Miller 300MT User manual

Miller 300MT User manual
 | May 1982 FORM: OM-273A
Effective With Serial No. JC612919
MODEL
300MT
MILLER ELECTRIC MFG. CO.
718 5S. BOUNDS ST. P.O. Box 1079
APPLETON, WI 54812 USA
ADDITIONAL COPY PRICE 65 CENTS
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 defect in workmanship and
material as of the time and place of delivery by Miller. No war-
ranty 1s made by Miller with respect to engines, trade ac-
cessories 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.
Except as specified below, Miller's warranty does not apply
to components having normal useful life of less than one (1)
year, such as spot welder tips, relay and contactor points,
MILLERMATIC parts that come in contact with the welding
wire including nozzles and nozzle insulators where failure does
not resuit from defect in workmanship or material.
Miller shall be required to honor warranty claims on war-
ranted Equipment in the event of failure resulting from a defect
X within the following periods from the date of delivery of Equip-
|
ment to the original user;
u
- a
. Arc welders, power sources and components .. 1 year
. Original main power rectifiers ........ aa . 3 years
(labor - 1 year oniy)
. Al welding guns and feeder/guns............ 90 days
. Alt other Millermatic Feeders. . ................ 1 year
. Replacement or repair parts, exciusive of labor . 60 days
. Batteries. ..............o.ee er]: aaa 6 months
a
| —
о с 4 WW
provided that Miller is notified in writing within thirty (30) days
! of the date of such failure.
Y -
A
a
WRITING, MILLER PRODUCTS ARE
A В 7.
As a matter of general policy oniy, Miller may honor claims
submitted by the original user within the foregoing periods.
In the case of Miller's breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedies
therefore shall be, at Miller's option (1) repair or (2} replacement
or, where authorized in writing by Miller in appropriate cases, (3)
the reasonable cost of repatr or replacement at an authorized
Miller service station or (4) payment of or credit for the purchase
price {less reasonable depreciation based upon actual use} upon
return of the goods at Customer's risk and expense. Upon receipt
of notice of apparent defect or failure, Miller shall instruct the clai-
mant on the warranty claim procedures to be followed.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA-
TION AS TO 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
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX-
~ CLUDED AND DISCLAIMED BY MILLER.
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN
INTENDED FOR
ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED AND
EXPERIENCED IN THE USE AND MAINTENANCE OF
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR
CONSUMER USE. MILLER” WARRANTIES DO NOT EXTEND
TO, AND NO RESELLER IS AUTHORIZED TC EXTEND
MILLER'S WARRANTIES TO, ANY CONSUMER.
NR, Ne SSL Pe Mare
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December 10, 1982 FORM: OM-273A
ERRATA SHEET
After this manual was printed, refinements in equipment design occurred, This sheet lists exceptions to data
appearing later in this manual.
AMENDMENT TO SECTION 3 - INSTALLATION
Amend WARNING block at beginning ot Section 3-6C. ELECTRICAL INPUT CONNECTIONS: Input Conductor Con-
nections”
RUE ELECTRIC SHOCK can kill.
- 6 Do not touch five electrical parts.
® /tis recommended that a fusible line disconnect switch be installed in the input circuit to the welding power
source.
This would provide a safe and convenient means to completely remove all electrical power from: the welding power
source whenever it is necessary to internally inspect or service the unit.
® Employ “lockout/ tagging procedures” on input line before making input connections to the welding power
source.
Lockout/ tagging procedures consist of padiocking line disconnect switch in open position, removing fuses from fuse
- box, or tagging circuit breaker or other disconnecting device.
® (Connect input conductors to the welding power source before connecting to three-phase input power.
Amend Figure 3-2. input Conductor Connections
Line Disconnect
Switch
Input Voitage
Label NU =
Input Voitage
Jumper Links >< |
Terminals
-
Ground _
Terminal 18-048 935
Figure 3-2. Input Conductor Connectiens
Dia. Part Replaced
** Mkgs. NG. With | Description | Quantity
2-9 CBI 020278 053 283 CIRCUIT BREAKER, manual reset 1 pole 15 amp 250 volts........... 1.
084 192 BUS BAR, jumper - resistor paralleling . .................... aaa 1
| **First digit represents page no. - digits following, dash represents item no. ;
"BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Oct. 29,1987 FORM: OM-273A
ERRATA SHEET
After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to data
appearing later in this manual.
AMENDMENT TO SECTION 7 - TROUBLESHOOTING
Amend Figure 7-1, Circuit Diagram For Welding Power Source
as Ll
> >
5 a
a 3
Ll
% =
Circuit Diagram No. C-090 530
COM ACTOR
GA чи
EC a
Iwas O GR Sh
ACS
DUPER
3 POL E
COS
A} E
Cs
2 POLE
Tw ISTLOL
Figure 7 - 1. Circuit Diagram For Welding Power Source Effective With Serial No. JD689047 And Following
TP3 IH HECT
TP a RECT
TF2 IN THANS
Dia. Part Replaced
x Mkgs. No. With Description Quantity
2-10 605 583 605 583 CATCH (qty chg){Eff w/JH068600) .............. 1
2-11 027 408 098 887 DOOR, access-front (Eff w/JHO68600 thru
HJ295149)................. SE LL 1
2-11 098 997 109 449 DOOR, access-front (Eff w/HJ295150)............ 1
4- R50-52,111,112 000885 000 885 RESISTOR (gty chg)................e_recveereo. 5
4- R56,64,70,78,85,93,
129,217, 219,305 035827 035827 RESISTOR (gty chg)..................eemremrrmn 10
5-11 C17,18 031 670 097 749 CAPACITOR, ceramic 0.05 uf 500 volts ........... 1
5-15 084 674 091 086 BASE (Eff w/JD688891 thru
HI295 140) . oo eee eee eee eee ee eee 1
5-15 091 086 116876 BASE I(Effw/HJ295150)....................—... 1
091 055 FRAME, upright-base (Eff w/JD688891) .......... 1
010 143 CLAMP, 3/8 dia .................e..000cee0r00e. 2
**First digit represents page no. - digits following dash represent item no.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-273A Page 2
E TABLE OF CONTENTS uumacm
Section No. Page No.
SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1. Introduction La ee eee ee eee eer aaa 1
1-2. General Precautions ........o _...e.eee0aaaaaomaradaaaraaoaranaa 1
1-3. ArcWelding .......... a eee eee eee sea a ea a eee eee 05e 4
1 - 4. Standards Booklet INdeX....... 5
SECTION 2 - INTRODUCTION
2-1. General Information And Safety ............_eeoeeceeceredroa maria. 7
2-2. Receiving-Handling . ......... RR RR 7
2-3. Description ..................... ee i 4 a a a a a a a a a a a 6 7
SECTION 3 - INSTALLATION
3-1. Location ........1222200 0011110 LA LA AA A A A A A A A A ae A a a a a aa ae 7
3-2. Weld Output Connections ..........._e.eeeeeresernoneoroerorena 8
3-3. 116VoltsAcReceptacles . ........ eereeeereme.. 8
3-4. Remote Contactor Control! Connections. .........e ee ee.eeeeeoeooeaa 9
3 - 5. Remote Voltage Control Connections ............—._eeeeeeeenmeococa 9
3-6. Electrical Input Connections .............eoee.eecesrecorean0en.. 9
SECTION 4 - OPERATOR CONTROLS
4-1. PowerControl Switch... ...... ee. 10
4-2. PilotLight ..... RER RR RR KR eee eee 10
4 - 3. Voltage AdjustmentControl .................. cit, 10
4-4, \Мо!-Атреге Сигуеё$ . oe ea 10
4-5, Duty CyCE 0000 eee 11
4 - 6. Remote Voltage Control Receptacle & Switch. ..................... 11
4 - 7. Remote Contactor Control Receptacle & Switch. ................... 11
4-8. Мег 8 RR 11
4-9. Foldback Circuit Operation RR RR Ran 11
4-10. Overload Protection............12211110 0000 a aa aa aa a La aa aan 12
SECTION 5 - SEQUENCE OF OPERATION
5-1. Gas Metal-Arc Welding (GMAW).. 111112000020 4 aa a aa ee... 12
5-2. Shutting Down . .. 0014 44e eee aa ee ee ee ee ea a aa eau ue 12
SECTION 6 - MAINTENANCE
6-1. FanMotor ern 12
6 - 2. Internal Cleaning ... eee eee 12
6-3. WeldCables .......... ..errerrorerenoonnoroona 12
6-4. Control Circuit Protection . ........ i iin 12
SECTION 7 - TROUBLESHOOTING
7-1. General ee ee 13
7-2. Troubleshooting Chart .............. 0. iii. 13
mSECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCEm
1-1. INTRODUCTION - We learn by experience.
Learning safety through personal experience, like a
chiid touching a hot stove is harmful, wasteful, and un-
wise. Let the experience of others teach you.
Safe practices developed from experience in the use of
welding and cutting are described in this manual.
Research, development, and field experience have
evolved reliable equipment and safe installation, opera-
tion, and servicing practices. Accidents occur when
equipment is improperly used or maintained. The
reason for the safe practices may not always be given.
Some are based on common sense, others may require
technical volumes to expiain. It is wiser to follow the
rules.
Read and understand these safe practices before at-
tempting to install, operate, or service the equipment.
Comply with these procedures as applicable to the par-
ticular equipment used and their instruction manuals,
for personal safety and for the safety of others.
Failure to observe these safe practices may cause
serious injury or death. When safety becomes a habit,
the equipment can be used with confidence.
These safe practices are divided into two Sections:
1 - General Precautions, common to arc welding and
cutting; and 2 - Arc Welding {and Cutting) (only).
Reference standards: Published Standards on safety are
also available for additional and more complete pro-
cedures than those given in this manual. They are listed
in the Standards Index in this manual. ANSI 249.1 is
the most complete.
The National Electrical Code, Occupational Safety and
Health Administration, loca! industrial codes, and local
inspection requirements also provide a basis for equip-
ment installation, use, and service.
1-2. GENERAL PRECAUTIONS
A. Burn Prevention
Wear protective clothing - leather {or asbestos)
gauntlet gloves, hat, and high safety-toe shoes. Button
shirt collar and pocket flaps, and wear cuffiess trousers
to avoid entry of sparks and slag.
Wear helmet with safety goggles or glasses with side
shields underneath, appropriate filter lenses or plates
{protected by clear cover glass). This is a MUST for
welding or cutting, {and chipping} to protect the eyes
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
Avoid oily or greasy clothing. A spark may ignite them.
Hot metal such as electrode stubs and workpieces
should never be handled without gloves.
Medical first aid and eye treatment. First aid facilities
and a qualified first aid person should be available for
each shift uniess medical facilities are close by for im-
mediate treatment of flash burns of the eyes and skin
burns.
Ear plugs should be worn when working on overhead or
in a confined space. A hard hat shouid be worn when
others work overhead.
Flammable hair preparations should not be used by per-
sons intending tc weld or cut.
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 cutting) may
produce. Prevent them with adequate ventilation as
described in ANSI Standard Z49.1 listed 1 in Standards
index. NEVER ventilate with oxygen.
Lead -, cadmium -, zinc -, mercury -, and beryllium -
bearing and similar materials, when welded (or cut} may
produce harmful concentrations of toxic fumes. Ade-
quate local exhaust ventilation must be used, or each
person in the area as well as the operator must wear an
air-supplied respirator. For beryllium, both must be us-
ed.
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 ven-
tilated, or the operator wears an air-supplied respirator.
Work in a confined space only while it is Deir | en-
tilated and, if necessary, while wearing an air-supplied
respirator. |
Gas leaks in a confined space should be avoided.
Leaked gas in large quantities can change oxygen con-
centration dangerously. Do not bring gas cylinders into
a confined space.
Leaving confined space, shut OFF gas supply at source
to prevent possible accumulation of gases in the space
if downstream valves have been accidently opened or
left open. Check to be sure that the space is safe before
re-entering it.
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 pro-
ducts. The ultraviolet (radiant) energy of the arc can
also decompose trichloroethylene and per-
chloroethylene vapors to form phosgene. DO NOT
WELD or cut where solvent vapors can be drawn into
the welding or cutting atmosphere or where the radiant
energy can penetrate to atmospheres containing even
minute amounts of trichloroethylene or per-
chloroethylene.
OM-273 Page 1
C. Fire and Explosion Prevention
Causes of fire and explosion are: combustibles reached
by the arc, flame, flying sparks, hot slag or heated
material; misuse of compressed gases and cylinders:
and short circuits.
BE AWARE THAT flying sparks or falling slag can pass
through cracks, along pipes, through windows or
doors, and through wall or floor openings, out of sight
of the goggled operator. Sparks and slag can fly 35 feet.
To prevent fires and explosion:
Keep equipment clean and operable, free of oil, grease,
and (in electrical parts} of metallic particles that can
cause short circuits.
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, ven-
tilators. If the work cannot be moved, move com-
bustibles at least 35 feet away out of reach of sparks
and heat; or protect against ignition with suitable and
- snug-fitting, fire-resistant covers or shields.
Walls touching combustibles on opposite sides shouid
not be welded on (or cut). Walls, ceilings, and floor near
work should be protected by heat-resistant covers or
shields.
Fire watcher must be standing by with suitable fire ex-
‘tinguishing equipment during and for some time after
welding or cutting if:
a. appreciable combustibles (including building
construction) 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 com-
~ bustibles to sparks
d. combustibles adjacent to walls, ceilings,
roofs, or metal partitions can be ignited by
radiant or conducted heat.
Hot work permit should be obtained before operation to
ensure supervisor's approval that adequate precautions
have been taken.
After work is done, check that area is free of sparks,
glowing embers, and flames.
An empty container that held combustibles, or that can
produce flammable or toxic vapors when heated, must
never be welded on or cut, unless container has first
been cleaned as described in AWS Standard A6.0,
listed 3 in Standards index.
This includes: a thorough steam or caustic cleaning (or
a solvent or water washing, depending on the com-
bustible’s solubility) followed by purging and inerting
with nitrogen or carbon dioxide, and using protective
equipment as recommended in A6.0. Waterfilling just
below working level may substitute for inerting.
Page 2
A container with unknown contents should be cleaned
(see paragraph above). Do NOT depend on sense of
smell or sight to determine if it is safe to weld or cut.
Hollow castings or containers must be vented before
welding or cutting. They can explode.
Expiosive atmospheres. Never weld or cut where the air
may contain flammable dust, gas, or liquid vapors (such
as gasoline}.
D. Compressed Gas Equipment
Standard precautions. Comply with precautions in
this manuai, and those detailed in CGA Standard
P-1, PRECAUTIONS FOR SAFE HANDLING OF
COMPRESSED GASES IN CYLINDERS, listed 6 in
Standards index.
1. Pressure Regulators
Regulator relief valve is designed to protect only the
regulator from overpressure: it is not intended to
protect any downstream equipment. Provide such
protection with one or more relief devices. -
Never connect a regulator to a cylinder containing
gas other than that for which the regulator was
designed.
Remove faulty regulator from service immediately
for repair (first close cylinder valve). The following
symptoms indicate a faulty regulator:
Leaks - if gas leaks externally.
Excessive Creep - if delivery pressure continues to
rise with downstream valve closed.
Faulty Gauge - if gauge pointer does not move off
stop pin when pressurized, nor returns to stop pin
after pressure release.
Repair. Do NOT attempt repair. Send faulty
regulators for repatr to manufacturers designated
repair center, where special techniques and tools
are used by trained personnel.
2. Cylinders
Cylinders must be handled carefully to prevent
leaks and damage to their walls, valves, or safety
devices:
Avoid electrical circuit contact with cylinders in-
cluding third rails, electrical wires, or welding cir-
cuits. They can produce short circuit arcs that may
lead to a serious accident. (See 1-3C.)
ICC or DOT marking must be on each cylinder. It is
an assurance of safety when the cylinder is properly
handled.
Identifying gas content. Use only cylinders with
name of gas marked on them; do not rely on color to
identify gas content. Notify supplier if unmarked.
NEVER DEFACE or alter name, number, or other
markings on a cylinder. It is illegal and hazardous.
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.
Locate or secure cylinders so they cannot be knocked
over. |
Passageways and work areas. Keep cylinders clear of
areas where they may be struck.
Transporting cylinders. With a crane, use a secure sup-
port such as a platform or cradle. Do NOT lift cylinders
off the ground by their valves or caps, or by chains,
slings, or magnets.
Do NOT expose cylinders to excessive heat, sparks,
slag, and flame, etc. that may cause rupture. Do not
allow contents to exceed 130°F. Cool with water spray
where such exposure exists.
Protect cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when moving cylinders.
Stuck valve. Do NOT use a hammer or wrench to open
a cylinder valve that can not be opened by hand. Notify
your supplier.
Mixing gases. Never try to mix any gases in a cylinder.
Never refill any cylinder.
Cylinder fittings should never be modified or exchang-
ed.
3. Hose
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.
Use ferrules or clamps designed for the hose (not or-
dinary wire or other substitute) as a binding to connect
hoses to fittings.
No copper tubing splices. Use only standard brass fit-
tings to splice hose.
Avoid long runs to prevent kinks and abuse. Suspend
hose off ground to keep it from being run over, stepped
on, or otherwise damaged.
Coil excess hose to prevent kinks and tangies.
Protect hose from damage by sharp edges, and by
sparks, slag, and open flame.
Examine hose regularly for leaks, wear, and loose con-
nections. Immerse pressured hose in water; bubbles in-
dicate ieaks. |
Repair leaky or worn hose by cutting area out and splic-
ing (1-2D3). Do NOT use tape.
4. Proper Connections
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 lintiess cloth.
— Match regulator to cylinder. Before connecting, check
that the regulator label and cylinder marking agree, and
that the regulator inlet and cylinder outlet match.
NEVER CONNECT a regulator designed for a particular
gas or gases to a cylinder containing any other gas.
Tighten connections. When assembling threaded con-
nections, clean and smooth seats where necessary.
Tighten. If connection leaks, disassemble, clean, and
retighten using properly fitting wrench.
Adapters. Use a CGA adapter (available from your sup-
plier) between cylinder and regulator, if one is required.
Use two wrenches to tighten adapter marked RIGHT
and LEFT HAND threads.
Regulator outlet {or hose) connections may be iden-
tified 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 ex-
cessive compression heat at high pressure seat by
allowing seat to open on pressurization. Leav= adiusting
screw engaged slightly on single-stage regu'>ter
Stand to side of regulator while opening cylinder valve.
Open cylinder valve slowly so that regulator pressure in-
creases slowly. When gauge is pressurized {gauge
reaches regulator maximum} leave cylinder valve in
following position: For oxygen, and inert gases, open
fully to seal stem against possible leak. For fuel gas,
open to less than one turn to permit quick emergency
shutoff.
Use pressure charts {available from your supplier) for
safe and efficient, recommended pressure settings on
regulators.
Check for leaks on first pressurization and regularly
there-after. Brush with soap solution (capful of Ivory
Liquid* or equivalent per gallon of water). Bubbles in-
dicate leak. Clean off soapy water after test; dried soap
is combustible. |
E. User Responsibilities
Remove leaky or defective equipment from service im-
mediately for repair. See User Responsibility statement
in equipment manual.
*Trademark of Proctor €t Gamble.
OM-273 Page 3
F. Leaving Equipment Unattended
Close gas supply at source and drain gas.
G. Rope Staging-Support
Rope staging-support should not be used for welding or
cutting operation; rope may burn.
1-3. ARC WELDING - Comply with precautions in
1-1, 1-2, and this section. Arc Welding, propsrly done,
is a safe process, but a careless operator invites trouble.
The equipment carries high currents at significant
voltages. The arc is very bright and hot. Sparks fly,
fumes rise, ultraviolet and infrared energy radiates,
weldments are hot, and compressed gases may be us-
ed. The wise operator avoids unnecessary risks and pro-
tects himself and others from accidents. Precautions
are described here and in standards referenced in index.
A. Burn Protection
Comply with precautions in 1-2.
The welding arc is intense and visibly bright. Its radia-
tion 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 more severe and painful.
DON'T GET BURNED; COMPLY WITH PRECAU-
TIONS.
1. Protective Clothing
Wear long-sleeve clothing (particularly for gas-shieided
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
pockets to prevent entry of sparks.
2. Eye and Head Protection
Protect eyes from exposure to arc. NEVER look at an
electric arc without protection.
Welding helmet or shield containing a filter plate shade
no. 12 or denser must be used when welding. Place
over face before striking arc.
Protect filter plate with a clear cover plate.
Cracked or broken helmet or shield should NOT be
worn; radiation can pass through to cause burns.
Cracked, broken, or loose filter plates must be replaced
IMMEDIATELY. Replace clear cover plate when
broken, pitted, or spattered.
Page 4
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 in the field of vision.
3. Protection of Nearby Personnel
Enclosed welding area. For production welding, a
separate room or enclosed bay is best. In open areas,
surround the operation with low-reflective, non-
combustible screens or panels. Allow for free air circula-
tion, particularly at fioor level.
Viewing the weld. Provide face shields for ali persons
who will be looking directly at the weld.
Others working in area. See that all persons are wearing
flash goggles.
Before starting to weld, make sure that screen flaps or
bay doors are closed.
B. Toxic Fume Prevention
Comply with precautions in 1-2B.
Generator engine exhaust must be vented to the outside
air. Carbon monoxide can kill.
C. Fire and Explosion Prevention
Comply with precautions in 1-2C.
Equipment's rated capacity. Do not overload arc
welding equipment, It may overheat cables and cause a
fire.
Loose cabie connections may overheat or flash and
cause a fire.
Never strike an arc on a cylinder or other pressure
vessel. It creates a brittle area that can cause a violent
rupture or lead to such a rupture later under rough
handling.
D. Compressed Gas Equipment
Comply with precautions in 1-2D.
E. 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 surface when welding,
without suitable protection.
To protect against shock:
Keep body and clothing dry. Never work in damp area
without adequate insulation against electrical shock.
Stay on a dry duckboard, or rubber mat when damp-
ness or sweat can not be avoided. Sweat, sea water, or
moisture between body and an electrically HOT
part - or grounded metal - reduces the body surface
electrical resistance, enabling dangerous and possibly
lethal currents to flow through the body.
1. Grounding the Equipment
When installing, connect the frames of each unit such
as welding power source, control, work table, and
water circulator 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 li-
quid such as oil or fuel.
Three-phase connection. Check phase requirements of
equipment 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 equip-
ment ground lead to the third (live) wire, or the equip-
ment will become electrically HOT - a dangerous condi-
tion that can shock, possibly fatally.
Before welding, check ground for continuity. Be sure
conductors are touching bare metal of equipment
frames at connections.
If a line cord with a ground lead is provided with the
equipment for connection to a switchbox, connect the
ground lead to the grounded switchbox. If a three-
prong plug is added for connection to a grounded
mating receptacle, the ground lead must be connected
to the ground prong only. If the line cord comes with a
three-prong plug, connect to a grounded mating recep-
tacle. Never remove the ground prong from a plug, or
use a plug with a broken off ground prong.
2. Electrode Holders
Fully insulated electrode holders should be used. Do
NOT use holders with protruding screws.
3. Connectors
Fully insulated lock-type connectors should be used to
join welding cable lengths.
4. Cables
Frequently inspect cables for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn
or damaged insulation to avoid possibly - lethal shock
from bared cable. Cables with damaged areas may be
taped to give resistance equivalent to original cable.
Keep cable dry, free of oil and grease, and protected
from hot metal and sparks.
5. Terminals And Other Exposed Parts
Terminals and other exposed parts of electrical units
shouid have insulating covers secured before operation.
6. Electrode Wire
Electrode wire becomes electrically HOT when the
power switch of gas metal-arc welding equipment is ON
and welding gun trigger is pressed. Keep hands and
body clear of wire and other HOT parts,
7. Safety Devices
Safety devices such as interlocks and circuit breakers
should not be disconnected or shunted out.
Before installation, inspection, or service, of equip-
ment, shut OFF all power and remove line fuses {or lock
or red-tag switches) to prevent accidental turning ON of
power. Disconnect all cables from welding power
source, and pull all 115 volts line-cord plugs.
Do not open power circuit or change polarity while
welding. If, in an emergency, it must be disconnected,
guard against shock burns, or flash from switch arcing.
Leaving equipment unattended. Always shut OFF and
disconnect all power to equipment.
Power disconnect switch must be available near the
welding power source. |
1-4. STANDARDS BOOKLET INDEX
For more information, refer to the following standards
or their latest revisions and comply as applicable:
1. ANSI Standard 249.1, SAFETY IN VE. NG
AND CUTTING obtainable from the American
Welding Society, 2501 NW 7th St., Miami, FL
33125.
2. NIOSH, SAFETY AND HEALTH IN ARC
WELDING AND GAS WELDING AND CUTTING
obtainable from the Superintendent of
Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
3. OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the U.S. Govern-
ment Printing Office, Washington, D.C. 20402.
4. ANSI Standard 287.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
5. ANSI Standard Z41.1, STANDARD FOR MEN'S
SAFETY-TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
OM-273 Page b
10.
Page 6
ANSI Standard 249.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO-
CESSES obtainable from the American National
Standards Institute, 1430 Broadway, New York,
NY 10018.
AWS Standard A6.0, WELDING AND CUT-
TING CONTAINERS WHICH HAVE HELD COM-
BUSTIBLES obtainable from the American
Welding Society, 2501 NW 7th Street, Miami,
FL 33125.
NFPA Standard 51, OXYGEN - FUEL GAS
SYSTEMS FOR WELDING AND CUTTING ob-
— tainable from the National Fire Protection
Association, 470 Atlantic Avenue, Boston, MA
02210.
NFPA Standard 70-1978, NATIONAL ELEC-
TRICAL CODE obtainable from the Nationa! Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
NFPA Standard 51B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
11.
12.
13.
14.
15.
CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS obtainable
from the Compressed Gas Association, 500 Fifth
Avenue, New York, NY 10036.
CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the
Canadian Standards Association, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W 1R3.
NWSA bookiet, WELDING SAFETY
BIBLIOGRAPHY obtainable from the National
Welding Supply Association, 1900 Arch Street,
Philadelphia, PA 19103.
American Welding Society Standard AWSF4.1
“Recommended Safe Practices for the Prepara-
tion for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances”,
obtainable from the American Weiding Society,
2501 NW 7th Street, Miami, FL 33125.
ANSI Standard Z88.2 ‘Practice for Respiratory
Protection” obtainable from the American Na-
tional Standards Institute, 1430 Broadway, New
York, NY 10018.
assesses SECTION 2 - INTRODUCTION 550mm IE
Input At Rated
Rated Load Output
Welding Max. 60 Hz. Three-Phase
Current Open- .
Amperes Voltage | Circuit | Amperes At Overall Weight
Model |100% Duty Cycle | Range | Voltage | 230V | 460V | kva kw Dimensions Net Ship
Height - 27-1/2 in. (699 mm)
a | 0 E | 1232 | 42 | 38 | 19 | 15.1 | 12.4 | Width - 22-1/4 in. (565 mm) 1209 os (292 og
pe Depth - 35-3/4 in. (908 mm) gs. gs.
Figure 2-1. Specifications
pa
2 - 1. GENERAL INFORMATION AND SAFETY
A. General
Information presented in this manual and on various
labels, tags, and plates provided on this unit pertains to
equipment design, installation, operation, maintenance
- and troubieshooting which should be read, understood
and followed for the safe and effective use of this equip-
ment.
B. Safety
The installation, operation, maintenance, and
troubleshooting of arc welding equipment requires
practices and procedures which ensure personal safety
and the safety of others. Therefore, this equipment is to |
be installed, operated and maintained only by qualified :
persons in accordance with this manual and all ap-
plicable codes such as, but not limited to, those listed at
the end of Section 1 - Safety Rules For Operation Of
Arc Welding Power Source.
Safety Instructions specifically pertaining to this unit ap-
pear throughout this manual highlighted by the signal
words and which identify
different levels of hazard.
RINDE statements include installation, operating,
and maintenance procedures or practices which if not
carefully followed could result in serious personal injury
or loss of life. |
statements include installation, operating
and maintenance procedures or practices which if not
carefully followed could result in minor personal injury
or damage to this equipment.
A third signal word, ИВТ 7:18 highlights instruc-
tions which need special emphasis to obtain the most
efficient operation of this equipment.
2-2. RECEIVING-HANDLING - Prior to installing
this equipment, ciean 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 will be furnished by the manufacturer on re-
quest if occasion to file claim arises.
When requesting information concerning this equip-
ment, it is essential that Model Description and Serial
Number of the equipment be supplied.
2 - 3. DESCRIPTION - This unit is a thre- “hase
constant potential DC arc welding power source with
solid state control. It produces DC weld current and is
designed to be used for Gas Metal-Arc Welding
(GMAW). The number in the model designation refers
to the rated welding current in amperes.
SEM SECTION 3 - INSTALLATION "N
3 - 1. LOCATION (Figure 3-1)
AVANT VIR IMPROPER LIFTING OF EQUIPMENT
can result in personal injury and equipment
damage.
e Use equipment of adequate capacity to lift the
unit.
e [fusing lift forks to handle this unit, be sure the lift
forks are long enough to extend out of the op-
posite side of the base.
Using lift forks too short will expose internal com-
ponents to damage should the tips of the lift forks
penetrate the bottom of the unit.
RESTRICTED AIR FLOW causes overheating and
possible damage to internal parts.
e Maintain at least 18 inches (457 mm) of
unrestricted space on all sides of unit and keep
underside free of obstructions.
® Do not place any filtering device over the intake air
passages of this welding power source.
Warranty is void if any type of filtering device is used.
This welding power source has a lifting device for mov-
ing the unit and holes in the base for mounting pur-
poses. Figure 3-1 gives overall dimensions and base
mounting hole layout.
The location should allow room to remove cover and
panels for maintenance and repair.
OM-273 Page 7
7/16 in. (11.1 mm)
Dia. 4 Holes
Base Mounting Hole Layout
inches | Millimeters
A 1-1/2 38.1
В 32-3/4 831.9
C 35-3/4 908.1
D 1-1/8 28.6
E 2211/4 565.2
F 20 508.0
G 27-172 698.5
H 2-3/4 65.9
Tr-(85 286
Figure 3-1. Dimensional Drawing
The service life and efficiency of this unit are reduced
when the unit is subjected to high levels of dust, dirt,
moisture, corrosive vapors, and extreme heat.
3-2. WELD OUTPUT CONNECTIONS (Figure
4-1) - To obtain the full rated output from this unit, itis
necessary to select, install, and maintain proper welding
cables. Failure to comply in any of these areas may
result in less than satisfactory welding performance.
A. Welding Cables
If welding cables were not ordered with this unit, the
steps listed should be followed to ensure the best
welding performance:
Table 3-1. Welding Cable Size
“TOTAL LENGTH OF CABLE (COPPER) IN WELD CIRCUIT
WELDING
AMPERES | *50 | 100 150 200 250 300 350 400
100 4 4 2 2 2 1 1/0 1/0
150 2 2 2 1 1/0 2/0 3/0 3/0
200 1 1 1 1/0 2/0 3/0 4/0 4/0
250 1/0 1/0 1/0 2/0 3/0 4/0 4/0 2-2/0
300 2/0 2/0 2/0 3/0 4/0 4/0 2-2/0 | 2-3/0
350 3/0 3/0 3/0 4/0 4/0 2-2/0 | 2-3/0 | 2-3/0
400 3/0 3/0 3/0 4/0 2-2/0 | 2-3/0 | 3-2/0 | 2-4/0
A002 623
NOTE: "A. G50 FEET OR LESS.
“В. CABLE SIZE IS BASED ON DIRECT CURRENT (DC),
100% DUTY CYCLE AND EITHER A 4 VOLTS OR LESS
DROP OR A CURRENT DENSITY OF NOT OVER 300
CIRCULAR MILS PER AMP.
*C. WELD CABLE INSULATION WITH A VOLTAGE
RATING TO WITHSTAND THE OPEN-CIRCUIT VOLT-
AGE (OCV) OF THE WELDING POWER SOURCE MUST
BE USED. WHILE MOST WELDING POWER SOURCES
HAVE AN OPEN-CIRCUIT VOLTAGE OF LESS THAN
100 VOLTS, SOME WELDING POWER SOURCES OF
SPECIAL DESIGN MAY HAVE HIGHER OPEN-CIRCUIT
VOLTAGE.
1. Keep cables as short as possible and place cables
close together. Excessive cable length adds
resistance which may reduce output or cause
overloading of the unit.
2. Select adequate size welding cable for the an- |
ticipated maximum weld current. Use total
length of welding cables in the circuit to deter-
mine cable size. For example: If the electrode
holder cable is 75 feet (23 m) long and the work
cable is 25 feet (8 m) long, select the size cabie
recommended in Table 3-1 for 100 ft (31 m).
Page 8
3. Do not use damaged or frayed cabies,
4. Install correct size lugs onto ends of both cables
for connecting to work clamp, wire feeder, and
weld output terminals.
5, Install work clamp onto cable.
B. Installation (Figure 4-1)
LLU ELECTRIC SHOCK can Kill.
Do not touch live electrical parts.
. Shut unit down and be sure it cannot be acciden-
tally energized before making weld output con-
nections.
1. Connect work cable to NEGATIVE weld output
terminal.
2. Connect one end of remaining cable to
POSITIVE weld output terminal.
3. Connect remaining end of POSITIVE weld out-
put cable to wire feeder.
The connections given are for DC
reverse polarity. If DC straight polarity is desired,
reverse cable connections to weld output terminals
{work becomes positive).
3-3. 115 VOLTS AC RECEPTACLES (Figure
4-1} - Two receptacles, both labeled 115 VOLTS AC,
are provided. The duplex 115 VOLTS AC receptacle will
furnish up to 15 amperes of 115 volts AC to operate ex-
ternal accessories. The three-pole, twistlock, 115
VOLTS AC receptacie is intended to be used for supply-
ing operating power to the wire feeder. To secure the
corresponding three-pole plug into the twistlock recep-
tacle, rotate the plug clockwise.
The 115 volts auxiliary power circuitry
is protected by a circuit breaker CB1. Should an
overload condition occur at either of the 115 VOLTS
AC receptacles, the circuit breaker would open and sus-
pend all output to these receptacles. It will then be
necessary to manually depress the circuit breaker to
reset it.
3-4. REMOTE CONTACTOR CONTROL CON-
NECTIONS (Figure 4-1)
Although the term CONTACTOR is
used on the nameplate and throughout this manual, the
outputis not switched on or off by a physical secondary
contactor; rather, the output is controlled by a Silicon
Controlled Rectifier (SCR) stack which functions as a
contactor,
The REMOTE CONTACTOR CONTROL receptacle pro- |
vides a junction point for connecting a Remote Contac-
tor Control device to the contactor control circuitry in
the welding power source. This receptacie is provided
for use with the Gas Metal-Arc Welding (GMAW) pro-
cess.
To connect the Remote Contactor Control to the
REMOTE CONTACTOR CONTROL receptacle, insert
the two-pole plug from the Remote Contactor Control
device into the REMOTE CONTACTOR CONTROL
receptacle and rotate clockwise.
3-5. REMOTE VOLTAGE CONTROL CONNEC-
TIONS (Figure 4-1)
If the welding application warrants
such usage, this receptacle can also function as the
~ Contactor Control receptacle by employing the ap-
propriate switch (control) and placing the REMOTE
CONTACTOR CONTROL switch in the ON position.
The REMOTE VOLTAGE CONTROL receptacle pro-
vides a junction point for connecting a Remote Voltage
Control (and/or a Remote Contactor Control) to the
control circuitry of the welding power source. Insert the
Remote Control plug fully into the receptacle and rotate
the threaded collar clockwise.
3 - 6. ELECTRICAL INPUT CONNECTIONS
A. Electrical Input Requirements
This welding power source is designed to be operated
from a three-phase, 60 Hertz, AC power supply which
has a line voltage rating that corresponds with one of
the electrical input voltages shown on the nameplate.
Consult the local electric utility if there is any question
about the type of electrical system available at the in-
stallation site or how proper connections to the welding
power source are to be made.
B. Matching The Welding Power Source To
The Available Input Voltage
This unit is equipped with input voltage jumper links on
the primary terminal boards which allow operation from
different line voltages. This unit is shipped with the
jumper links positioned for the highest voltage stated on
the nameplate. If the unit is to be operated from the
lower input voltage, open the rear panel access door
and reposition the jumper links to correspond to the
available line voltage (see input voltage label inside rear
access door).
ELEUIENE INCORRECT INPUT VOLTAGE
JUMPER LINK PLACEMENT can damage unit.
e Position jumper links as shown on the input
voltage label located on rear panel access door.
e: FE Store unused jumper links across link-
ed terminals.
C. Input Conductor Connections
NTE ELECTRIC SHOCK can Kill.
Do not touch live electrical parts.
. It is recommended that a fusible line disconnect
switch be installed in the input circuit to the
welding power source.
This would provide a safe and convenient means to
completely remove all electrical power from the welding
power source whenever it is necessary to internally in-
spect or service the unit. -
e Employ “Tockout/tagging procedures” on input
line before making input connections to the
welding power source.
Lockout/tagging procedures consist of padiocking line
disconnect switch in open position, removing fuses
from fuse box, or tagging circuit breaker or other
disconnecting device.
® Connect input conductors to the welding power
source before connecting to single-phase input
power.
Table 3-2 provides guidelines for selecting the proper
size input conductors and line fuses. The input conduc-
tors should be covered with an insulating material that
meets local electrical standards.
Table 3-2. Input Conductor And Fuse Size
Primary Wire Size _ Fuse Size {Amperes)
200V 230V 460V 575V | 200V | 23CV | 460V | 575V
No. 8 No. 8 No. 12 | No. 14
{No. 10} | {No. 10} | (№. 12) {No. 14)
70 60 30 20
B-048 933
Figure 3-2. Input Conductor Connections
Install terminal lugs of adequate amperage capacity (see
Table 3-2) and correct stud size to the input and ground
conductors. Open the rear panel access door and insert
the conductors through the access hole in the rear panel
(see Figure 3-2). This hole will accept standard conduit
fittings.
OM-273 Page 9
MZLLILISE ELECTRIC SHOCK can kill. Connect the input conductors to the line terminals on
e Do not connect an input conductor to the ground the primary terminal board and connect the ground con-
terminal in the unit. ductor to the ground terminal. (Refer to the input
e [Do not connect the ground conductor to an input voltage label for identification of these terminals.)
line terminal.
incorrect input connections can result in an electrically Connect the remaining end of the ground conductor to
energized welding power source chassis. The ground a proper ground. Use a grounding method that is accep-
terminal is connected to the welding power source table to the local electrical inspection authority.
chassis and is for grounding purposes only.
SECTION 4 - OPERATOR CONTROLS sms nm
Voltage
Adjustment
Voltmeter Ammeter Control Pilot Light
Remote Contactor O1 ‘ Power
Control и rer ee farrell o Control
| © | | ¥ 4 | Switch
115 Volts AC IS TON
Twistlock 1. leales «E — 115 Volts
Receptacle | ©) ©) с ‚ ML # AC Duplex
Remote Voltage > Se | Receptacle
Control Receptacls Pai а — DE N
KZ ST 37 —3 on
Remote Voltage | бои с ps к ro
Control Switch Не 38 3 4 —4
= >=)
Remote Contactor | & — £ — ¢ 3
Control Switch | — — т ST вы
| = DLL ES
Positivo Weld |
Output Terminal
о
5
— Negative Weld
Output Terminal
T8-085 306.
Figure 4-1. Front Panel View
4-1. POWER CONTROL SWITCH (Figure 4-1) of the welding power source. Rotating the contro! in a
| | clockwise direction increases the load voltage. The
scale surrounding the VOLTAGE ADJUSTMENT con-
P
OWER | ON trol is calibrated in DC volts.
6») O OFF The VOLTAGE ADJUSTMENT con-
trol can be adjusted while welding.
Place the POWER CONTROL switch in the ON position *
to energize the welding power source and place itina | 4-4. VOLT-AMPERE CURVES (Figure 4-2) - The
ready-to-weld status. Place the POWER CONTROL | volt-ampere curves show the voltage and amperage
switch in the OFF position to shut the welding power 50 |
source down.
4 - 2, PILOT LIGHT (Figure 4-1) - A PILOT light is 40
provided to indicate when the welding power source is an млн
energized and in a ready-to-weld status. The PILOT a sor —
light should illuminate whenever the POWER switch is о
in the ON position. | o 20 L —
4 -3. VOLTAGE ADJUSTMENT CONTROL
(Figure 4-1) 10 E] MIN.
\/ a a
0 100 200 300 400 500
DC AMPERES
B-084 982
The VOLTAGE ADJUSTMENT control provides a
means of selecting the desired voltage within the range Figure 4-2. Volt-Ampere Curves
Page 10
output capabilities of the welding power source at the
min. and max. values of the VOLTAGE ADJUSTMENT
control. Curves of other settings will fall between the
curves shown.
With the use of the volt-ampere curves it is possible to
determine the weld current at any particular load
voltage.
4 - 5. DUTY CYCLE (Figure 4-3) - The duty cycle of
a welding power source is the percentage of a ten
minute period that a welding power source can safely
be operated at a given output. This welding power
source is rated at 100 percent duty cycle. This means
that the welding power source can be safely operated at
rated load continuously. Figure 4-3 enables the operator
to determine the safe output of the welding power
source at various duty cycles.
RATED OUTPUT —
600
500
>
400 <
>
WELDING AMPERES
300
250
30 40 50 60 70 80 90 100
% DUTY CYCLE 5.085 000
Figure 4-3. Duty Cycle
EXCEEDING DUTY CYCLE RATINGS
will damage the welding power source.
® Do not exceed the duty cycles indicated on the
duty cycle chart.
4 - 6. REMOTE VOLTAGE CONTROL RECEP-
TACLE & SWITCH (Figure 4-1)
IV
If a Remote Voltage Control is to be used, make con-
nections from the Remote Voltage Control to the
REMOTE VOLTAGE CONTROL receptacie as in-
structed in Section 3-5.
When remote contro! of the voltage is desired, it is
essential that the REMOTE VOLTAGE CONTROL
switch be placed in the ON position. Likewise, if a
Remote Voltage Control is not to be utilized, the switch
must be in the OFF position. When in the OFF position
only the VOLTAGE ADJUSTMENT control on the front
panel will control the voltage.
if the welding application warrants
such usage, this receptacle can also function as the
Contactor Control receptacle by employing the ap-
propriate switch (control) and placing the REMOTE
CONTACTOR CONTROL switch in the REMOTE post
tion.
4 - 7. REMOTE CONTACTOR CONTROL RECEP-
TACLE & SWITCH (Figure 4-1) |
ВЕМОТЕ
СОМТАСТОВ | ON
[A] Vo O OFF
ELECTRIC SHOCK can till.
e Do not touch five electrical parts. |
When the REMOTE CONTACTOR CONTROL switch is
in the OFF position, open-circuit voltage is present at
the secondary terminals for as long as the welding
power source is energized.
The contactor control circuitry in this welding power
source enables the operator to remotely control the
availability of weld output from the work station.
If a Remote Contactor Control is to be used, make con-
nections to the REMOTE CONTACTOR CONTROL
receptacle as instructed in Section 3-4. Place the
REMOTE CONTACTOR CONTROL switch in the ON
position. Place the POWER CONTROL switch in the ON
position. Weld output will be available whenever the
remote contactor control switch is closed.
If a Remote Contactor Control is not to be used, place
the REMOTE CONTACTOR CONTROL switch in the
OFF position. When in the OFF position, weld output
will be available after the POWER CONTROL sv "ch is
placed in the ON position. Weld output will continue
until the POWER CONTROL switch is placed in the OFF
position.
4 - 8. METERS (Figure 4-1) - This welding power
source is equipped with a DC ammeter and a DC
voltmeter. These meters are internally connected to the
welding power source weld output terminals. The
voltmeter indicates the DC voltage at the secondary ter-
minals, but will not necessarily indicate the actual
voltage at the welding arc. If the welding cables are ex-
cessively long, or have poor, loose connections, the dif-_
ference between actual arc voltage and the voltage at
the welding power source secondary terminals may be
considerable. The ammeter indicates the weld current
output of the welding power source.
4 - 9. FOLDBACK CIRCUIT OPERATION - The
foldback circuit is designed to prevent SCR failure caus-
ed by sustained short-circuit conditions. This circuitry
will automatically reduce the output until the short-
circuit condition is removed, at which time normal unit
operation will automatically resume. The circuitry will
not affect normal operation of the welding power
source.
OM-273 Page 11
4-10. OVERLOAD PROTECTION - This unit is
equipped with normally-closed thermostat TP3 located
on the rectifier and wired in series with the main contac-
tor W coil. Should overheating of the rectifier occur, the
thermostat would open dropping out the main contac-
tor and thereby suspending ail weld output. A cooling
period would then be needed before resuming opera-
tion.
This unit is also equipped with two normally open ther-
mostats TP-1 in the rectifier, and TP-2 in the main
transformer which, when activated, apply power to the
fan motor. The fan motor will run until both thermostats
open or the unit is shut down.
Ts SECTION 5 - SEQUENCE OF OPERATION mess arama
ELECTRIC SHOCK can kill; MOVING
PARTS can cause serious injury; IMPROPER AIR
FLOW AND EXPOSURE TO ENVIRONMENT can
damage internal parts.
e Keep all covers and panels in place while
operating.
Warranty is void if the welding power source is operated
with any portion of the outer enclosure removed.
ARC RAYS, SPARKS, AND HOT SURFACES can
burn eyes and skin; NOISE can damage hearing.
® Wear correct eye, ear, and body protection.
FUMES AND GASES can seriously harm your
health.
® Use enough ventilation to keep fumes and gases
from the breathing zone.
See Section 1 - Safety Rules For Operation Of Arc
Welding Power Source for basic welding safety infor-
mation.
5-1. GAS METAL-ARC WELDING (GMAW)
1. Install the unit as instructed in Section 3.
2. Place the REMOTE CONTACTOR CONTROL
switch in the desired position (see Section 4-6).
3. Place the REMOTE VOLTAGE CONTROL switch
in the desired position.
——m——————_" SECTION 6 -
MAINE ELECTRIC SHOCK can Kill.
® Disconnect input power and employ
“lockout/tagging procedures” before internally
inspecting or servicing.
Lockout/tagging procedures consist of padlocking line
disconnect switch in open position, removing fuses
from fuse box, or tagging circuit breaker or other
disconnecting device.
Periodically inspect the labels on this
unit for legibility. All precautionary labels must be main-
tained in a clearly readable state and replaced when
necessary. See Parts List for part number of precau-
tionary labels.
6 - 1. FAN MOTOR - This unit is equipped with an
exhaust fan and relies on forced draft for adequate cool-
ing. The fan motor is manufactured with lifetime sealed
bearings and requires no maintenance.
Page 12
4. Rotate the VOLTAGE ADJUSTMENT control to
the desired position.
5. Turn on shieiding gas supply.
6. Place the Line Disconnect Switch in the ON posi-
tion.
7. Piace the POWER CONTROL switch in the ON
position and begin weiding (see Section 4-2).
. SHUTTING DOWN
1. Break the arc.
2. Allow the welding power source to idle for 3
minutes with no load applied.
3. Place the POWER CONTROL switch in the OFF
position.
4. Turn off the shielding gas at the shielding gas
source.
КОЛО HIGH CONCENTRATION ОЕ
SHIELDING GASES can harm health or kill.
e Shut off gas supply when not in use.
MAINTENANCE mms Sn
6 - 2. INTERNAL CLEANING - Occasionally blow
out the dust and dirt from around the internal com-
ponents of the weiding power source. Do this
periodically, depending upon the location of the unit
and the amount of dust and dirt in the atmosphere.
Remove the outer enclosure of the welding power
source and use a clean, dry airstream or vacuum suction
for this cleaning operation.
6 - 3. WELD CABLES - Periodically inspect cables
for breaks in insulation and ensure that all connections
are clean and tight. Repair or replace cables as
necessary. Clean and tighten connections periodically.
6 - 4. CONTROL CIRCUIT PROTECTION - The en-
tire control circuit of the welding power source is pro-
tected by cartridge type fuse F1. This fuse is located
behind the rear access panel, immediately to the upper
right.
assesses SECTION 7 - TROUBLESHOOTING mee Sm
7-1. GENERAL - It is assumed that proper installa-
tion has been made, according to Section 3 of this
manual, and that the welding power source has been
functioning properly until this trouble developed.
7-2. TROUBLESHOOTING CHART - The follow-
ing chart is designed to diagnose and provide remedies
for some of the troubles that may develop in this
welding power source.
tion should be contacted. In all cases of equipment
malfunction, the manufacturers recommendations
shouid be strictly followed.
КОН ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
e Disconnect unit from input power before internal-
ly inspecting or servicing.
MOVING PARTS can cause serious injury.
` ® Keep clear of moving parts.
‘Use this chart in conjunction with the circuit diagram | HOT SURFACES can cause severe burns.
while performing troubleshooting procedures. If the | e Allow cooling period before servicing.
trouble is not remedied after performing these pro-
cedures, the nearest Factory Authorized Service Sta-
Troubleshooting of internal parts to be performed only
by qualified persons. | |
TROUBLE
PROBABLE CAUSE
REMEDY
Completely inoperative.
Open line fuse(s).
Replace open line fuse(s).
Defective POWER CON-
TROL switch.
Replace defective POWER CONTROL switch.
Poor and/or improper input
connections.
Refer to Section 3-6 for proper input connections. |
Main rectifier SRI1
overheating.
Allow unit to cool down. See Section 4-9.
No weld output; fan
operative.
Poor electrical input and/or
primary connections.
Check electrical input and/or primary connections
at the primary terminal board TE1.
Improper electrical input
and/or secondary connec-
tions.
Refer to Sections 3-6 and 3-2 for proper electrical
input and secondary connections.
REMOTE CONTACTOR
CONTROL switch S4 in ON
position without a remote
contactor control con-
nected to the welding
power source.
desired, retain the REMOTE CONTACTOR CON-
if remote contactor control is not desired, piz~e
the REMOTE CONTACTOR CONTROL switch 54
in the OFF position. If remote contactor control is
TROL switch S4 in the ON position and make
remote contactor control connections as in-
structed in Section 3-4.
Printed circuit card PCI
defective or loose in edge
connector.
Check printed circuit card PC1 connection. If PC1
loose in connector, tighten. If PC1 defective,
replace.
Limited output and low load
voltage.
Operation on single-phase.
Open line fuse on one
phase.
Check incoming three-phase power for correct
voltage. Replace fuse if open.
Input voltage jumper links
connected for incorrect in-
put voltage.
See input voltage label.
Poor and/or improper input
connections.
Refer to Section 3-6 for proper input connections,
OM-273 Page 13
TROUBLE
PROBABLE CAUSE
REMEDY
Erratic weld current.
Incorrect welding cable
size.
Use proper size and type of cable. See Section
Loose welding cable con-
nection.
Tighten all welding connections.
Improper wire feeding set-
up. :
See INSTALLATION Section in Wire Feeder
Owner's Manual. |
Defective SCR in тат гес-
tifier SR1.
Replace defective SCR.
Printed circuit card PC1
defective.
Replace printed circuit card PC1.
High weld output;
VOLTAGE ADJUSTMENT
Control does not vary out-
put.
Printed circuit card PCT
defective or loose in edge
connector.
Check printed circuit card PC1 connection. If PC1
loose in connector, tighten. If PC1 defective,
replace.
No output at 115 VOLTS
AC receptacle RC3 and
RC4.
Circuit breaker CB1 open.
Reset circuit breaker CBT.
Page 14
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IO STAN L
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123H Ni Lat
LAH MI Tal
JAY SIN
JAILISOd
Lan
OM-273 Page 15
12а равоя иполо резина 104 WILIBeIG NIN ‘Z-Z 84N814
Y-bE9 ESO-9 "ON WEIBEIQ HNL) sos
S13d0n "Y 058 NO
JASN 10N 20794 177y x
HY HAMS
HOLIVANDD
Page 16
May 1982 FORM: OM-273A
Effective With Serial No. JC612919
PARTS
LIST
13 12
Figure A - Front View
OM 273 Page 1
ltem Dia. Part
No. Mkgs. No. Description Quantity
Figure A Front View
1 RCH 039 634 RECEPTACLE, twistlock - flange 2P2W 20 amp 2b0 volts .................. 1
039 635 CONNECTOR BODY, twistlock 2P2W 20 amp 250 voltS. 1
2 V 025 637 METER, voit dc 0-50 scale 111020000042 i ec ee eee 00 1
3 S2,4 011 609 SWITCH, toggle SPDT 15amp12bvolts ............ cis, 2
4 A 025 663 METER, amp de 50 MV 0-400 scale ..............eeeemererverexeeeeneno. 1
5 019 627 KNOB, pointer (R5).................oeeemerdrrrirrerearacareca ca rene, 1
6 PLT 027 645 LIGHT, indicator-redlens125voltsac ........... iii. 1
7 Si 011620 SWITCH, toggle SPST 16 amp 125 volts ...............eee2eece0vereeoo. 1
8 RCA 604 176 RECEPTACLE, straight duplex - grounded 2P3W 15 amp 277 volts .......... 1
9 CBI 020 278 SWITCH, circuit breaker 15 amp..........0200202000000 120 e 114 a eee eee 0 1
10 605 583 CATCH, spring loaded - door .................. e. .eeeseororecanrenmeree.. 2
11 + 027 408 DOOR, access front ............_ e. .0eexieesiaaeaaracararonnnernavercero 1
047 497 LABEL, general precautionary ............ee ee. e_eececeeccenecrororaroraroo 1
12 NEG 039 046 TERMINAL, power output (consistingof) ................................ 1
601 976 . SCREW, cap - hex hd 1/2-13 x 1-1/2 ... ii ieee. 1
039 045 . TERMINAL BOARD, black .... cc iii i 0 se eee ee a a a ea ae en 1 -
601 880 . NUT, пех - ат 172-13 ee eee ee eee 1
039 044 BUS BAR «i i a ee ea 1
601 879 NUT, hex -full 1/2-13 ee eee e ns 1
13 POS 039 047 TERMINAL, power output{consistingof) ............... iii... 1
601 976 . SCREW, cap - hex hd 1/2-13 x 1-1/2 i eee eee 1
039 049 . TERMINAL BOARD, red .......12111 100110 ea aa 4 a aa aa a a a 4 ae aa a 0 1
601 880 . МОТ, Пех - ат 172-13 ................ 5..5... 80 вне ea a ae a a ae a a a ea an 1
039 044 BUS BAR oe a a aan 0 1
601 879 .NUT, hex - full 1/2-13 ee eee eee cain 1
| 039 684 CAP, dust - connector (RC1)................ 2.2... 00 00000aaaaooeenace.. 1
14 RCI 035 523 RECEPTACELE, 5 socket MS-3102A-165-86$..................2. 0000 1
15 RC3 039 773 RECEPTACLE, twistlock - grounded 2P3W 15 amp 277 volts ............... 1
16 NAMEPLATE (order by model Et serial number) ............... 2... 00... 1
039 687 CAP, twistlock - grounded 2P3W 15 amp 277 volts ........_......e882e=..... 1
+ When 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.
OM-273 Page 2
cl
LL
MBIA apis 3497 - q einBi
8L
Page 3
Dia. Part .
No Mkgs. No. Description Quantity
Figure B Left Side View
1 018 144 PANEL, rear. ....... iii ieee ites 1
2 R7 026 520 RESISTOR, grid ........... iain. PS 1
3 WwW 605 855 CONTACTOR, 40 amp 3 pole 120 volts (consisting of) . . 1
032349 , COIL, 120 voltsac............ _eeereererererecteo. 1
CRI 059 266 RELAY, enclosed 120 volts ac DPDT 20 amp .......... 1
4 CR6 039 498 RELAY, enclosed 120 volts ac 3PDT w/fiange ......... 1
5 026 627 GASKET, lifting eye ..........._—.—.—._—-—eerrerereereare 1
6 R4,6. 028 840 RESISTOR, WW adj300 wattbohm................. 2
7 T2 605 856 TRANSFORMER, control 230/460-1115 .............. 1
8 049 361 COVER, circult card ...........e_eeoee reee eeeeeran 1
073 756 STAND-OFF, No. 6-32 x 5/8 x 1/4 hex.......... ene. 5
PC1 085 442 CIRCUIT CARD, control {consistingof)............... 1
A50,51 052 133 . AMPLIFIER, operational .........e._.eeeresscaroooo 2
AB? 035 845 . AMPLIFIER, operational ............ e—_ececesrmemoo 1
A201,300,301 009 159 . AMPLIFIER, operational .................Ñ..Ñ”eeooooo 3
C51-53 035 834 .CAPACITOR, metalized film 1.5 uf 100 volts ......... 3
C54,56,59-61,63, |
66-68,70,73,74 035 833 . CAPACITOR, mylar0.033 uf 100 volts de. ........... 12
C55,62,69 035 835 .CAPACITOR, electrolytic 4.7 uf 35 volts ............. 3
C57,58,71,72,77,
80,82,96,300,301 053 991 . CAPACITOR, ceramic 0.05 uf500 volts ............. 10
C76,79 000 859 . CAPACITOR, electrolytic 220 uf 35 volts de .......... 2
C78,81,201 007 742 .CAPACITOR, electrolytic 10 uf 35 volts ............. 3
C83,88-93,97-99 059 122 . CAPACITOR, ceramic 0.01 uf500 volts ............. 10
C102 003 530 . CAPACITOR, ceramicTufb50volts ................. 1
C202 072 935 .CAPACITOR, electrolytic 33 uf 35 volts de ........... 1
C302-304 072 130 . CAPACITOR, tantalum 1 uf35voltsde.............. 3
C3056 031 677 .CAPACITOR, tantalum 5.6 uf 35 volts de ............ 1
D50-52,54-56,58-60,62-64,
66-68,70-72,74,75,81,
82,87,201,301,302 028 351 . DIODE, signal 0.020 amp 75 volts straight polarity . . .. 26
D53,57,61,65,69,73,76,77 026 202 . DIODE, rectifier 1 amp 400 volts straight polarity ...... 8
D90 028 293 . DIODE, zener6.2voltsTwatt ...................... 1
C300 008 968 . INTEGRATED CIRCUIT, dual SPST................. 1
Q50,52,54,56,58,60 037 277 . TRANSISTOR, 200MA30 volts NPN ............... 6
Q51,53,55,57,59,61,300 035 842 . TRANSISTOR, 6 amp 40 volts PNP ................. 7
063 000 088 . TRANSISTOR, 800MA 40 volts NPN ............... 1
0201 037 200 . TRANSISTOR, 200MA 40 volts NPN ............... 1
0202 037 201 . TRANSISTOR, 200MA 40 volts PNP................ 1
R50-52 000 885 . RESISTOR, carbon film 0.25 watt 10Kohm .......... 3
R53,54,61,62,68,75,76,
82,83,90,91,124,141-146 035 884 . RESISTOR, carbon film 0.25 watt 100K ohm ......... 18
R55,63,69,77,84, |
92,108,216,218 03b 826 . RESISTOR, carbon film 0.25 watt 6800 ohm ......... 9
R56,64,70,78,85,93,111, |
112,129,217 ‚219,305 035 827 . RESISTOR, carbon film 0.25 watt 10K ohm .......... 12
R57,65,71,79,86,94 035 825 . RESISTOR, carbon film 0.25 watt TK ohm ........... 6
R58,72,87 035 823 . RESISTOR, carbon film 0.25 watt 100 ohm .......... 3
R59,66,73,80,88,95 035 824 . RESISTOR, carbon film 0.25 watt 270 ohm .......... 6
R60,67,74,81,89,96 605 919 . RESISTOR, carbon0.25watt47ohm............... 6
R104 035 820 . RESISTOR, carbon film 0.50 watt 470 ohm .......... 1
R107,126,302 035 888 . RESISTOR, carbon film 0.25 watt 2200 ohm ......... 3
R109 039 332 .RESISTOR, carbon film 0.25 watt 15K ohm .......... 1
R113,116 030 089 . RESISTOR, carbon 0.5 watt 2.7 ohm ............... 2
R119 030 045 . RESISTOR, WW fixed 3.25 watt 100 ohm ........... 1
.R122 038 325 . RESISTOR, carbon film 0.25 watt 82K ohm .......... 1
R125,209 035 887 . RESISTOR, carbon film 0.25 watt 3300 ohm ......... 2
R127 039 329 . RESISTOR, carbon film 0.25 watt 2700 ohm ......... 1
R147,148,301 035 896 . RESISTOR, carbon film 0.25 watt 33K ohm .......... 3
R156,304,306-308,316 039 331 . RESISTOR, carbon film 0.25 watt 4700 ohm ......... 6
OM-273 Page 4
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure B Left Side View (Cont'd)
R157 009 172 . POTENTIOMETER, cermet 20 turn 0.5 watt 50K ohm . 1
R159 009 173 . POTENTIOMETER, cermet 20 turn 0.5 watt 5K ohm. .. 1
R201,205,214 044 785 . RESISTOR, carbon film 0.25 watt 100K ohm ........ . 3
R202,206 052 139 . RESISTOR, carbon film 0.25 watt 39K ohm .......... 2
R203,204 072 559 . RESISTOR, carbon film 0.25 watt 22K ohm .......... 2
R207,208,303 072 561. RESISTOR, carbon film 0.25 watt 270K ohm......... 3
R210,315 039 334 . RESISTOR, carbon film 0.25 watt 27K ehm.......... 2
R211,215 044 633 . RESISTOR, carbon film 0.25 watt 1.2K ohm ......... 2
R212 053 572 . RESISTOR, carbon film 0.25 watt 12K ohm .......... 1
R213 039 327 .RESISTOR, carbon film 0.25 watt 220 ohm ..... LL... 1
R220 044 635 .RESISTOR, carbon 0.25 watt 680 ohm.............. 1
R221 044 634 .RESISTOR, carbon film 0.25 watt 330 ohm .......... 1
R311 003 272 . RESISTOR, carbon film 0.25 watt 1 meg ohm ........ 1
R312 039 330 . RESISTOR, carbon film 0.25 watt 3900 ohm :........ 1
R314 039 106 . RESISTOR, carbon film 0.25 watt 470 ohm .......... 1
SR50 035 841 .RECTIFIER, integrated 1.5 amp 200 volts ............ 1
T50-55 035 846 . TRANSFORMER, pulse .......................... 6
VR50 081 832 . REGULATOR, voltage 0.5 amp 15 volts ............. 1
VR51 046 932 . REGULATOR, voltage 15 volts1.5amp ............. 1
081 381 . CONNECTOR, edge - 12 pin ............... se... 1
081 382 . CONNECTOR, edge - 14 pin ..............._ee...e... 1
9 RS 083 777 POTENTIOMETER, carbon 1 turn 2 watt 1000 ohm (con-
sisting of) ..................e ee. .eeerirrrerocenn. 1
072 590 . LOCK, shaft - potentiometer ....................... 1
10 084 675 PANEL, front.............eeeeeeeaaemnoaaaooaa aa 1
11 C17,18 031 670 CAPACITOR, ceramic 0.05 uf 500 volts de ............ 2
12 SR1 047 073 RECTIFIER, SCR main (consisting of) ................ 1
C7-9 048 420 .CAPACITOR, ceramic 0,01 uf 500 volts de........... 3
C10-12 046 455 .CAPACITOR, ceramic 0.01 uf 500 volts dc........... 3
SCR1-6 047 074 . THYRISTOR, SCR 175 amp 300 volts ............... 6
TP1 021 548 . THERMOSTAT, NO ......... iin. 1
TP3 012 786 . THERMOSTAT, NC .............e0a.a0aaanear ie... 1
048 959 .BUSBAR, 1/3x1x11-3/8 ....................... 1
048 775 . BUS BAR, tab connecting 3/16 x 1 x 1-1/8.......... 4
037 915 .BUSBAR,1/8x1x3-7/8....... i iii ii, 1
071 078 HEAT SINK oe eee 3
081 379 . HOUSING, connector - edge 12 pin receptacle. ....... 1
13 C4,5 009 063 CAPACITOR ASSEMBLY (consisting of) ............. 2
031 670 .CAPACITOR, ceramic 0.05 uf 500 volts de ........... 4
14 084 674 BASE .... a Lea La aa ana data Lane 1
15 082 491 BUS BAR, connecting-capacitors................... 2
16 C6 044 676 CAPACITOR, electrolytic 20,000 uf60 volts. .......... 5
17 71 072 757 STABILIZER .... i i i, 1
18 T1 **084 752 TRANSFORMER, power - main (consisting of).......…. 1
**084 677 . TRANSFORMER SUBASSEMBLY (consisting of) .... 1
026 316 .. STRIP, 1/16 x3-15/32x4-3/8 ................... 4
026 741 . . WEDGE, 3/8 x1x5-1/2 ii, 3
010398 . . WEDGE, 5/16 x1x5-1/2 ......... ii... 3
**084 579 . COIL, primary/secondary No. 1 .................... 1
**084 580 . COIL, primary/secondary No. 2&3 ................. 2
TP2 084 680 THERMOSTAT, NO ....... ie. 1
C21-23 052 830 CAPACITOR ASSEMBLY (consistingof} ............. 1
032 924 .CAPACITOR, ceramic 0.005 uf 3000 volts de ........ 3
TE1 035 398 TERMINAL, primary {consistingof) .................. 1
| 010 913 . WASHER, flat3/16IDx1/20D ................... 16
601 835 . NUT, hex 10-32... oii 32
601 836 . МЫТ, пех - ат 1/4-20 ............................ 6
038 887 .STUD, No. 10-32 x 1-3/8 w/hex collar .............. 16
038 888 .STUD, 1/4-20 x 1-1/2 w/hex collar ................ 3
Page 5
Нет Dia.
No. Mkgs.
Part
No.
Description
Quantity
Figure B
Left Side View (Cont'd)
19 FM
20
F1 .
RC2
*Recommended Spare Parts.
038 058
038 618
032 603
024 601
032 604
047 718
*604 259
070 404
045 633
081 380
023 562
085 669
006 016
006 017
.TERMINALBOARD ........... ii,
LINK, Jumper... RR RAR aa ne
MOTOR, fan 230 volts (consisting of) ................
. BEARING.
FF % я п 4 = ET * Fr F тн ни яч % mw wm
BLADE, fan 60 Hz 14 inch 3 wing 19 deg .............
CHAMBER, plenum 14 inch” ..............e.— e...
FUSE, cartridge 3amp600volts.....................
HOLDER, fuse - cartridge 30 amp 600 volts w/clips. ....
CONNECTOR, edgew/leads. .......................
HOUSING, connector-edge 14pin...................
CLAMP, hose 5/16 -7/8 dia ..............eeo eee...
PANEL, mtg
PANEL, side
COVER, top
**Replace at Factory or Factory Authorized Service Station. |
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
-COMPonents ........_ec.eosooorvrnrwana
0... +... ¥ moron hE oN oE_ amo" om Fm
== №) = == == = = = = md DN 0 —
OM-273 Page 6
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