10)
1 L 11122 005 558 .. SPRING, selector .. ккики. 1
C2 andrade 072 027 .. LEVER ..... e LL LL AL La Lea a ee a ea a a ee a a a aa ee 1
‚ОЗ 2... к....... 072 082 .. BUSHING, sti .265 1D x .484 OD ............. .... ... .......... 1
Cd 111111111112 011 845 .. CONTACT ASSEMBLY, movable (consistingof) .................. 2
EC ...112.22000 000 011 074 .... SPRING, pressure contact ............... ... unin. 1
CB 011 953 .... CONTACT ee ee eee aa a ee 2
107 22111 1 ae 011 075 .... SPRING, pressurecontact .............. iin. 1
. 8 LS2 603 946 .. SWITCH, micro ........100 004420 AAA La 4 a AA 4 A da a Le a a aa aa 1
‚ 9. LST 109810... SWITCH, limit +54 125V ce 1
‚10 ............. 086184 .. BUS BAR ........ 0. 00.0000e0ieaaracverererenane cera, 2
a. 070 204 .. BUS BAR ........ 0... 000. 0000ericacieoverenenaronaenoro. 2
12 .............. 011644 .. CONTACT, stationary ........... iii... 6
13... 072 028 .. GUIDE, contact ........ araraacoo ona 2
14 ............. 072026 .. BRACKET, mtg ........ 2.0.0.0 0000000 a0acaaaoacaoa 1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-274
Page 32
item Dia. Part
No Mkgs No. Description Quantity
140120 Figure 7-7. Rectifier, SCR Main (Fig 7-1 item 2)
es 082 694... CLAMP ........ e .rearecereavereavevenernereneneooneao 2
2 21121111 10000 048 779 .. HEAT SINK . 41 A aa a ea aa ea ALL ee 10
C3 028516 .. PIN, spring compression . «o.oo tii et i et eee ieee 14
. 4 .SCR2356. 048736 .. THYRISTOR, 300A 200V ...... iii, 4
CS 045 034 .. HEAT SINK . oe ee eee a 6 2
6 C7-12 048 420 .. CAPACITOR, rectifier ......... i i iin 6
7 PLG60 081 379 .. CONNECTOR, rect 12skt plug Amp 1-87158-2 ................... 1
Cee 081 378 .. CONNECTOR, rect skt 22-18ga Amp 102100-2 ................. 12
‚ 8 ..... D1..... 086 353 .. DIODE, 800A 300V .......... 2.2... 00.00.00 rAaa aaa era 1
‚ 9 ............., 139115... STRIP, migrectifier ......... coi, 2
10 ............. 035 409 .. STRIP, mtg ........... 222.00 000rererreaenareenenoorrer 2
11...8CR1,4....112940.. THYRISTOR, 800A 200V ........ i iin. 2
12... 138773 .. STIFFENER, rectifier .. .. iii i eee eee. 2
18 ............. 086 354 .. CLAMP Le Le a eee aa 1246 1
ana 0» TP1 012786 .. THERMOSTAT, NC . ...... 7
Cee TP4 021548... THERMOSTAT, NO ...... 7
Cee 144 036 .. BUSBAR,tabconnecting............. od
RAS 048 775 .. BUSBAR,tabconnecting.................................... E
57-087 138-D
Figure 7-7. Rectifier, SCR Main
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-274 Page 33
OPTIONS AND ACCESSORIES
DSS-8 DUAL
SCHEDULE a E
SWITCH Ss
For 10 ft. (3 m) gun. (#079 691)
For 15 ft. (4.6 m) gun (#079 693)
Two-position trigger switch fastens
to the gun handle. Operates the
power source contactor and selects
desired schedule. For use with
DDSC-P1 or DSC-PS.
DSS-8PS DUAL
SCHEDULE SWITCH
10 ft. (3 m) gun (4041 804)
15 ft. (4.6 m) gun (#041 805)
Functions same as the DSS-8
switch.
DSS-9 DUAL si
SCHEDULE
SWITCH
For 10 ft. (3 m) gun. (#071 832)
For 15 ft. (4.6 m) gun. (#071 833)
A two-position slide switch fastens
to the gun handle and is used to
select the desired schedule. The
standard gun trigger operates the
power source contactor.
RDC-PS-1 REMOTE
DIGITAL CONTROL
(4041 758) For use with digital
feeders only. Presets background
voltage and peak amperage for use
with a single digital wire feeder or
one wire on a dual digital wire
feeder. Meter displays actual
condition while welding.
LOCKING COVER
(#094 692)
Secures control knobs.
DDSC-P1 DIGITAL DUAL
SCHEDULE CONTROL
(For use with digital feeders only.)
(#041 757) For use with digital
wire feeders to set a second
welding schedule. Two controls are
required to set two schedules on
each wire of a dual wire feeder. The
DDSC-PI must be used in
conjunction with either an RDC-PS-1
or RDC-PS-2. A DSS-8 or DSS-9
switch is required to operate this
control and must be ordered
separately.
Note: Cannot be used with Pulset control.
LOCKING COVER
(#094 693)
Secures control knobs.
RDC-PS-2 REMOTE CONTROL
(For use with digital feeders only.)
(#041 759) Provides the same
functions as RDC-PS-1. For dual
digital wire feeders.
LOCKING COVER
(#045 504)
Secures control knobs.
RPC-2A REMOTE
PENDANT CONTROL
(#041 798)
Adjusts background voltage and peak
amperage. Includes 20 fi. (6 m) cord
and plug. | |
POLARITY REVERSING/
ISOLATION CONTROL
(#041 894)
A dual function control designed for
use with dual wire feeders or any
application where electrical
isolation and/or polarity reversing
capabilities are required. For
example, one wire of a dual feeder
can be electrically cold while
welding with the other. The wires
can also be run on opposite or the
same polarity (straight and
reverse). Both functions can be
performed at the same time.
25 ft. (7.6 m) EXTENSION CABLE
(#047 813)
Connects to existing 10 ft. (3 m) 115
volt and contactor contro! cable.
Permits feeder to be located 35 ft.
(10.7 m) from the power source.
Note: Additional cable is necessary when
extending a feeder with an RDC-PS-1,
RDC-PS-2 or Pulset Control.
(#041 803) 25 ft. (7.6 m) cable.
No. 20 RUNNING GEAR
(#041 581)
Four 8 in. {203 mm) poly/rubber
blend wheels with 30 in. (762 mm)
towing handle. All running gear is
shipped unassembled.
No. 5CR CYLINDER RACK
(#041 584)
Use with No. 20 running gear.
8/89
OPTIONS AND ACCESSORIES
PULSET CONTROL
(#042 110)
DSC-PS DUAL SCHEDULE
CONTROL
(For use with Pulset control only.)
(#041 987) The Pulset Control is
designed to take the guess work
out of pulsed welding. It is used
with the Miller Pulstar 450 power
source and a Miller digital wire
feeder. Weld parameters {peak
amperage, background voltage,
and wire feed speed) for 2 popular
sizes of mild steel, stainless steel,
and aluminum wire have been
preprogrammed into the Pulset’s
memory system. Programs for
welding .035 and .045 stainless
steel and mild steel and .047
and .062 aluminum wire can be
selected with six position switch.
The arc can be fine tuned with an
arc power control and an arc length
control providing the optimum
welding condition.
if a different arc start condition is
required, a Start Power adjustment
and Start Time adjustment is
provided. A dual schedule control
which provides easy programming
and selection of two different weld
parameters on the same wire, is
available as an option.
For maximum flexibility the Pulset
conirols the power source in either
the pulsed or nonpulsed mode.
When operating in the nonpulsed
mode the unit controls output
voltage. Wire speed is adjusted with
the speed contro! on the wire feeder.
Systems already in the field which
have digital wire feeders, can easily
be fitted with the Pulset. |
equipment will meet the requirements of
Non-digital feeders are not
compatible and cannot be used.
The manufacturer makes no warranties,
express or implied, that welds made
using the synergic parameters of this
application.
8/89
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