Miller 100HVAP User manual

Miller 100HVAP User manual
June 1976
FORM: OM-129
Effective With Serial No. HG057040
MODEL
STOCK NO.
1 OOHVAP
900 237
>~
MODEL/STOCK NO.
SERIAL/STYLE NO.
OWNERS
DATE PURCHASED
MANUAL
MILLER ELECTRIC MFG. CO.
APPLETON, WISCONSIN, USA 54911
ADDITIONAL COPY
PRICE 55 CENTS
NWSA CODE NO. 4579
I
LIMITED WARRANTY
MILLER Electric
Mfg. Co., Appleton, Wisconsin, warrants all new equipment to be free from defects in
material and factory workmanship for the periods indicated below, provided the equipment is installed and
operated according to manufacturers instructions.
c
C
~
MILLER Electric
Co.s obligation, under this warranty, is expressly limited to replacing or repairing
correcting any manufacturing defect without charge during the warranty period if
MILLERS
inspection confirms the existence of such defects. MILLERS option of repair or replacement
will be f.o.b. factory at Appleton, Wisconsin or f.o.b. a MILLER authorized service facility, and therefore
no compensation for transportation costs of any kind will be allowed.
Mfg.
any defective part
C
c
~
or
CI
CI
The warranty
a
i
period, beginning
on
the date of sale to the
original purchaser-user
of the
equipment, will be
as
follows:
Arc welders, power sources, and components
Original
3.
20E, 20K,
I
1.
2.
Engine
and all
1 year
3 years
main power rectifiers
4.
All other Millermatic Feeders
1 year
5.
All engines
1 year
Warranties
are
(unconditionally)
90 days
welding guns.
engine manufacturers, subject to their procedures and to be handled
will be made in respect to trade
or agencies. No warranty
warranties of their respective manufacturers.
covered by the
their authorized local Service Stations
through
accessories, such being subject
MILLER Electric
directly
or
Mfg.
indirectly
to the
Co. will
from the
not
use
of
be liable for any loss
or
consequential damage
or
expense
accruing
equipment covered in this warranty.
-
I
c
This warranty supersedes
I
warranties expressed
or
all previous MILLER warranties and is exclusive with
implied.
no
other guarantees
or
c
ERRATA SHEET
After this manual
was
printed, refinements
in
equipment design occurred. This
sheet lists
exceptions
to
data
~pearing later
in
this manual.
AMENDMENT TO SECTION 2
Amend
Figure
Add the
2-1.
-
INTRODUCTION
:~
Specifications
following NOTE
LL
block:
1~ The power factor correcting capacitors supplied in this product contain no PCBs.
The dielectric material is
OSHA C/ass Ill B fluid having a flash point of 440F. (227C). Each individual capacitor/s protected by an internal
i~iii
an
(JL
recognized pressure sensitive
AMENDMENT TO SECTION 7
Amend
Figure
7-1. Circuit
disconnect and
-
an
internal fuse.
TROUBLESHOOTING
Diagram
SEE
NSTRUCTION BOOK
ROPER
~OR
PRIMARY CONNECTIONS
23d5
~~-1 E~~I -Ii
START
I
I
PwS-45
(OPTIONAL-EXTRA)
Figure
Item Or
Dia.
Page No.
Mkgs.
8
Cl
7-1. Circuit
Part
No.
031 609
102 173
13
13
18
SRi
037 568
23
Ti
033 735
015966
Pg 3
C2,3
Diagram
Circuit Diagram No. A-084 612
For Models Effective With Serial No. JB563994
Replaced
With
Description
059 416
CAPACITOR, paper-oil 35 uf 460 volts
102 173 WINDTUNNEL (50 Hz)
014 601 WINDTUNNEL. 14 inch (60 Hz)
035 914 RECTIFIER, integrated 30 amp 400 volts (Eff W/JB563994)
**See Note COIL, primary
018457
046 140
COVER, top
CAPACITOR, ceramic 0.05 uf 500 volts dc(Eff W/JB563994)
Quantity
1
1
1
1
1
1
2
NOTE: When ordering this item be sure to provide the primary voltages of the unit.
**Replace at Factory or Factory Authorized Service Station.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
10/16 /8 1
OM-129
Page
A
TABLE OF CONTENTS
Section No.
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
SECTION 1
1
1
1
1
-
.
-
-
1.
No.
Page
Introduction
1
2. General Precautions
1
3.
Arc
3
4.
Standards Booklet Index
Welding
4
INTRODUCTION
SECTION 2
2-1.
General
5
2
Receiving-Handling
5
2
-
2.
3.
5
Description
2-4. Safety
-
SECTION 3
5
INSTALLATION
3-1.
Location
5
3
2.
Electrical Input Connections
6
3.
Secondary Connections
Shielding Gas Valve Connections
7
4.
5.
Remote Contactor Control Connections
7
3
3
3
-
.
-
FUNCTION OF CONTROLS
SECTION 4
4
-
1.
7
Power Switch
4-
Amperage Adjustment Control
3. Amperage Range Indicator
4
4.
4
4
4
-
-
-
-
2.
Start Current Control Switch
Duty Cycle
6. VoltAmpere
7
Curves
8
SEQUENCE OF OPERATION
SECTION 5
5- 2.
7
7
7
5.
5- 1.
7
Hydrogen Welding
Shutting Down
Atomic
8
8
MAINTENANCE
SECTION 6
10
6- 1.
Fan Motor
6- 2.
Internal
6- 3.
Lubricating
10
6
Overload Protection
10
Power Factor Correction
10
-
4.
6- 5.
SECTION 7
PARTS LIST
Cleaning
TROUBLESHOOTING
10
SECTION
1-1.
1-SAFETY RULES FOR OPERATION OF ARC
INTRODUCTION
Lead, cadium, zinc, mercury, and beryllium bearing and simi
lar materials, when welded (or cut) may produce harmful
concentrations of toxic fumes, Adequate local exhaust venti
We
learn by experience. Learning safety through personal
experience like a child touching a hot stove is hannful, waste
ful, and unwise. Let the experience of others teach you.
Safe practices developed from experience in the
ing and
cutting
use
lation
tained. The
given. Some
practices
can
death. When safety becomes
be uted with confidence.
a
Work
habit, the equipment
safe practices are divided into two Sections: 1
General Precautions, common to arc welding and cutting; and
2
Arc Welding (and Cutting((onlyl.
Vapors from chlorinased solvents can be decomposed by the
heat of she arc (or flame) so form PHOSGENE, a highly toxic
gas, and other lung and eye irritating products. The ulsra
violet (radiant) energy of the arc can also decompose sri
chloroeshylene
and perchloroeshylene vapors to form phos
gene. DO NOT WELD or cut where solvent vapors can be
drawn into the welding or cussing atmosphere or where she
radians energy
can
penetrate
to
atmospheres containing
even
-
-
Reference standards: Published Standards on safety are also
for additional and more complete procedures than
those given in this manual. They are listed in the Standards
available
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 alto provide a basis for equipment installation.
use, and service.
minute
C.
of srichloreshylene
amounts
Fire and
or
perchloreshylene.
Explosion Prevention
Causes of fire and explosion
are: combustibles reached by she
flame, flying sparks, hot slag or heated material; misuse
of compressed gases and cylinders; and shors circuits.
arc,
Be aware that flying sparks or falling slag can past through
cracks, along pipes, through windows or doors, and through
or floor openings, out of sight of the goggled operator.
Sparks and slag can fly 35 feet.
wall
To prevent fires and explosion:
GENERAL PRECAUTIONS
Keep equipment clean and operable, free of oil,
(in electrical parss( of metallic particles that can
Burn Prevention
leather (or asbestos) gauntlet
protective clothing
gloves, hat, and high safe tv-toe shoss. Button shirt collar and
pocket flaps, and wear cuffless trousers to avoid entry of
sparks and slag.
Wear
grease, and
short
cause
circuits.
-
glasses with side shields
underneath, appropriate filter lenses or plates (protected by
clear cover glass(. This is a MUST for welding or cutting, (and
Wear helmet with safety
goggles
pains
or
metal
clothing.
greasy
such
electrode
as
A
spark
can
away
out
dip tanks, storage areas, venrilasors. If the
moved, move combustibles at least 35 feet
of reach of sparks and heat; or protect against
rooms,
not be
with suitable and
ignition
snug-fitting, fire-resistant
covers or
shields.
stubs
first aid and eye
treatment.
qualified first aid person should
unless medical
facilities
are
close
be
Walls
touching combussibles
and
workpieces should
First aid
available
facilities and a
for each shift
by for immediate
treatment
overhead.
a.
appreciable
sion(
b.
are
not
wish
suitable
(including building
combustibles
fire
ex
time after weld
some
construc
within 35 feet
appreciable combustibles
are
further than 35 fees bus
c.
ignited by sparks
openings (concealed
d.
feet may expose combussibles to sparks
combustibles adjacent to walls, ceilings,
partitions
should
sides should not be
can
be
Ear plugs should be worn when working on overhead or in a
confined space. A hard hat should be worn when others work
preparatiods
opposite
(or
on
Fire watcher must be standing by
tinguishing equipment during and for
ing or cutting if:
of flash burns of the eyes and skin burns.
Flammable hair
on
cut(, Walls, ceilings, and floor near work
should be prosecsed by heat-resistant covers or shields.
welded
may ignite them.
be handled without gloves.
intending
spray
work
to
Avoid oily
Medical
If combustibles are in area, do NOT weld or cut. Move the
work if practicable, to an area free of combustibles. Avoid
or
protect the eyes from radiant energy and flying
metal. Replace cover glass when broken, pitted, or spattered.
See 1-3A.
chipping)
never
confined space should be avoided. Leaked gas
concentration danger
confined space.
Leaving confined space, shut OFF gas supply as source. The
space will then be safe to re-enter, if downstream valves have
been accidensly opened or left open.
may cause serious in
These
a
large quantities can change oxygen
ously. Do not bring gas cylinders into a
in
of installer, user, and serviceman. Installa
operation, checking, and repair of this equipment must
be done only by a competent person, experienced with such
equipment.
Hot
the
in
Gas leaks in
tion,
A.
as
a confined space only while is is being ventilated
and, if necessary, while wearing an air-supplied respirator.
Responsibilities
1-2.
well
area as
air-supplied respirator.
wears an
Read and understand these safe practices before attempting
to install, operate, or service the equipment. Comply with
these procedures as applicable to the particular equipment
used and their instruction manuals, for personal safety and
for the safety of others.
or
each person in the
air-supplied respirator. For beryllium,
Metals coased wish or containing materials that emit toxic
fumes should not be heated unless coating is removed from
the work surface, she area is well ventilated, or the operator
reason
Failure to observe these sate
or
an
of weld
described in this manual.
for the safe practices may not always be
are based on common sense, others may require
technical volumes to explain. It is wiser to follow the rules.
jury
be used,
muss
operator muss wear
both must be used.
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
are
POWER SOURCE
WELDING
be used
by persons
to weld or cut.
Hot
work
ensure
can
be
or
visible) in floors
ignited by radiant
or
or
walls wish in 35
roofs,
or
metal
conducted heat.
permit should be obtained before operation so
approval that adequate precautions have
supervisors
been taken.
B.
Toxic Fume Prevention
Adequate ventilation. Severe discomfort, illness or death can
result from fumes, vapors, heat, or oxygen enrichment or
depletion that welding (or cutsing( may produce. Prevent
them
wish
dard
Z49.1
adequate
with oxygen.
listed
1
described in ANSI Stan
Standards index. NEVER ventilate
ventilation
in
as
Afser work is done, check shas
embers, and flames.
area is
free of
sparks, glowing
An empty container that held combustibles, or that can pro
duce flammable or soxic vapors when heated, muss never be
welded on or cut, unless container has firss been cleaned as
described in AWS Standard A6.O, listed 3 in Standards index.
OM-12g
Page
1
This
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 A6.O. Waterfilling just below working level may
substitute for inerting.
includes:
solvent
a
water
or
A container with
unknown
contents
paragraph aboie). Do NOT depend
to
determine if it is safe
Hollow
or
or
can
castings
cutting. They
to
weld
containers
should be cleaned (see
on sense
of smell
or
cylinders.
Stuck valve. Do NOT
acylinder valve that
Supplier.
Mixing
be vented before
use a
or metal wrench to open
be opened by hand. Notify your
welding
gases. Never try to
mix
any gases in
a
cylinder.
Never refill any cylinder.
explode.
Cylinder fittings should
Explosive atmospheres. Never weld
contain
hammer
can not
sight
or cut.
must
Protect cylinders particularly valves from bumps, falls, falling
objects, and weather. Replace caps securely when moving
flammable dust, gas,
where the air may
liquid vapors (such as gaso
or
never
be modified
or
exchanged.
or Cut
3.
Hose
line).
0.
Prohibited use. Never use hose other than that designed for
the specified gas. A general hose identification rule is: red for
fuel gas, green for oxygen, and black for inert gases.
Compressed Gas Equipment
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P.1, PRECAU
TIONS FOR SAFE HANDLING OF COMPRESSED GASES
IN CYLINDERS, listed 6 in Standards index.
Pressure Regulators
1.
Use ferrules or clamps designed for the hose (not ordinary
or other substitute) as a binding to connect hoses to
wire
fittings.
No copper tubing splices. Use only standard brass fittings
to
splice hose.
Regulator
relief valve is designed to protect only the regula
from overpressure; it is not intended to protect any
downstream equipment. Provide such protection with one or
more relief devices.
Avoid long runs
ground to keep
wise damaged.
Never
Coil
tor
regulator
connect a
to a
cylinder containing gas other
was designed.
excess
prevent kinks and abuse. Suspend hose off
it from being run over, stepped on, or other
to
hose to prevent kinks and
tangles.
than that for which the regulator
Protect hose
Remove faulty regulator from service immediately for repair
(first close cylinder valve). The following symptoms indicate
a
from
damage by sharp edges,
and by sparks,
slag, and open flame.
Examine hose regularly for leaks, wear, and loose connec
Immerse pressured hose in water; bubbles indicate
leeks.
faulty regulator:
tions.
Leaks if gas leaks externally.
if delivery pressure continues
Excessive Creep
downstream valve closed.
-
-
if gauge pointer
Faulty Gauge
when pressurized, nor returns
-
to
rise with
Repair leaky
does not move off stop pin
to
stop
pin
or
hose by cutting
worn
(1-2D3). Do NOT
use
area Out
arid
splicing
tape.
after pressure
Proper Connections
release.
4.
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.
Clean 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-
2.
less cloth.
Cylinders
handled carefully to prevent leaks and
or safety devices:
Cylinders
must
damage
their walls, valves,
to
be
Avoid electrical circuit contact with cylinders including third
rails, electrical wires, or welding circuits. They can produce
short circuit
that may
arcs
lead
to
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.
the
serious accident. (See
a
1-3C.)
ICC
Match
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.
or
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
name,
number,
or
if unmarked. NEVER DEFACE
markings
other
on
a
or
alter
cylinder. It is illegal
and hazardous.
Empties: Keep valves closed, replace caps securely;mark MI;
keep them separate from FULLS and return promptly.
Prohibited
use.
Never
use
a
cylinder
than its intended use, NEVER
as a
or
where
they
work
areas.
or
Keep cylinders clear of
a
areas
may be struck.
supplier)
regulator, if one is required, Use two
adapter marked RIGHT and LEFT
CGA adapter (available from your
Pressurizing Steps:
Drain regulator of residual gas through suitable vent before
opening cylinder br manifold valve) by turning adjusting
screw in (clockwise). Draining prevents excessive compression
heat at high pressure seat by allowing seat to open on pressur
ization. Leave adjusting screw engaged slightly on single-stage
regulators.
Before opening cylinder valve, check that hoses are con
such
nected and that downstream valves
nets.
Stand
Do NOT expose cylinders to excessive heat, sparks, slag, and
flame, etc. that may cause rupture. Do not allow contents to
exceed
exists.
2
a
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.
roller.
Transporting cylinders. With a crane, use a secure support
as a platform or cradle. Do NOT lift cylinders off the
ground by their valves or caps, or by chains, slings, or mag
Page
Use
its contents for other
support
Secure from falling. Chain or secure cylinders upright when
regulator (and hose) are connected tot.
Passagewavs and
Adapters.
between cylinder and
wrenches to tighten
HAND threads.
130F.
Cool with water spray where such exposure
to
side of
Open cylinder
are
closed.
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
creases
possible leak. For fuel gas, open
permit quick emergency shutoff.
to
less
than
one
turn
3.
to
Protection of Nearby Personnel
Enclosed
Use
charts
pressure
(available from your
supplier) for safe
settings on regulators. It
and
efficient, recommended pressure
will reduce backfiring and chance of flashbacks.
operation
on first pressurization and regularly there
after. Brush with so~ solution (capful of Ivory Liquid
or
equivalent per gallon of water). Bubbles indicate leak. Clean
off soapy water after test; dried soap is combustible.
Viewing the weld. Provide face shields for
looking directly at the weld.
in
area,
Remove leaky
Before
to
weld, make
iately
doors
and
B.
Leaving Equipment Unattended
at source
starting
are
persons who
See that all persons
sure
that
are
wearing
screen
flaps
or
flash
bay
closed.
with precautions in 1-2B.
Generator engine exhaust
Carbon monoxide can kill.
must
be vented to the outside air.
and drain gte.
Fire and
Explosion Prevention
Rope Staging-Support
with
Comply
Rope staging-support should not
ting operation; rope may burn.
be used for
welding
or
in 1-2C.
precautions
cut
Equipments
equipment.
capacity. Do
rated
not
It may overheat cables and
overload
cause a
welding
arc
fire,
ARC WELDING
Loose cable connections may 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.
all
Toxic Fume Prevention
Comply
C.
1-3.
separate
the
a
areas, surround
will be
Responsibilities
Close gas supply
G.
open
low-reflective, non-combustible screens or
for free air circulation, particularly at floor
Others working
goggles.
User
In
for leaks
or defective equipment from service immed
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.
with
Allow
panels.
For production welding,
area.
level.
Check
E.
welding
enclosed bay is best.
or
room
Never strike an
a brittle
creates
to such a
operator avoids unnecessary risks and protects himself and
others from accidents. Precautions are described here and in
standarth referenced in index.
0.
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.
Protective Clothing
1.
Iong.sleeve clothing (particularly for gte-shielded arc) in
addition to gloves, hat, and shoes (1-2Al. As necessary, use
additional protective clothing such as leather jacket or
sleeves, flame-proof apron, and fire-resistant leggings. Avoid
outergarments of untreated Cotton.
Wear
Bare skin protection. Wear dark, substantial clothing. Button
to protect chest and neck and button pockets to pre
vent entry of sparks.
collar
Eye
2.
and Head Protection
Protect eyes from exposure to
tric arc without protection.
Welding
or
helmet
denser
striking
must
NEVER look
arc.
containing a filter plate
when welding. Place over
shield
or
be used
at
an
shade
elec
no.
9
face before
arc.
Protect filter plate with
Cracked
or
radiation
can
broken
pass
a
clear
helmet
through
or
cover
plate.
shield should
or
loose filter
or
must be replaced IM
plate when broken, pitted,
not
to
give
be lowered
some
over
worn
under the
protection to the eyes should the helmet
the face before an arc is struck. Looking
momentarily with unprotected eyes (particularly a
high intensity gas-shielded arc) can cause a retinal burn that
at
an
arc
may leave
a
permanent dark
area in
lrademark of Proctor & Gamble.
rupture later under rough handling.
hot conductort
To protect
or
other bare metal in the
welding
against
shock:
Keep body and clothing dry. Never work in damp area with
out adequate insulation against electrical shock. Stay on a
dry duckboard, or rubber mat when dampness or sweat can
not be avoided. Sweat, sea water, or moisture between body
and an electrically HOT part
reduces
or grounded metal
the body surface electrical resistance, enabling dangerous and
possibly lethal currents to flow through the body.
-
1.
-
Grounding the Equipment
installing, connect the frames of each unit such as
welding power source, control, work table, and water circula
tor to the building ground. Conductors must be adequate to
carry ground currents safely. Equipment made electrically
HOT by stray current may shock, possibly fatally. Do NOT
GROUND to electrical conduit, or to a pipe carrying ANY
gas or a flammable liquid such as oil or fuel.
When
Three-phase connection. Check phase requirement of equip.
If only 3-phase power is available,
ment before installing.
two wires of the
connect single-phase equipment to only
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.
the field of
vision.
welding, check ground for continuity. Be sure conduc
touching bare metal of equipment frames at connec
are
ions.
If
goggles with side shields MUST be
other pressure vessel, It
violent rupture or lead
a
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.
a
line cord with
ment
Flash
or
cause
Shock Prevention
Before
spattered.
helmet
can
NOT be worn;
plates
cover
cylinder
a
-
to cause burns.
MEDIATELY. Replace clear
a
that
cause
Comply with precautions in 1-20.
tors
Cracked, broken,
on
area
flash and
Compressed Gas Equipment
Exposed
Comply
arc
or
a
for connection
ground
to a
lead is
switchbox,
provided
connect
with the
the
equip
ground lead
grounded switchbox. If a three-prong plug is added for
mating receptacle, the ground lead
ground prong only. If the line cord
comes with a three-prong plug, connect to a grounded mating
receptacle. Never remove the ground prong from a plug, or
use a plug with a broken off ground prong.
to
the
connection to a grounded
must be connected to the
OM-129 Page 3
2.
Electrode Holders
Do
power circuit or change pOlarity while welding.
emergency, it must be disconnected, guard against
shock burns, or flash froni switch arcing.
not open
If. in
Fully insulated electrode holders should be used. Do NOT
use
holders with
protruding
an
screws.
Leaving equipment unattended. Always
3.
Connectors
connect all power to
Fully insulated lock-type
cable lengths.
should be used
connectors
to
Power disconnect switch
join
welding
4.
1-4.
inspect
cables
and dis
must
be available
near
the
welding
power source.
Cables
Frequently
shut OFF
equipment.
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 t~ed to give
resistance equivalent to original cable. Keep cable dry, free of
oil and grease, and protected from hot metal and sparks.
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.i, SAFETY IN WELDING AND
CUTTING obtainable from the American Welding
Society, 2501 NW 7th St., Miami, FIa. 33125.
2.
ANSI Standard Z87.1, SAFE PRACTICE FOR OCCUPA
TION AND EDUCATIONAL EYE AND FACE PROTEC
TION, obtainable from American National Standards
Institute, 1430 Broadway, New York, N.Y. 10018.
3.
American Welding Society Standard A6.0. WELDING
AND CUTTING CONTAINERS WHICH HAVE HELD
COMBUSTIBLES, obtainable same as item 1.
4.
NFPA
5.
NFPA St~idard 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. V. 10036.
7.
OSHA Standard 29 CFR, Part 1910, Subpart 0, WELD
ING, CUTTING AND BRAZING.
Terminals and other exposed parts of electrical units should
have insulating covers secured before qieration.
6.
Electrode Wire
Electrode wire becomes electrically HOT wt,en the power
switch of gas metal-arc welding equipment is ON and welding
gun trigger is pressed.
other HOT parts.
7.
and body clear of wire and
Safety Devices
Safety
not
Keep hands
devices such
be disconnected
as
or
interlocks and
shunted out.
circuit
breakers should
Before instaHation, inspection, or service, of equipment, shut
OFF all power and remove line fuses br lack or red.t~
switches) to prevent accidental turning ON of power. Discon
nect all cables from welding power source, and pull all 115
volts line-cord plu~.
Page
4
Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING AND CUTTING, obtainable from the
Fire Protection Association, 470 Atlantic
National
Avenue, Boston, Mass. 02210.
SECTION 2
Amperes Input At Rat ed
Load Output
Welding
Max.
Rated Welding
Current Amperes
Current
Open-
Ranges
Circuit
60 Hz.
100% Duty Cycle
Amperes
Voltage
230 Volts I 460
14-90
250
17-110
300
100@
70 Volts
Single-Phase
~
Figure
2-1.
INTRODUCTION
-
2-1.
Volts~
Weight
kva
Dimensions
kw
I
~
Height
17.0
10.5
Width
-
-
Net
47-1)2
510
-
I
I
22-1/4
lbs.
Depth
IshiP
29-1/8
1
550
lbs.
Specifications
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
The
following definitions apply to CAUTION, IMPORTANT,
and NOTE blocks found throughout this manual:
tion presented herein should be given careful consideration to
optimum performance of this equipment.
assure
2-2.
RECEIVING-HANDLING
I
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 tiled by
the purchaser with the carrier. A copy of the bill of lading
I
Under this heading, installation, operating, and main
tenance procedures or practices will be found that if
not carefully followed may create a hazard to per.
Prior to
and freight bill will be furnished by the
occasion to file claim arises.
carrier on
sonn
I
el.
I
request if
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.
F~TAN~1
~.
1
Under
this
heading, installation, operating, and main
procedures or practices will be found that if
carefully followed may result in damage to equip
tenance
2-3.
DESCRIPTION
not
ment.
single-phase welding power source which pro
high voltage ac welding current. This welding power
is designed specifically for the Atomic Hydrogen
source
Welding (AHWI process.
This Unit
It
a
duces
NOTE
2-4.
SAFETY
I
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
I
Under this heading, explanatory statements will be
found that need special emphasis to obtain the most
efficient operation of the equipment.
I
I
welding applications.
SECTION 3
-
INSTALLATION
A
proper installation site should be selected for the welding
source if the Unit ~S to provide dependable service, and
power
remain relatively maintenance free.
I
This
welding
excess
special
of
power
80 voltS
precautions
has open-circuit voltages in
and is to be used only where
source
ac
have
been
taken
to
protect
I
the
the high open-circuit
from contact with
voltage. THIS POWER SOURCE MUST NOT BE
USEDFORSTANDARDMANUALWELDING
operator
i
3-1.
LOCATION
(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
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
tained
maintenance functions.
1
r~C
I
Do
43.1/4*
not
passages
7/16
Dia.
place
of
IMPORTANT
I
filtering device over
welding power source
the intake air
any
the
as
this would
subject
welding power source internal components to an
overheating condition and subsequent failure. War
ranty is void if any type of filtering device is used
restrict
I
the
volume of
intake air and thereby
the
4 HoleS
NH
1-1/2
20
22-1/4
-
~
26-1/8
Holes are provided in the welding power
mounting purposes. Figure 3-1 gives overall
the base mounting hole layout.
29-1/8
1-1/8
*47-1/2
Including Amperage
Adiustmeflt CofltrO
Hole Layout
Base
hase
for
dimensions and
TB-006 716
On
for
Figure 3-1. Overall Dimensions And
source
Mounting
most welding power sources
moving the unit. However, if
lifting
the unit, be
extend
completely
sure
a
a
lifting
device is
provided
fork lift vehicle is used for
that the lift forks
are
long enough
to
under the base.
OM-129
Page
5
Connect
IMPORTANT
primary
the
two
terminal
input conductors to the terminals on the
hoard iine and connect the ground conduc
to the ground terminal. (Refer to the input vol sage label
for identification of these terminals. See Figure 3-2 for loca
tion of this label. I The remaining end of the ground conduc
tor
The
of
use
orks
short
too
to
extend Out of the
internal
opposite side of the base will expose
ponents to damage should the tips of
com
tor
the lift forks
3-2.
should
be connected
grounding method that
inspection authority.
penetrate the bottom of the unit.
ELECTRICAL INPUT CONNECTIONS
~round
source
power
that
recommended
is
disconnect
line
a
Switch
be
only. Do
I
terminal
input Circuit to the welding power
This would provide a sate and convenient
source.
means to completely remove all electrical power from
in
installed
a
proper
acceptable
ground. Use
to
the
whatever
electrical
local
CAUTION
NOTE
It
to
is
the
result
not
to
in
is
chassis
and
connect
arty
an
connected
terminal
one
ol
is
for
conductor
a
the line
electrically
to
welding
the
I
grounding
from
terminals
energized
purposes
the ground
this will
as
welding
power
chassis.
source
power source whenever it is necessary to
internal function on the unit.
welding
perform any
the
r4~~hlh~hhhhI.
I
making electrical
Before
welding
dures
connections
input
the
to
I
lockout proce
machinery
power source,
should be employed. If the connection is to be
made from a line disconnect switch, the switch should
be padlocked in the open position. II the connection is
made from a fuse box, remove the fuses from the box
and padlock the cover in the closed position. If lock
facilities
ing
being
worked
red tag
a
switch
that the circuit is
A.
available, attach
(Or fuse box(
not
are
disconnect
line
to
warn
to
the
others
on.
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 an5 question about the
type of electrical system available at the installation site or
how proper connections to the welding power
be made.
B.
source
are
AB-901 379-6A
Figure
C.
to
this welding power source may be operated are stated on the
welding power source nameplate and on the Input voltage
iabel. See Figure 3.2 br iocation of this label. The input
voltage jumper inks on this welding power source are posi
tioned for tOe niqhest ol this 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 wInch
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
If the input voltages on the welding power
power source.
source nameplate differ from those shown in Figure 3-3, the
input voltage jumper links must he positioned as shown on
the input voltage label.
CAUTION
the
connect
not
input
conductors
single-
the
to
phase power supply until all electrical input connec
tions have been made to the welding power source
input conductors should
The
material
3-1
is
conforms
which
provided only
as
a
to
with
covered
be
insulating
an
local electrical standards.
guide for selecting
Table
the proper size
input conductors and fuses.
Input Conductor and Fuse Sizes
Table 3-1.
Input Conductor Size
-
AWG
Fuse Size In Amperes
208V
230V
460V
575V
No. 4
No. 4
No. 8
No. 1 0
Ground Wire
Insert
the
tion
208V
230V
460V
575V
125
110
60
50
NOTE
If only one
umper 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
No. 8
input conductors plus
one
ground
conductor
panel. The hole will
standard conduit fittings. See Figure 3-2 for hole loca
through
accept
two
-
arid
the
access
hole
Matching The Welding Power Source To The Avail
able Input Voltage
The input voltage jumper links provided on the primary ter
minal board permit the welding power source to he operated
from various line voltages. The various voltages from which
Input Conductor Connections
Do
3-2. Input Conductor Connections
on
the
rear
~which
are
required for
this connection
size,
230 VOLTS
460 VOLTS
NOTE
o~
I
It
is
recommended
that
a
terminal
lug of adequate
capacity be attached to the ends of the in
ground conductors. The hole diameter in the
terminal lug must be of proper size to accommodate
line and ground terminal studs on the primary
ne
amperage
put
Page
0
OR
and
terminal hoard
6
I
TA-012 314
Figure 3-3. Input Voltage Jumper Link Arrangement
nfl
.
3-3.
SECONDARY CONNECTIONS
The
secondary connections
consist of three
hinged
this
welding
power
on
SHIELDING GAS VALVE CONNECTIONS
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
source to control
on and off flow of gas to the electrode
Atomic
source
welding
door
access
on
3-4.
output terminals located behind the
the lower portion of the front panel.
holder.
The
terminal is labeled WORK. The
center
300
O.C.V. is to
nal,
voltage terminal, labeled 250 O.C.V.
labeled
Atomic
the
left
high voltage termi
The low
of center.
is to the
right of
The automatic GAS valve is located behind the hinged access
the lower portion of the front panel. The valves
on
input and output connections both have right hand thread
center.
door
electrode holders are 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.
with
pending
In
ing.
Hydrogen Welding
leads.
two
on
the requirements of the
Be
the hose from the gas supply is attached to the con
labeled IN. The gas hose from the electrode holder
must be attached to the connection labeled OUT.
welding application.
the
Atomic Hydrogen Welding process the arc is main
independent of the work piece and therefore it is not
necessary to attach a lead to the work piece which would
make the work piece part of the welding arc circuit.
sure
nection
3-5.
tained
REMOTE
TIONS
A five
power
the internal
which
provides ON
a
two.
START and OFF
or
or
arc.
The five pole terminal strip (iT) is located behind the
door on the lower portion of the front panel.
closed
door
access
energized. There
are 300 volts of open-circuit voltage
present across
these terminals when welding and a hazard exists ~f the
terminals are left exposed.
welding
to
STOP functions for starting and breaking the
terminals
secondary
(optional)
device
circuitry. These devices usually consist of
button control
the
Keep
control
contactor
contactor
whenever the
CONNEC
pole terminal strip (iT) is provided on this welding
to be used as a Junction point for connecting a
remote
I
CONTROL
source
power
CA U TI ON
CONTACTOR
hinged
access
source is
Connect the ON
or
and the OFF
5,
and
START button leads to terminals No. 1
or STOP button leads to terminals No. 2
and 3.
SECTION 4-FUNCTION
Amperage Adjustment
CONTROLS
OF
Control
NOTE
Start Current Control Switch
N
Because
this
primary
coil
while
4-3.
Amperage Range Indicator
welding
design
power
the
is of the
source
amperage
be
can
moving
adjusted
I
welding.
AMPERAGE RANGE INDICATOR
(Figure 4-1)
~
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
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
nameplate,
Power Switch
from 17 to 110 amperes. If the welding power source is being
the 300 CCV. range, amperage is read on the
left hand scale which is numbered from 14 to 90 amperes.
TB006 716
operated in
Figure 4-1. Control Location
4-1.
POWER SWITCH
Placing
4-4.
in the ON position will energize the
fan and control circuitry and place the
the power switch
welding
welding
power
(Figure 4-1)
power source
source
power
in
switch
the
in
a
ready.to-welrl
OFF
position
status.
will
shut
START CURRENT CONTROL SWITCH
The
start
hand
Placing the
welding
current
for
If the Start
CAUTION
trol switch
the
tt~~liosItioil
Even though the power switch is ri
the welding power source is anparently shut
and
down, electrical input power is siill priiserui on all cii
cuitry up to the power switch. Tn i;ompleinlv Lit off
ac current
controls
the start circuit of the
providing increasingly larger
welding
amounts
of
Initiation,
circu,i
in
switch, located in the upper left
panel, is a 10-position selector
is
not
needed, place the start current con
position. This position removes
the first (No. 1 I
reactnr and
transformer
winding
from the start
circuit.
-
I
arc
front
the
by
source
power
power source down,
of
This Switch
switch.
the
control
current
corner
(Figure 4-1)
all electrical input power to the weldinq power source,
it will be necessary to place the line disconnect switch
in
the
OFF
position
or
remove
the
electrical
ist ciod
~ising
input
en
numbererl positions
circuit fuses.
start
current
ele
(between No. 1
control
switch
should
disintegrate the tungsten
higher settings are provided for use
settings may
4-2.
(Figure 4-1)
AMPERAGE ADJUSTMENT CONTROL
The amperage adlustment control on the
power source provides the operator with
selecting
the
exact
desired amperage
on
setting
of
thr
the welding
r.anahility of
within the
es
Ihe
and No. 5)
be
used.
lower
on
the
Higher
electrodes, The
with
larger size
tungsten electrodes.
4-5.
DUTY CYCLE
entire
range of the unit. Rotating the amperage adiustment control
in a counterclockwise direction, will increase the amperage,
The duty cycle of a welding power source is the percentage
of a ten minute period that the welding power source can
clockwise rotation will decrease the amperage.
safely
be operated
at
a
given
current
setting.
This dual-range
OM-129 Paq~
7
welding power
amperes in the
source is rated at 100% duty cycle at 100
250 O.C.V. range, and 100% duty cycle at 85
amperes in the 300 O.C.V. range. The welding power source
can be safely operated up to these limits in those ranges
300
Continuously. If the welding
Cycle will decrease.
250
Current
increased, the duty
5
200
IMPORT
Operating
this
capability
may
In
I
welding
cause
power source beyond its rated
the transformer to overheat. The
I
transformer is protected by a thermostat which will
and shut down the welding power source until
I.jhe transformer cools.
150
open
100
I
50
4-6.
VOLT-AMPERE CURVES
(Figure 4-2)
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
25
0
A C
Figure 4-2. Volt-Ampere Curves
CAUTION_-~
power source delivers approximately 300
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.
ac
I
I
Prior to
Securely ground the chassis of the welding
3.
4.
The
protective
covering
door
access
comply
damage.
power
over
device. Hold
stabilized.
cooling
In addition to
being
a
I
hazard,
When
9.
10.
(AHW)(Figure 5-1)
2.
Connect
source as
3.
the
4.
welding
the gas supply lines to
described in Section 3.4
welding
the
-
power
arc
is stabilized, release the START button.
the gas flow to the lowest point possible when
well defined arc is obtained but not so low that small
begin
form
on
the electrodes.
SHUTTING DOWN
1.
Break the
arc
mote contactor
power
to
2.
Allow
with
the
no
by depressing the STOP button
welding
power
source
to
idle for 3
3.
Place the power switch in the OFF position.
4.
Turn off the
welding
Place
of
this
welding
power
the
use
power
the start
source
current
as
shielding gas.
described in Section 3-5.
control
CAUTION
switch in the desired
position.
I
5.
Rotate the amperage adjustment control to the desired
setting.
6.
Page 8
Turn the power switch ON.
confined~
failure to
performed in a
shielding gas Supply could result in a
build-up of gas fumes, thereby endangering personnel
reentering the welding area.
If
welding
turn
off
is
the
re
minutes
load applied.
source
operation
the
on
control device.
of a remote contactor control device
initiate and/or break the arc. Connect this device to
Efficient
requires
to
the electrode holder to the
described in Section 3-3.
is
Commence welding.
11.
5-2.
Connect
arc
Adjust
beads
source as
depressed until the
before.
I
ATOMIC HYDROGEN WELDING
button
Initiate
a
5-1.
the
trodes
may
enclosure removed.
and/or permanent bodily
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
8.
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
improper
may result in serious
Close the internal contactor circuit by depressing the
START button on the remote contactor control
7.
the
output terminals must be kept closed whenever the
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.
imperative that pprotective
it is
welding,
clothing (welding coat and gloves) and eye protection
(glasses and/or welding helmet) be put on. Failure to
of
source.
2.
125
SEQUENCE OF OPERATION
-
welding
volts
100
AMPERES
B-006 767
!
This
75
50
POWER SWITCH
CR1
S1
ON
_ I .~.
CLOSES
FAN MOTOR ON
START SWITCH HELD CLOSED
+
W2
CLOSES
__________________I____________________
PRIMARY CONTACTOR
+
W1
CLOSES
I
GAS VALVE OPENS
I
~OcV
START CURRENT AVAILABLE
TOUCH START ELECTRODES
I
ARC INITIATED
CR1
CLOSES
HOLDS IN CONTACTOR
THROUGH CONTACTOR
W1
INTERLOCK
START SWITCH RELEASED
W2OPENS
START CIRCUIT OPEN
INTENTIONAL ARC OUTAGE
WELDING ARC
I
Hi
STOP SWITCH OPENED
CONTACTOR OPENS
CR1
CLOSES
GAS VALVE CLOSES
ZERO OCv
UNINTENTIONAL ARC OUTAGE
WELDING ARC OUTAGE
I
CR1
DROPS OUT
V
CONTACTOR DROPS OUT
GAS VA
~
ZERO OCV
Figure 5-1.
Arc
CR1 CLOSES
A-006 996
Flowage Chart
OM-129 Page 9
SECTION 6
-
MAINTENANCE
6-3.
LUBRICATING
Oocasional lubrication of the threaded shaft
Be
the branch circuit
sure
main disconnect switch is
circuit fuses are removed
or
electrical input
or
before attempting any inspection
inside of the welding power source.
open
6-1.
or
work
on
I
the
6-4.
FAN MOTOR
the amperage
OVERLOAD PROTECTION
thermostat is located on the side of the control trans
former coil. Excessive overloading 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
welding power source has been overloaded to the point of
overheating, allow the fan to continue operating to aid in
A
All
models are 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.
6-2.
on
adjustment control and the moving coil slides is essential,
especially when the welding power source is in continuous
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.
INTERNAL CLEANING
cooling.
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 vacuum suction( should be
used for this cleaning operation.
6-5.
POWER FACTOR CORRECTION
Power factor correction capacitators are built into the weld
ng power source. These capacitators require no maintenance
If a capacitator should fail it can readily be
or attention.
recognized by a bulging case and/or oil spillage.
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
It is recommended that the circuit
diagram
the trouble is still not
be used for reference
TROUBLE
Welding
power
source
remedied, it is recommended that
a
serviceperson be called.
during troubleshooting,
PROBABLE CAUSE
completely
cases
REMEDY
Open line lute(s).
Replace line fuse(s), if open.
Defective power switch (Si).
Check
inoperative.
Voltage
links
primary connections
incorrectly, or missing.
on
board connected
Welding
output
continues
fan
terminated,
running,
Fan inoperative but weld output
(T2) overheated
thermostat (TP( to open,
Transformer
causing
Refer
for
to
and
Section 3-2C
Allow unit time
source
replace defective
to
or to
the
switch
power
(Si).
input voltage label.
cool. Do not exceed
welding
power
rating.
Electrode cables shorted.
Check electrode cables.
Defective fan motor (FM).
Check for and replace defective fan motor (FM).
normal.
Shorted
or open
fan motor (FM) leads.
Check
for
and
correct
shorted
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
voltage, and/or the
open-circuit
fan operates with
reduced speed.
links
Voltage
on
connections
the
of
the
Check the
voltage.
too
low
a
opens
voltage,
at
Insufficient
shielding
Check
gas.
the
high,
or
Slider
on
resistor (RI) is improperly
set.
the input
voltage label.
power line for correct
voltage.
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.
Page 10
incoming
flow-setting,
too
or
Check the electrode holder connections.
tungsten electrodes.
Contactor
Refer to Section 3-2C
incorrect
Loose electrode connections.
Erratic welding output.
oxidizing
for
voltage.
Low primary line
Excessive
primary
connected
board
of
SEE
INSTRUCTION BOOI~
PRIMARY
PROPER
FOR
CONNECTIONS
TORCH COMMON
TORCH
250 VOLTS
TORCH
300 VOLTS
12345
l~1~1i
I
START
I
~o-H
PwS
-
(0 PT IONS
ax
XT RA~
Circuit Diagram No. CA-900 237-1
Figure 7-1. Circuit Diagram
OM-129 Page 11
June 1976
FORM: OM-129
Effective With Serial No. HG057040
MODEL/STOCK NO.
SERIAL/STYLE NO.
DATE PURCHASED
PARTS LIST
MILLER ELECTRIC MFG. CO.
APPLETON, WISCONSIN, USA 54911
NWSA CODE NO. 4579
MODEL
STOCK NO.
100HVAP
900 237
a,
I
t
-a c~
_4-_
-
.1
£
m
0
N) (0 -V
V
C
CD
Item
Dia.
Factory
No.
Mkgs.
Part No.
024 603
PANEL, front
SWITCH, toggle 3PST 60
SHAFT, control
SEAL, rubber shaft
COLLAR, locking 3/4-6
024 604
BALL, steel
024605
BEARING,ball
HANDLE, control shaft
BEARING,nylon
MOTOR, fan 230 volts (60 Hz) or
MOTOR, fan 1/4 hp 230 volts (50 Hz)
BLADE, fan 60 Hz 14 inch 3 wing 19 deg or
BLADE, fan 50 Hz 14 inch 5 wing 30 deg
PANEL, rear
TERMINAL ASSEMBLY, primary (consisting of)
BLOCK, terminal 30 amp 3 pole
LINK, jumper- terminal block
LINK, connecting-switch
LINK, jumper primary panel
STUD, brass 1/4-20 x 1-1/2 w/hex collar
NUT, brass hex jam 1/4-20
STUD, brass 3/8-16 x 2
NUT, brass hex jam 3/8-16
WASHER, lock -steel split 3/8
WASHER, flat steel 3/8
014 721
1
Si
3
011 789
024 611
604 439
019 611
4
024606
5
FM
5
FM
032 603
032 605
032 604
605 799
6
014 703
7
038 680
038 602
038 620
100621
038 652
038 888
601 836
038 937
601 837
602 213
602 243
010 915
602 051
038685
Cl
031 609
1
amp
1
1
-
1
1
.
1
1
1
1
-
.
.
-
.
.
-
.
.
-
.
INSULATION
-
.
x
1-1/4
BASE
TERMINAL, power output red (consisting of)
SCREW, cap steel hex hd 1/2-13 x 1-1/2
TERMINAL BOARD, red
-
-
-
BUS BAR
NUT, stell
NUT, steel
.
601 879
-
8
2
7
3
3
1
1
4
1
-
601 880
1
3
4
100886
039 044
1
3
WASHER, flat-brass 1/4 ID x 5/8 OD
SCREW, machine brass round hd 1/4-20
TERMINAL BOARD, primary
CAPACITOR, paper oil 35 uf 460 volts ac
.
039 047
039 043
1
1
9
039 049
1
.
10
601 976
1
.
026754
8
Quantity
Complete Assembly
Figure A
2
Description
3
1
1
1
jam 1/2-13
1
hex full 1/2-13
1
1
hex
-
-
11
Fl
~012 607
12
TP
012 605
CLIP, spring bus bar
HOLDER, fuse cartridge 30 amp 250 volts
FUSE, cartridge 10 amp 250 volts
THERMOSTAT ASSEMBLY, rectifier
102173
WINDTUNNEL
1
-
-
012 604
11
13
-
1
1
1
14
Z
036671
REACTOR
1
15
T2
036 672
1
16
S2
011 632
TRANSFORMER, kva 2
SWITCH, rotary 10 position 50 amp 300 volts
KNOB, pointer
CONTACTOR, 4P 115/230 volts ac (consisting of)
019 609
17
CR2,W
034 909
010 296
COIL, contactor 115/230 volts ac
KIT, points-contactor
VALVE, 115 volts ac 2 way 1/4 IPS port 1/8 orifice
FITTING, hose brass elbow male 1/4 NPT x 5/8-18
034 910
~034 911
GS1
003 538
1
2
1
.
4
.
-
1
2
18
SRi
037 568
RECTIFIER, w/mounting brackets
1
19
Ri
030617
RESISTOR,WWadj25watt2000ohm
1
20
R2
604178
RESISTOR,carbon2wattl0Oohm
1
OM-129 Page 2
Item
Dia.
Factory
No.
Mkgs.
Part No.
Figure
2T
038 621
iT
038 622
21
CR1
Ti
23
Ti
Quantity
Complete Assembly (Contd.)
A
22
Description
034 623
**033 736
**033735
014711
015966
BLOCK, terminal 30 amp 4 pole
BLOCK, terminal 30 amp 5 pole
RELAY, 110 volts dc DPDT
COIL,secondary
COIL,primary
PANEL,side
COVER,top
NAMEPLATE (order by stock, model, and serial numbers)
Recommended Spare Parts.
*Replace
at
Factory
or
Authorized Service Station.
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 3
2
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