Miller 100HVAP User manual

Miller 100HVAP User manual
February 1982
FORM: OM-129A
Effective With Serial No. JB563994
MODEL
100 HVAP
OWN E RS
MANUAL
hullER
MILLER ELECTRIC MFG. CO.
718 S. BOUNDS ST. P.O. Box 1079
APPLETON, WI
54912 USA
NWSA CODE NO. 4579
PRINTED IN U.S.A.
~,
LIMITED WARRANTY
EFFECTIVE: JUNE 1, 1979
This warranty supersedes all previous MILLER warranties and is ex
clusive with no other guarantees or warranties expressed or implied.
(
LIMITED WARRANTY-Subject to the terms and conditions
hereof, Miller Electric Mfg. Co. Appleton, Wisconsin warrants
to its Distributor/Dealer that all new and unused Equipment
furnished by Miller is free from detect in workmanship and
material as of the time and place of delivery by Miller. No warranty is made by Miller with respect to engines, trade accessories or other items manufactured by others. Such
engines, trade accessories and other items are sold subject to
the warranties of their respective manufacturers, if any
All
engines are warranted by their manufacturer for one year from
date of original purchase.
As
as
specified below, Millers
general policy only, Miller may honor claims
original user within the foregoing periods.
writing by Miller in appropriate cases, 131
repair or replacement at an authorized
Miller service station or 14) payment of or credit for the purchase
price Iless reasonable depreciation based upon actual usel upon
risk and expense. Upon receipt
return of the goods at Customers
or, where
authorized in
the reasonable cost of
components having
such as spot welder tips, relay and contactor points,
MILLERMATIC parts that come in contact with the welding
ANY IMPLIED WARRANTY,
wire
TION
to
not
including
nozzles and nozzle insulators where failure
result from defect
in
workmanship
or
?
of notice of apparent defect or failure, Miller shall instruct the claimant on the warranty claim procedures to be followed,
does not apply
normal useful life of less than one Ii)
warranty
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
year,
GUARANTY OR REPRESENTA-
PERFORMANCE, AND ANY REMEDY FOR
BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
doss
material.
Miller shall be
required to honor warranty claims on warEquipment in the event of failure resulting from a defect
within the following periods from the date of delivery of Equip.
ment to the original user:
?
TO
AS
k~
IMPLIED WARRANTY OF MERCHANTABILITY OR OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EOUIPMENT FURNISHED BY MILLER IS EX
ranted
~
(
of
matter
In the case of Millers breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedies
therefore shall be, at Millers option It) repair or 121 replacement
.
Except
a
submitted by the
ANY
CLUDED AND DISCLAIMED BY MILLER.
1.
2.
Arc welders, power sources and components
Original main power rectifiers
.
1 year
.
3 years
4.
All welding guns and feeder/guns
All other Millermatic Feeders
5.
Replacement
3.
6.
or
AS
EXCEPT
llabor- 1 year only)
90
ULTIMATE
days
Batteries
60 days
6months
.
WELDING
EQUIPMENT
AND
CONSUMER USE. MILLER
provided
that Miller isnotified in
writing
within
thirty 130) days
TO,
of the date of such failure.
.,~
AND
MILLERS
~.
~-
PROVIDED
BY
MILLER
IN
FOR
ARE
INTENDED
PRODUCTS
COMMERCIAL/INDUSTRIAL
BY
PURCHASE
USERS AND FOR OPERATION BY PERSONS TRAINED AND
MAINTENANCE
OF
AND
IN
THE
USE
EXPERIENCED
1 year
repair parts, exclusive of labor
EXPRESSLY
MILLER
WRITING,
~
...~
~
NO
RESELLER
NOT
FOR
CONSUMERS
OR
WARRANTIES DO NOT EXTEND
IS
AUTHORIZED
WARRANTIES TO, ANY CONSUMER.
TO
EXTEND
~
~
~
January 14, 1986
ERRATA SHEET
After this manual
appearing
was
printed, refinements
Dia.
Part
Replaced
No.
Mkgs.
No.
With
T2
038 680
036672
006913
15
23
Ti
equipment design occurred. This sheet lists exceptions
to data
later in this manual.
Item
7
in
FORM: OM-129A
**Replaceat Factory
or
Description
094 648 TERMINAL ASSEMBLY, primary
095780 TRANSFORMER, KVA2(Effw/JE818085)
**095 741 COIL,pri(Effw/JE818085)
Factory Authorized Service Station
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Quantity
TABLE OF CONTENTS
Page No.
Section No.
SAFETY RULES FOR.OPERATION OF ARC WELDING POWER SOURCE
SECTION 1
1
1
1
1
-
-
-
-
1
1.
Introduction
2.
General Precautions
1
3.
Arc
3
4.
Standards Booklet Index
SECTION 2
Welding
4
INTRODUCTION
2-1.
General
5
2
Receiving-Handling
Description
Safety
5
-
2.
2- 3.
2-4.
SECTION 3
3-1.
3
3
3
3
-
-
-
-
4
4
4
4
4
-
-
-
-
-
-
Location
5
2.
Electrical Input Connections
6
3.
Secondary Connections
Shielding Gas Valve Connections
7
4.
5.
Remote Contactor Control Connections
7
1.
Power Switch
5
-
-
7
2.
Amperage Adjustment Control
3. Amperage Range Indicator
4.
Start Current Control Switch
5.
Duty Cycle
6. VoltAmpere
1.
2.
Hydrogen Welding
Shutting Down
Fan Motor
Internal
Cleaning
6- 3. Lubricating
5.
7
8
8
8
MAINTENANCE
6- 2.
-
7
7
Curves
Atomic
6-1.
6
7
SEQUENCE OF OPERATION
SECTION 6
6- 4.
7
FUNCTION OF CONTROLS
SECTION 5
5
5
INSTALLATION
SECTION 4
4
5
10
10
10
Overload Protection
10
Power Factor Correction
10
SECTION 7
PARTS LIST
TROUBLESHOOTING
SECTION
1-1.
1-SAFETY RULES FOR OPERATION OF ARC
INTRODUCTION
WELDING
POWER SOURCE
Lead, cadium, zinc, mercury, and beryllium bearing and simi
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,
lar
We learn by experience. Learning safety through personal
experience like a child touching a hot stove is harmful, waste
ful, and unwise. Let the experience of others teach you.
both must be used.
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.
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
Work
in a confined space only while it is being ventilated
and, if necessary, while wearing an air-supplied respirator.
Gas leaks in
Read and understand these safe practices before attempting
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.
in
Failure to observe these safe practices may cause serious in
or death. When safety becomes a habit, the equipment
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 ultra
violet (radiant) energy of the arc can also decompose tn
chloroethylene and perchloroethylene vapors to form phos
gene. DO NOT WELD or cut where solvent vapors can be
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.
drawn into the
welding or cutting atmosphere or where the
radiant energy can penetrate to atmospheres containing even
minute amounts of trichlorethylene or perchlorethylene,
-
Reference standards: Published Standanis 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 Z49.1 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.
1-2.
A.
confined space should be avoided. Leaked gas
concentration danger
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.
jury
These safe practices are divided into two Sections: 1
General Precautions, common to arc welding and cutting; and
2- Arc Welding (and Cutting)(only).
a
large quantities can change oxygen
ously. Do not bring gas cylinders into a
to
can
air-supplied respirator.
C.
Fire and
Explosion Prevention
Causes of fire and
explosion are: combustibles reached by the
flame, flying sparks, hot slag or heated material; misuse
of compressed gases and cylinders; and short circuits.
arc,
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 fly 35 feet.
GENERAL PRECAUTIONS
To prevent fires and explosion:
Burn Prevention
Keep equipment clean and operable, free of oil,
(in electrical parts) of metallic particles that can
Wear
leather (or asbestos) gauntlet
protective clothing
gloves, hat, and high safety-toe shoes. Button shirt collar and
pocket flaps, and wear cuffless trousers to avoid entry of
sparks and slag.
grease, and
cause
short
circuits.
-
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.
If combustibles are in area, 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
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.
work
Walls
touching combustibles on opposite sides should not be
(or cut). Walls, ceilings, and floor near work
on
welded
Avoid oily
Hot
never
or
greasy
clothing.
A
spark
metal such as electrode stubs
be handled without gloves.
may
and
ignite
them.
workpieces
should
Medical first aid and eye treatment. First aid facilities and a
first aid person should be available for each shift
unless medical facilities are close by for immediate treatment
of flash burns of the eyes and skin burns.
qualified
Ear plugs should be worn when working on overhead or in a
confined space. A hard hat should be worn when others work
overhead.
Flammable hair preparations should
to weld or cut.
not
be used
by persons
intending
should be protected by heat-resistant
covers or
Fire watcher must be standing by
tinguishing equipment during and for
ing or cutting if:
with
some
shields.
suitable fire ex
time after weld
appreciable combustibles (including building construc
tion) are within 35 feet
b. appreciable combustibles are further than 35 feet but can
be ignited by sparks
c.
openings (concealed or visible) in floors or walls 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.
a.
Hot
work
ensure
permit should be obtained before operation to
supervisors approval that adequate precautions have
been taken.
B.
Toxic Fume Prevention
After work
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
with oxygen.
listed
1
in
Standards
index. NEVER ventilate
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 A6.O, listed 3 in Standards index.
OM-129 Page 1
thorough steam or caustic cleaning (or a
washing, depending on the combustibles
solubility) followed by purging and inerting with nitrogen or
carbon dioxide, and using protective equipment as recom
mended in AGO. Waterfilling just below working level may
substitute for inerting.
Stuck valve. Do NOT use a hammer or metal wrench to open
a cylinder valve that can not be opened by hand. Notify your
A container with
supplier.
This
includes:
solvent
a
water
or
unknown contents should be cleaned (see
paragraph above). Do NOT depend
to
determine if it is safe to weld
Hollow
or
or
can
castings
cutting. They
containers
on sense
of smell
or
cylinders.
sight
Mixing gases. Never try
or cut
be vented before
must
Protect cylinders particularly valves from bumps, falls, falling
objects, and weather. Replace caps securely when moving
welding
to mix any
3.
designed
to
use.
Use ferrules or clamps designed for the hose (not ordinary
or other substitute) as a binding to connect hoses to
fittings.
tubing splices.
overpressure; it is not intended to protect any
downstream equipment. Provide such protection with one or
fittings
to
relief devices.
Avoid long runs to prevent kinks and abuse. Suspend hose off
ground to keep it from being run over, stepped on, or other
wise damaged.
Never connect a regulator to a cylinder containing gas other
than that for which the regulator w~ designed.
Coil
Remove faulty regulator from service immediately for rej~air
(first close cylinder valve). The following symptoms indicate
slag, and
excess
hose to prevent kinks and
Protect hose
a
Use only standard brass
hose,
protect only the regula
from
more
exchanged.
wire
No copper
Regulators
relief valve is
or
Never use hose other than that designed for
gas. A general hose identification rule is: red for
fuel gas, green for oxygen, and black for inert gases.
splice
tor
be modified
specified
the
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-i, PRECAU
TIONS FOR SAFE HANDLING OF COMPRESSED GASES
IN CYLINDERS, listed 6 in Standards index,
Regulator
never
Hose
Prohibited
Compressed Gas Equipment
Pressure
cylinder.
cylinder.
Never refill any
Cylinder fittings should
1.
a
explode.
Explosive atmospheres. Never weld or cut where the air may
contain flammable dust, gas, or liquid vapors (such as gaso
line),
D.
gases in
Leaks if gas leaks externally.
Excessive Creep
if delivery pressure continues to rise with
downstream valve closed.
if gauge pointer does not move off stop pin
Faulty Gauge
when pressurized, nor returns to stop pin after pressure
release.
-
tions.
leaks.
sparks,
and by
damage by sharp edges,
open flame.
Examine
faulty regulator:
from
tangles.
hose
for leaks, wear, and loose connec
pressured hose in water; bubbles indicate
regularly
Immerse
-
-
Repair leaky
4.
Clean
2.
less cloth.
Cylinders must be handled carefully
damage to their walls, valves, or safety
to
prevent leaks and
that may
lead to
a
or
cutting
area
out
and
splicing
tape.
cylinder
valve
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-
regulator to cylinder. Before connecting, check that
regulator label and cylinder marking agree, and that the
regulator inlet and cylinder outlet match. NEVER CON
NECT a regulator designed for a particular gas or gases to a
cylinder containing any other gas.
Match
serious accident. (See
1-3C.)
ICC
use
the
devices:
Avoid electrical circuit contact with cylinders including third
rails, electrical wires, or welding circuits. They can produce
short circuit arcs
hose by
worn
Proper Connections
Repair. Do NOT attempt repair. Send faulty regulators for
repair to manufacturers
designated repair center, where
special techniques and tools are used by trained personnel.
Cylinders
or
(1-2D3). Do NOT
connections. When assembling threaded connections,
clean and smooth seats where necessary. Tighten. If connec
tion leaks, disassemble, clean, and retighten. For metal-tometal seating, use correct wrenches, available from your
Tighten
DOT marking must be on each cylinder. It is
of safety when the cylinder is properly handled.
an
assurance
supplier. For 0-ring connections, hand tighten.
Identifying
marked
tent.
on
gas content. Use only cylinders with name of gas
them; do not rely on color to identify gas con
Notify supplier
number,
and hazardous.
name,
or
if unmarked. NEVER DEFACE
other
markings
on
a
or
alter
cylinder. It is illegal
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.
Empties: Keep valves closed, replace caps securely; mark MT;
keep them separate from FULLS and return promptly.
Prohibited use, Never use a cylinder or its contents for other
than its intended use, NEVER as a support or roller.
Secure from falling. Chain or secure cylinders upright when
regulator (and hose) are connected to it.
Passageways and work areas. Keep cylinders clear
where they may be struck.
of
a
areas
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.
Transporting cylinders.
such
as
a
ground by
platform
or
their valves
With
a
crane,
use
a
secure
support
cradle. Do NOT lift cylinders off the
or
caps,
or
by chains, slings,
or
Do NOT expose cylinders to excessive heat, sparks, slag, and
etc. that may cause rupture. Do not allow contents to
exceed 130F.
Cool with water spray where such exposure
exists.
Page
2
opening clinder
valve, check that hoses
are
are
con
closed.
mag
nets.
flame,
Before
nected and that downstream valves
Stand to side of
regulator while opening cylinder
valve.
valve slowly so that regulator pressure in
slowly. When gauge is pressurized (gauge reaches regu
lator maximum) leave cylinder valve in following position:
For oxygen, and inert gases, open fully to seal stem against
Open cylinder
creases
possible leak. For fuel gas, open
permit quick emergency shutoff.
less
to
than
one
turn
3.
to
Protection of Nearby Personnel
welding area. For production welding, a separate
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
Enclosed
Use
charts
pressure
(available from
supplier) for safe
settings on regulators. It
your
or
room
and efficient, recommended pressure
will reduce backfiring and chance of flashbacks.
level.
Check
for leaks
first
pressurization and regularly there
after. Brush with soap solution (capful of Ivory Liquid
or
equivalent per gallon of water). Bubbles indicate leak. Clean
on
Viewing the weld. Provide face shields for
looking directly at the weld.
all
persons who
are
wearing flash
will be
off soapy water after test; dried soap is combustible.
Others
E.
Remove leaky or defective equipment from service immed
iately and repair them only if recommended in equipment
instruction manual. Send others for repair to manufacturers
designated repair center where special techniques and tools
are used by trained personnel. Refer to User Responsibilities
statement in equipment manual.
F.
B.
starting
to
are
weld, make
sure
that
screen
flaps
or
bay
closed.
Toxic Fume Prevention
Comply
with
precautions
in 1.28.
Generator engine exhaust
Carbon monoxide can kill.
must be
vented to the outside air.
and drain gas.
at source
C.
G.
in area. See that all persons
Before
doors
Leaving Equipment Unattended
Close gas supply
working
goggles.
User Responsibilities
Fire and
Explosion
Prevention
Rope Staging-Support
Comply with precautions in 1-2C.
Rope staging-support should not
ting operation; rope may burn.
1-3.
be used for
welding
or Cut
Equipments
equipment.
ARC WELDING
Loose cable connections may
to
D.
Burn Protection
E.
with
precautions
in 1.2.
The welding arc is intense and visibly bright. Its radiation can
damage eyes, penetrate lightweight clothing, reflect from
light-colored surfaces, and burn the skin and eyes. Skin burns
resemble acute sunburn, those from gas-shielded arcs are
GET BURNED; COMPLY
more severe and painful. DONT
WITH PRECAUTIONS.
1.
Protective
Clothing
Wear long-sleeve clothing (particularly for gas.shielded arc) in
addition to gloves, hat, and shoes (1-2A). As necessary, use
additional protective clothing such as leather 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
vent entry of sparks.
2.
to
pre
Eye and Head Protection
Protect eyes from exposure
tric arc without protection.
Welding
or
pockets
helmet
or
to arc.
containing
shield
denser must be used when
striking
NEVER look
a
filter
at an
plate shade
welding. Place
over
elec.
no.
9
face before
arc.
Protect filter plate with
a
clear
broken helmet
Cracked
or
radiation
can
pass
through
or
cover
plate.
shield should
MEDIATELY.
or
or
a
such
flash and
cause a
a
an
brittle
arc
on
area
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 div. 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
reduces
or grounded metal
and an electrically HOT part
the body surface electrical resistance, enabling dangerous and
possibly lethal currents to flow through the body.
-
1.
-
Grounding the Equipment
instafling, 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.
When
Three-phase connection. Check phase requirement of equip
ment before installing. If only 3-phase power is available,
connect single-phase equipment to only two wires of the
3-phase line. Do NOT connect the equipment ground lead to
the third (live) wire, or the equipment will become electri
a dangerous condition that can shock, possibly
cally HOT
fatally.
-
NOT be worn;
to cause burns.
Before
tors
Cracked, broken,
or
a cylinder or other pressure vessel, It
that can cause a violent rupture or lead
rupture later under rough handling.
Never strike
creates
operator avoids unnecessary risks and protects himself and
others from accidents. Precautions are described here and in
standai~s referenced in index.
Comply
overheat
fire.
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 at 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
A.
welding
rated capacity. Do not overload arc
It may overheat cable5 and cause a fire.
loose filter plates must be replaced IM
cover plate when broken, pitted,
welding, check ground for continuity. Be sure conduc
touching bare metal of equipment frames at connec
are
ti ons.
Replace clear
spattered.
line cord with a ground lead is provided with the equip
for connection to aswitchbox, 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 prorig only. If the line cord
If
a
ment
Flash 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-shielded arc) can cause a retinal burn that
may leave
a
permanent dark
area
Trademark of Proctor & Gamble.
in the field of vision.
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.
comes
OM-129 Page 3
2.
Do not open power circuit or change polarity while welding.
If, in an emergency, it must be disconnected, guard against
Electrode Holders
Fully insulated electrode holders should
holders with protruding screws.
be used.
shock burns,
Do NOT
or
flash from switch
arcing.
use
3.
Leaving equipment unattended. Always
equipment.
Connectors
Fully insulated lock-type
welding cable lengths.
4.
shut OFF
and dis
connect all power to
connectors
should be used to
Power disconnect switch
join
power
1-4.
Cables
Frequently
inspect cables for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn or
lethal shock from
damaged insulation to avoid possibly
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.
must
be available
near
the
welding
Source.
STANDARDS BOOKLET INDEX
For more information, refer to the following standards
their latest revisions and comply as applicable:
or
-
5.
Terminals
1.
ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING obtainable from the American Welding
Society. 2501 NW 7th St., Miami, Fla. 33125.
2.
ANSI
3.
American Welding Society Standard A6.0, WELDING
CUTTING CONTAINERS WHICH HAVE HELD
COMBUSTIBLES, obtainable same as item 1.
Terminals and other exposed parts of electrical units should
have insulating covers secured before operation.
6.
Electrode Wire
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.
AND
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
as
not
or
devices such
be disconnected
4
NFPA Standard
FOR WELDING
National Fire
51. OXYGEN-FUEL GAS SYSTEMS
AND CUTTING, obtainable from the
Protection Association, 470 Atlantic
Avenue, Boston, Mass. 02210.
Safety Devices
interlocks and Circuit breakers should
shunted out.
Before installation, inspection, or service, of equipment, shut
OFF all power and remove line fuses br lock or red-tm
switches) to prevent accidental turning ON of power. Discon
nect all cables from welding power source, and pull all 115
volts line-cord plum.
Page
4.
5.
NFPA Standard 51B, CUTTING AND WELDING PRO
CESSES, obtainable same as item 4.
6.
CGA Pamphlet P-i. SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS, obtainable 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.
3-3.
SECONDARY CONNECTIONS
3-4.
SHIELDING GAS VALVE CONNECTIONS
Atomic Hydrogen Welding is a process wherein an arc is
maintained in an atmosphere of shielding hydrogen. An auto
matic GAS valve has been provided on this welding power
on and off flow of gas to the electrode
source to control
The
secondary connections on this welding power source
welding output terminals located behind the
hinged access door on the lower portion of the front panel.
Consist of three
holder.
The center terminal is labeled WORK. The high voltage termi
nal, labeled 300 O.C.V. is to the left of center. The low
The automatic GAS valve is located behind the
voltage terminal, labeled 250 O.C.V. is
to
door
Atomic
holders
Hydrogen Welding
electrode
the
right
of center.
are
In
two
the
tained
access
the
ing.
equipped
Connect either one of these leads to the
center terminal, labeled WORK and the other lead to either
the 250 O.C.V. terminal or the 300 O.C.V. terminal de
pending on the requirements of the welding application.
with
hinged
lower portion of the front panel. The valves
input and output connections both have right hand thread
on
leads.
Atomic Hydrogen Welding process the arc
independent of the work piece and therefore
is main
Be
the hose from the gas supply is attached to the con
IN. The gas hose from the electrode holder
sure
nection labeled
must be
3-5.
it is not
to attach a lead to the work piece which would
make the work piece part of the welding arc circuit.
attached to the connection labeled OUT.
REMOTE
TIONS
CONTACTOR
CONTROL
CONNEC
necessary
strip (iT) is provided on this welding
as a junction point for connecting a
remote contactor control device
(optional) to the internal
contactor circuitry. These devices usually consist of a twobutton control which provides ON or START and OFF or
STOP functions for starting and breaking the arc.
A five pole terminal
power source to be used
CAUTION
Ukeep
the secondary terminals access door closed
whenever the welding power source is energized. There
are 300 volts of open-circuit voltage present across
these terminals when welding and a hazard exists if the
terminals are left exposed.
U
The five pole terminal strip (iT) is located behind the
door an the lower portion of the front panel.
hinged
access
Connect the ON or START button leads to terminals No. 1
and 5, and the OFF or STOP button leads to terminals No. 2
and 3.
SECTION 4- FUNCTION
OF
CONTROLS
Amperage Adjustment Control
NOTE
Start Current Control Switch
Because this welding power source is of the moving
primary coil design the amperage can be adjusted
while welding.
4-3.
AMPERAGE RANGE INDICATOR
(Figure 4-1)
Amperage Range
An amperage range indicator is provided on the front panel in
order to register the amperage selected. The indicator changes
readings to coincide with the rotation of the amperage adjust
ment control.
Two amperage ranges are listed on the scale printed on the
nameplate, one on either side of the indicator. If the welding
power source is being operated in the 250 O.C.V. range,
amperage is read on the right hand scale which is numbered
from 17 to 110 amperes. If the welding power source is being
Switch
TB-006 716
operated in the 300 O.C.V. range, amperage is read
~igure
4-1.
4-1. Control Location
POWER SWITCH
(Figure 4-1)
4-4.
Placing
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
START CURRENT CONTROL SWITCH
(Figure 4-1)
start current control switch, located in the upper left
hand corner of the front panel, is a 10-position selector
switch. This switch controls the start circuit of the welding
welding
power
current
source
for
arc
by providing increasingly larger
amounts
of
initiation.
If the start circuit is
CAUTION
not
needed, place the
start current con
trol switch in the first (No. 1) position. This position removes
the ac current reactor and transformer winding from the start
I~ven though
the power switch is in the OFF position
welding power source is apparently shut
down, electrical input power is still present on all cir
cuitry 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 the electrical input
circuit.
the
IMPORTANT
When using 3/32
tungsten electrodes the
numbered positions (between No. 1 and No. 5)
start current control switch should be used.
circuit fuses.
may disintegrate the tungsten
higher settings are provided for use
settings
4-2.
the
The
power source down.
and
on
left hand scale which is numbered from 14 to 90 amperes.
AMPERAGE ADJUSTMENT CONTROL
(Figure 4-1)
lower
on
the
Higher
electrodes. The
with larger size
tungsten electrodes.
The amperage
adjustment control on the top of the welding
provides the operator with the capability of
selecting the exact desired amperage setting within the entire
range of the unit. Rotating the amperage adjustment control
power
in
source
counterclockwise direction, will increase the amperage,
clockwise rotation will decrease the amperage.
a
4-5.
DUTY CYCLE
The duty cycle of a welding power source is the percentage
of a ten minute period that the welding power source can
safely be operated
at a
given
current
setting. This dual-range
OM-129 Page 7
welding
power source is rated at 100% duty cycle at 100
amperes in the 250 O.C.V, range, and 100% duty cycle at 85
300
amperes in the 300
O.C.V. range. The welding power source
safely operated up to these limits in those ranges
continuously. If the welding current is increased, the duty
cycle will decrease.
be
can
250
200
IM POP TA NT
in
I
0
Operating
capability
this
welding
power
beyond its rated
source
>
U
150
V
may cause the transformer to overheat. The
transformer is protected by a thermostat which will
shut down the welding power
transformer cools
open and
1the
4-6.
source
4
until
100
50
(Figure 4-2)
VOLT-AMPERE CURVES
The
volt-ampere curves show the output voltage available at
given output current within the limits of the current
adjustment control setting. Load voltage is predetermined to
a
large degree by arc characteristics. With the use of the
volt-ampere curves, it is possible to determine the amperage
required for a specific load voltage.
any
SECTION 5
-
Figure
3.
4.
The
protective
covering
Prior to welding, it is imperative that proper protective
clothing (welding coat and gloves) and eye protection
(glasses and welding helmet) be put on. Failure to
comply may result in serious and/or permanent bodily
power
Close the internal contactor circuit by depressing the
START button on the remote contactor control
7.
door over the
be kept closed whenever the
access
device. Hold
stabilized.
output terminals must
unit is energized.
Replace power cables immediately if chafed or in
sulation is damaged. Use voltage rated cable only.
Never, under any circumstances operate the weld
ing power source with any portion of the outer
enclosure removed. In addition to being a hazard,
8.
enclosure removed.
ATOMIC HYDROGEN WELDING
Connect
source as
2.
the
electrode
holder to the welding power
described in Section 3-3.
welding
When
4.
Page
8
well defined
Commence
arc
welding.
SHUTTING DOWN
1.
Break the
arc
mote contactor
by depressing the STOP button
Place the power switch in the OFF position.
4.
Turn off the
Rotate the amperage adjustment control
Turn the power switch ON.
I
desired
shielding
source
to
gas.
CAUTION__-~
the desired
to the
the
confined~failureto
welding is performed in a
off the shielding gas supply could result in a
build-up of gas fumes, thereby endangering personnel
reentering the welding area.
If
turn
re
idle for 3 minutes
3.
in
on
control device.
Efficient operation of this welding power source
requires the use of a remote contactor control device
to initiate and/or break the arc, Connect this device to
the welding power source as described in Section 3-5.
setting.
6.
is stabilized, release the START button.
Allow the welding power
with no load applied.
switch
is
to the lowest point possible when
is obtained but not so low that small
beads begin to form on the electrodes.
position.
5.
arc
2.
the start current control
arc
-
power
Place
the
Adjust the gas flow
11.
source as
3.
until
the arc by bringing the twin tungsten elec
together momentarily in a touch start by ma
nipulation of the electrode holder trigger. If the elec
trodes freeze together, depress the STOP button and
gently force the electrodes apart, then proceed as
10.
(AHW)(Figure 5-1)
the
depressed
Initiate
9.
I
Connect the gas supply lines to
described in Section 3-4.
button
before.
5-2.
1.
the
trodes
a
5-1.
Volt-Ampere Curves
i_damage.
improper cooling may result in damage to the
welding transformer and the welding power source
components. Warranty is void if the welding power
source is operated with any portion of the Outer
I
4-2.
&tIIl.1~IJ
I
source.
2.
125
SEQUENCE OF OPERATION
ac
Securely ground the chassis of the welding
100
AMPERES
9-006 767
of open-circuit voltage. The welding power
to be used solely for
source is specifically designed
processes requiring high operating voltages. Read the
operating instructions carefully before operating and
observe the following precautions:
1.
75
50
A C
~weldingpo!rsourced&iversapproximately300
volts
25
0
SECTION 2- INTRODUCTION
Rated Welding
Current Amperes
Welding
Max.
Current
Open-
Amperes Input At Rated
Load Output
Ranges
Circuit
60 Hz.
Amperes
Voltage
230 Volts I 460
100@.
14-90
250
70 Volts
17-110
300
100%
Duty Cycle
Weight
Single-Phase
I
~
Voltsj
37
Net
Dimensions
kw
kva
17.0
10.5
Width
Depth
I Ship
5101550
Height-47-1/2
~22-1/4
29-1/8
lbs.
lbs.
.
Figure 2-1. Specifications
2-1.
GENERAL
This manual has been prepared especially for use in familiar
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.
2-2.
RECEIVING-HANDLING
The
following
definitions
apply
CAUTION, IMPORTANT,
to
and NOTE blocks found throughout this manual:
CAUTION
I
....
Under this heading, installation, ope rating, and main
procedures or practices will be found that if
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 lading
and freight bill will be furnished by the carrier on request if
tenance
not
carefully followed may
create
a
hazard to per
sonnel.
occasion to file claim arises.
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.
IL
.
heading, installation, operating, and main
tenance procedures or practices will be found that if
not carefully followed may result in damage to equip
Under
DESCRIPTION
this
mefit.
single-phase welding power source which pro
high voltage ac welding current. This welding power
is designed specifically for the Atomic Hydrogen
source
Welding (AHW) process.
This unit is
a
duces
2-4.
m
SAFETY
Under this heading, explanatory statements will be
found that need special emphasis to obtain the most
efficient operation of the equipment.
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.
SECTION 3
-
INSTALLATION
A
proper installation site should be selected for the welding
source if the unit is to provide dependable service, and
remain relatively maintenance free.
power
I
This welding power
excess of 80 volts
has open-circuit voltages in
and is to be used only where
special precautions have been taken to protect the
operator from contact with the high open-circuit
voltage. THIS POWER SOURCE MUST NOT BE
source
I
ac
USEDFORSTANDARDMANUALWELDING
3-1.
LOCATION
7/1 6
(Figure 3-1~
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.
ova r the in ta ke air
place any
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
Dia.
4 Holes
ranty is void if any type of
1-1/8
*47.1/2
lnciuding Amperage Adjustment Control
Hole Layout
device is used
Holes are provided in the welding power source base
mounting purposes. Figure 3-1 gives overall dimensions
the base mounting hole layout.
~
Figure 3-1. Overall Dimensions And Base
filtering
for
and
TB006 716
Mounting
On
most
for
moving
lifting
extend
welding
power sources
the unit. However, if
the unit, be
sure
a
a
lifting
device is
provided
fork lift vehicle is used for
that the lift forks
are
long enough
to
completely under the base.
OM-129 Page 5
Connect the two input conductors to the terminals on the
primary terminal board line and connect the ground conduc
tor to the ground terminal. (Refer to the input voltage label
for identification of these terminals. See Figure 3-2 for loca
IMPORTANT
The
of lift forks too short
use
extend Out of the
internal- com
to
opposite side of the base will expose
ponents to damage should the tips of
remaining end of the ground conduc
to a proper ground. Use whatever
grounding method that is acceptable to the local electrical
inspection authority.
tion of this label.) The
tor
lift forks
the
penetrate the bottom of the unit.
should
be connected
~
ELECTRICAL INPUT CONNECTIONS
3-2.
I
NOTE
The
It
that
recommended
is
in
installed
the
This
source.
line disconnect
a
circuit
input
provide
would
the
to
welding
safe
a
switch
and
be
terminal
convenient
connect
any
one
a
is
1
for
of the line terminals
electrically
an
connected
energized
this will
as
welding
power
chassis.
source
to completely remove all electrical power from
welding power source whenever it is necessary to
perform any internal function on the unit.
and
not
to
in
result
power
is
chassis
source
only. Do
1
the welding
to
grounding purposes
conductor from the ground
terminal
ground
power
means
the
.
CAUTION
I
Before
welding
dures
a
padlocked
made from
con~ons
fuse box,
a
the fuses from the box
remove
position. If lock
a red tag to the
in the closed
cover
available, attach
line disconnect switch (or fuse box)
that the Circuit lt being worked on.
ing facilities
A.
the
to
line disconnect switch, the switch should
in the open position. If the connection is
padlock the
and
input
lockout proce
machinery
power source,
should be employed. If the connection is to be
made from
be
electrical
making
are
not
to
warn
others
Electrical Input 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 electrical input
voltages shown on the welding power source nameplate. Con
sult the local electric utility if there is any question about the
type of electrical system available at the installation site or
proper connections to the
how
welding
power
source
are
AB-901 379-6A
Figure
C.
be made.
B.
connect
input
the
conducto~he
single-
power Supply until all electrical input connec
tions have been made to the welding power source
phase
The
input conductors should
material
3-1
is
covered with
be
an
insulating
conforms to local electrical standards. Table
only as a guide for selecting the proper size
which
provided
input conductors and fuses.
Table 3-1.
Input Conductor and Fuse Sizes
Conductor Size
-
230V
460V
575V
No.4
No.4
No.8
No.10
Insert
the
through
two
the
208V
230V
460V
1
575V1
125
110
60
NOTE
50
I
No. 8
-
input conductors plus
access
hole
accept standard conduit
tion and size.
Power Source To The Avail
Fuse Size In Amperes
AWG
208V
Ground Wire
Welding
this welding power source may be operated are stated on the
welding power source nameplate and on the input voltage
label. See Figure 3-2 for location of this label. The input
voltage jumper links on this welding power source are posi
tioned for the highest of the voltages stated on the name
plate. If the welding power source is to be operated from a
line voltage which is lower than the highest voltage for which
the unit was designed, the jumper links will have to be moved
to the proper position before operation of the welding power
source commences. Figure 3-3 shows the various positions for
which the jumper links may be set on the standard welding
power source. If the input voltages on the welding power
source nameplate differ from those shown in Figure 3-3, the
input voltage jumper links must be positioned as shown on
the input voltage label.
CAUTION
not
The
Input Voltage
The input voltage jumper links provided on the primary ter
minal board permit the welding power source to be operated
from various line voltages. The various voltages from which
Input Conductor Connections
Do
Matching
able
to
3-2. Input Conductor Connections
on
the
rear
ground conductor
panel. The hole will
one
fittings. See Figure 3-2 for hole loca
i
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
to be used. This will prevent losing the jumper links
which
are
required for
not
this connection
230 VOLTS
460 VOLTS
NOTE
I
It
is
recommended
that
a
terminal
lug of adequate
I
capacity be attached to the ends of the in
ground conductors. The hole diameter in the
lug must be of proper size to accommodate
the line and ground terminal studs on the primary
0
OR
amperage
put and
terminal
terminal board.
Page 6
'
1.1
c
~HGoR~
o~
L2
TA-012 314
J
Figure 3-3. Input Voltage Jumper
Link
Arrangement
POWER SWITCH
CR1
ON
S1
FAN MOTOR ON
CLOSES
START SWITCH HELD CLOSED
W2
CLOSES
PRIMARY CONTACTOR
+
W1
CLOSES
I
GAS VALVE OPENS
CR1
I
DROPS OUT
.L
START CURRENT AVAILABLE
TOUCH START ELECTRODES
I
ARC INITIATED
CR1
CLOSES
HOLDS IN CONTACTOR
THROUGH CONTACTOR
W2
W1
INTERLOCK
START SWITCH RELEASED
OPENS
START CIRCUIT OPEN
INTENTIONAL ARC OUTAGE
WELDING ARC
I
STOP SWITCH OPENEb
CONTACTOR OPENS
CR1
CLOSES
GAS VALVE CLOSES
ZERO OCV
UNINTENTIONAL ARC OUTAGE
WELDING ARC OUTAGE
I
CR1 DROPS
OUT
*
CONTACTOR DROPS OUT
GAS
ZERO OCV
Figure
5-1.
Arc
CRi
CLOSES
A-006 996
F~owage Chart
OM-129 Page 9
SECTION 6- MAINTENANCE
service. A light coat of lubricant should be evenly distributed
on the shaft and coil slides. A high temperature grease such as
Socony BRB or equivalent is recommended.
U
or main disconnect switch is
input circuit fuses are removed
before attempting any inspection or work on the
inside of the welding power source
Be
sure
open
i
6-1.
the branch circuit
6-4.
electrical
or
FAN MOTOR
thermostat
located
models
are
6-5.
INTERNAL CLEANING
POWER FACTOR CORRECTION
Power factor correction capacitators are built into the weld
ing power source. These capacitators require no maintenance
tf a capacitator should fail it can readily be
or attention.
recognized by a bulging case and/or oil spillage.
Occasional blowing out or vacuuming of the dust and dirt
from around the internal components is recommended. This
should be done periodically 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 (or
used for this cleaning operation.
the
on
overloading
welding power source has been overloaded to the point of
overheating, allow the fan to continue operating to aid in
cooling.
equipped with an exhaust fan and rely on
forced draft for adequate cooling. The fan motor is manu
factured with lifetime lubricated sealed ball bearings and no
attention should be required.
NOTE
suction) should be
vacuum
The
6-3.
is
side of the control trans
will actuate the thermostat
and temporarily open the contactor. It may take as long as
20 to 30 minutes for the transformer to cool. When the
A
former coil. Excessive
All
6-2.
OVERLOAD PROTECTION
LUBRICATING
factor
power
correcting capacitors supplied
in
The dielectric material
this product contain no PCBs.
is an OSHA Class Ill B fluid having a flash point of
440F.
(227C). Each individual capacitor is pro
Occasional lubrication of the threaded shaft on the amperage
adjustment control and the moving coil slides is essential,
especially when the welding power source is in continuous
by an internal UL recognized pressure Sensitive
disconnect and an internal fuse.
tected
SECTION 7- TROUBLESHOOTING
The data collected
here, discusses
some
of the
common
problems which
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
equipment malfunction, the manufacturers recommendations should be strictly adhered to and followed.
If after
performing the following procedures the trouble is still
It is recommended that the circuit
source
remedied, it is recommended that
a
serviceperson
of
be called.
diagram be used for reference during troubleshooting.
REMEDY
PROBABLE CAUSE
TROUBLE
Welding power
inoperative.
not
cases
completely
Welding output terminated, fan
continues running,
Open
line fuse(s).
Replace line fuse(s), if
Defective power switch (Si).
Check
Voltage links on primary connections
board connected incorrectly, or missing.
Refer to Section 3-2C
Transformer (T2) overheated
thermostat (TP) to open.
causing
Fan inoperative but weld output
Defective fan
motor
replace defective
or to
switch (Si).
power
the input
voltage label.
Allow unit time to cool. Do not exceed
source
Electrode cables shorted.
and
for
open.
welding
power
rating.
Check electrode cables.
(FM).
Check for and replace defective fan motor (FM).
normal.
Shorted
or open
fan motor (FM) leads.
Check
for
and
shorted
correct
or
open
fan
motor
(FM) leads.
Arc will
not
stabilize after being
Propeller obstructions.
Free propeller from obstructions.
Open control fuse (Fl).
Check for and replace open control fuse (Fl).
initiated.
Limited welding output, low
open-circuit voltage, and/or the
fan operates with reduced speed,
links
Voltage
board
on
of
Contactor
high,
low
a
opens
at
too
the
Refer to Section 3.2C
the
input voltage label.
S
Check the
voltage.
incoming
Slider
on
voltage.
resistor (R 1) is improperly
power line for correct
voltage.
Check the electrode holder connections.
Check
the
flow-setting,
or
or
incorrect
Insufficient shielding gas.
,
Page 10
the
Loose electrode connections.
welding output.
Excessive oxidizing
tungsten electrodes,
too
for
voltage.
Low primary line
Erratic
primary connections
connected
set.
shielding
supply,
gas
connections,
and lines.
If contactor opens at too
high
a
voltage
move
slider to
the left to reduce resistance. If contactor opens at too
low a voltage move slider to the right to increase the
resistance.
SEE
INSTRUCTION BOOK
PROPER
FOR
PRIMARY CONNECTIONS
TORCH COMMON
TORCH
250 VOLTS
TORCH
300 VOLTS
12345
0
lFM~EIU
I
START
:~
RW-4
(OPT ONA L- EXTRA)
Circuit
Diagram No. A084
612
Figure 7-1. Circuit Diagram
OM-129 Page 11
C.)
/
C,,
I
F..)
_
o
_
C.)
-4 _
~
_.~fL
~
!1
~
~77I1
F..) F..)
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a
a
a
CO
0
Item
Dia.
Part
No.
Mkgs.
No.
Figure
A
Complete Assembly
022010
2
Quantity
Description
Si
3
011 789
LINK,jumper-priswitch
024611
SHAFT,control
SEAL, rubber shaft
COLLAR, locking 3/4-6
BALL, 7/16
BEARING, ball
HANDLE, control shaft
BEARING, nylon
MOTOR, fan 230 volts (60 Hz) (consisting of) or
BEARING, ball
MOTOR, fan 1/4 hp 230 volts (50 Hz)
BLADE, fan 60 Hz 14 inch 3 wing 19 deg or
BLADE,fan50 Hzl4inch5wing3odeg
1
024604
024 605
019 611
024 606
5
FM
032 603
5
FM
024 601
032 605
032 604
605 799
014605
7
1
amp
2
024 603
6
1
007 600
604 439
4
PANEL,front
SWITCH, toggIe3PST6O
1
-
1
1
1
1
-
.
1
1
PANEL, rear
TERMINAL, primary (consisting of)
BLOCK, terminal 30 amp 3 pole
LINK, jumper terminal block
LINK, jumper primary panel
STUD, brass 1/4-20 x 1-3/4 w/hex collar
NUT, brass hex jam 1/4-20
STUD, brass 3/8-16 x 2-1/8
NUT, brass hex jam 3/8-16
WASHER, Iock-spIit3/8
.WASHER,flat-3/8
038 680
038 602
038 620
038 652
038 889
601 836
038 891
601 838
602 207
602243
026754 .INSULATION
010915 .WASHER,flat-brassl/4IDx5/8OD
602 051
SCREW, machine brass round hd 1/4-20 x 1-1/4
TERMINAL BOARD
038 685
059 416 CAPACITOR, paper oil 35 uf 460 volts ac
032 320 BASE
039 047 TERMINAL, power output red (consisting of)
601 976
SCREW, cap- hex hd 1/2-13 x 1-1/2
TERMINAL BOARD
039 049
039044 .BUSBAR
601 880
NUT, hex jam 1/2-13
601 879 .NUT,hexfulll/2-13
012 604 HOLDER, fuse cartridge 30 amp 250 volts
*012 607 FUSE, cartridge 10 amp 250 volts
012 657 THERMOSTAT, NO
.
-
.
-
.
3
.
8
2
-
.
.
6
-
.
1
.
3
4
4
-
.
.
8
Cl
9
10
4
1
3
-
1
.
1
.
1
1
.
11
ii
Fl
12
13
TP
102173
014 601
14
Z
15
12
16
S2
17
1
1
-
CR2,W
1
WINDTUNNEL(5OHz)or
WINDTUNNEL, 14 inch (60 Hz)
1
036 671 REACTOR
036 672 TRANSFORMER, kva2 115-230-250
011 632 SWITCH, rotary 10 position 50 amp 300 volts
1
019 609
035 049
1
4
034 909
034910
*034 911
GS1
003 538
GS1
+000 539
080 841
+080 872
010 296
1
KNOB. oointer
LINK, connector contactor
CONTACTOR, 4P 115/230 volts ac (consisting of)
.COIL,115/230voltsac
KIT, points contactor
VALVE, 2 way 1/4 IPS port 1/8 orifice (consisting of)
COIL, ll5voltsac(ControlsCo)
VALVE, 2 way 1/4 IPS port 1/8 orifice (consisting of)
COIL, 115 voltsac(Eemco)
FITTING, hose brass elbow male 1/4 NPT x 5/8-18
-
2
1
4
-
.
or
1
.
1
.
1
-
1
2
OM-129 Page 13
Item
No.
Figure
18
Dia.
Part
Mkgs.
No.
035 914
1
046 140
2
1
19
Ri
RECTIFIER, integrated 30 amp400 volts
CAPACITOR, ceramic 0.05 uf 500 volts
030 617 RESISTOR,WWadj25watt2000 ohm
20
R2
604 178
2T
038 621
038 622
034623
**033 736
**006 913
014711
C2,3
1T
21
CR1
22
Ti
23
Ti
tOi8 457
047 497
015 103
012 591
015531
010 876
RESISTOR, carbon2watt 100 ohm
BLOCK, terminal 30 amp 4 pole
BLOCK, terminal 30 amp 5 pole
RELAY,llOvoltsdcDPDT
COIL, secondary
COIL, primary
PANEL,side
COVER, top
LABEL, general precautionary
DOOR, access front lower
ROD, indicator-amperage
-
HOOK,lift
1
1
1
1
1
2
1
1
1
1
2
HANGER, minerallic No. 1
NAMEPLATE (order
by model
and serial number)
*Recommended Spare Parts.
**Replace at Factory or Factory Authorized Service Station.
+ When ordering coils be sure to provide manufacturers name.
tWhen ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 14
Quantity
Complete Assembly (Contd.)
A
SRi
Description
1
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