Miller 330P User manual

Miller 330P User manual
August 1973 FORM: OM-340
Effective with serial No. HD684370
MODEL
320P
330P
320A/BP
330A/BP
320A/B/SP
330A/B/SP
MODEL/STOCK NO. SERIAL/STYLE NO. DATE PURCHASED
OWNER'S MANUAL
MILLER ELECTRIC MFG. CO.
APPLETON, WISCONSIN, USA 5497
NWSA CODE NO. 4579
STOCK N
901 013
901 034
901 020
901 041
901 027
901 048
ERRATA SHEET
After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to data appearing later in
this manual.
>
NOTE —_
| The data contained in this Errata Sheet applies to 300 ampere units effective with serial number HE745449 |
I and on. }
Item Dia. Part No. Listed Replaced with
No. Mkgs. In Parts List Part No. Description Quantity
299 54 011 611 011 622 SWITCH, toggle 3PDT 15 amp 125 volts .............. .. 1
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
GRO
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SEE INSTRUCTION BOOK FOR
PROPER PRIMARY CONNECTIONS
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CONTACTOR _—- a ce LINK #RCyL METERS
CONTROL 1-12 COPTIONAL-EXTRAI
C - 12 ACs AVAILABLE ONLY
12- 20 WITH Z KVA TRANSFORMER
ALL OPEN
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WORK ELECTRODE
AC СТАЖ = На BALANCE SELECTION
BALANCE RMIMAL BAL ANCE
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EXTERNAL Ra
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DET AC DC REY
Circuit Diagram No. CB-901 034-1B
OM-340 Page A
CERTIFICATE
NAME OF EQUIPMENT: MODEL NO.
SERIAL NO. DATE
This equipment has been type-tested under standardized field test conditions as recommended
by the Joint industry Committee on High Frequency Stabilized Arc Welding Machines found to rad-
¡ate less than 10 microvolts per meter at a distance of one mile, the maximum allowable limit
established by the Federal Communications Commission for equipment of this type.
Installations using this equipment on the basis of these tests, may reasonably be expected to
‘meet the radiation limitations established by the Federal Communications Commission, only when in-
stolled, opercted and maintained as specified in the instruction book provided.
USER'S CERTIFICATION
The welding equipment identified above has been installed in accordance with the specific in-
structions applicable to this model as outlined in the instruction book furnished. Н is being used
only for the purpose for which it was intended and is being maintained and operated in accord-
ance with the manufacturers instructions.
Date Installed Signed_
Mom [ABLE OF CON TEN TS 0s ne
Paragraph No. Page No.
SECTION 1 — SAFETY RULES FOR OPERATION OF ARC WELDING MACHINE
. General ........... LL AA A Aa a aa A a a ea a a ea
. Welding Cables .. 11122204 ee eee ree eas
. Electrode Holder ........224200 04 4 4 4 82 4 1 4 4 4 4 4 6 4 84 4 4 a a ee 0 1 ee a eu 0
. Parallel Connections .........eeeeeeeteocereresrrere.. eee
. Power Disconnect Switch ........_ooerecusceororraricaroroarorga
. Polarity Switch .........o.eonvrocaaren. LL a 4 a 4 0 4 a 0 a 4 a 4 a ee 1 aa 06
. Range Switch 112020000200 04 a 1 1 4 40 i ee a ee a ma area eae
. Exhaust Gases ........o.eeonmenaaoedreoreacvendaverereroerecacoe,
Hollow Castings (Welding of) .........eo_eceressarenoranoorarceoo
Explosion Hazards 100202000004 a 4 a 4 44 a 4 a a 4 6 ea 4 4 4 4 0 4 0 0 sa ee à
Ventilation ....11100 0100404 44 6 4 440 44 a 1 6 4 a a ea a 1 00 ee
Se] te ee ee ree ie reece aaa
Fire Hazards .........e _reresracivrenrocrerocesoorcarearerare, |
Electrical Shock-Voltage .........eoeeeeegnreraaronrerercmr vt0tercao.
Electrical Shock-Dampness ........... RER RK EEE RR
StartingUnder Load ©... i ee i irae a
Face Protection . titi tt et testi eee ee a
. Eye Protection oot ttt ee eee eee eee
. 0% od 12 To EEO
1-23. Hot Metal Burns ...........em_eevorncoreareraoreavooremenrvoanoa
1-24. Grinding and Chipping ......_.e_eoonereosaaredororororrarvecovene eo
1-25. Compressed Gas Cylinder ...........e..erearecarererrrrearare
— — wml med — — ll mk — == od ¡do so o o sed med
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SECTION 2 — INTRODUCTION
1. General 1.202104 44 0 4 4 4 0 8 4 4 4 84 0 a 4 a 0 KK RK RR RR RR KR 0
2. Receiving-Handling .. 1.224000 4 22440 a 44 4 a Va 1 a 0e 0 8e 0 0 a eau au 0 6
3. Description .........es..eeremecorrerevareraooaorereoraarerovona
4.
7.
2.
2.
2-4. Safety ....... ir. .a.ecrdoerneonaeorarerernocaro. ere ame
сл CM Mn
SECTION 3 — INSTALLATION
3-1. Location ERKENNE RR RK RR RER KA
3-2. Primary Connections .........oeece.eredarornaroedooonoaanoódo rro
3-3. Secondary Connections ......... cores. enadarareraneaderoraroer=a,.
3-4. Gas And Water Connections .......e...ereeseroedaoecrarerereearorc,
3-5. Contactor Control Connections. ........-...e._zesrocoorrrmedtórearo,
3-6. Remote Amperage Contrel Connections .........e.e2ereorecoreeren.
~~ =] ~J ~] Oy OO
SECTION 4 — FUNCTION OF CONTROLS
. Current Controf..........e ne .rraraarenerenarvicv—rraanenanooaa
. Start Adjustment. ......... 2... .rayredreredaneronarererocrera
. Contactor Control Receptacle And Switch .........................
. High Frequency Switch «o.oo i RR RK RK
. On-Off Power Switch ........ ee ae ia
. Primary Overload Circuit Breaker ..........o_.eeaeereracreareor.
. Water-Gas Post-Flow Timer .. 11.222004 0010 0 04 4 a 4 4 24 14 4 14 4 aa ae 0
. High Frequency Intensity Control .......... o een mregeeerese reee
- 9. Balancing Resistor Switch .........o. e 14 4 4 04 a 0 a 4 a 4 4 4 4 4124 8 a a 24 0 10
4-10. Full Wave/Half Wave Balance 420014141114 0440 4 a 4 4 4 4 403 a 44 6 10
4-11, Panel Connection ....112424 210140444344 4 4 a a 4 4 4 KR 0 de 4 0 0 1 a 00 4 0 11
4-12. Automatic-Manual Weld Switch 102020010124 4 44 4 0 42 12 64 1 8 1 2 12e 6 11
4-13. Spot Weld Timer ... 111204412144 44 44 4 Ve 4 4 4 4 ea a 4 4 4 4 4 2 4 0 0 KR 12
4-14. Duty Cycle ee ee ee ee ee eee eee 4 0 12
4-15. Volt-Ampere Curve .....Ñ...o oe ee de0earreev0vaarorecamerveraranoeoa 12
O O © © © O 0 CO
+
SE SS
LO 09 “1 OY сл A Wh —
SECTION 5 — SEQUENCE OF OPERATION
5-1. Shielded Metal-Arc Welding .......... cities 13
5-2. Gas Tungsten-ArcWelding. ...... cinta iia 13
5-3. Gas Tungsten-Arc Spot Welding .......... co iii. 13
SECTION 6 — MAINTENANCE
6-1, Rectifier 20.00.0000 it ter eateries aaa Cee о 14
6-2. Fan Motor .......ooeeacsrorrdaaereser=eacoroaaiorenaren ón. 14
6-3. Rectifier ......... e. ce secxaaacaodroaraaorro0renaoaramoortemee. 14
6-4. Spark Gap .......oereervcoororara orarannenvororerarrrerarnes 14
6-5. Control Circuit Fusing.........—-.esrresrcesrrecrereraeracvrrene. 14
6-6. Thermal Protection ..........ecocorerar—aceorenareoaeerorenmem.. 15
SECTION 7 — TROUBLESHOOTING
SECTION 8 — CERTIFICATION FOR HIGH FREQUENCY ARC WELDING EQUIPMENT
8-1. General 1122242224 4446 10 4 4 aaa ee ae ees 21
8-2. General Information ......e.e.rees0oresenmecrrersesanvered rr tdore. 21
8-3. Power Service ......oe.2remogeaaasiroranmarorareranoroarerearo 21
8-4. Welding Machine —.........r_ecoexeveserrrorarrrrcoarene rare. 21
8-5. Welding Leads .......o_ecrreorecmedredrerrorerercarecareanere 22
8-6. Wiring in The Vicinity Of The WeldingArea ...................... 22
8-7. Grounds —....eñ.eomeon0doreadorararcerecranroroeresnarorecare. 22
8-8. Metal Building .....12220 04040000 a aa 00e na eee 0 SA 101500110000 22
8-9. Individual Installation Certification ....2204440 0440000000 0 10 001000 23
8-10. Check List... 1.120004 2 11014 aa a ea ee ae a tne ae a eee ee +0 23
PARTS LIST
=== SECTION 1- SAFETY RULES FOR OPERATION OF ARC WELDING MACHINE —
1-17.
GENERAL
These rules apply to ac and de welding generstors, ac trans-
former and ac/dc welding machines, and dc transformer recti-
fier welding machines.
.in arc-welding operations, where electrically energized parts
are exposed, observe the following safety rules to insure max-
imum personal safety and protect nearby persons.
Failure to observe these safety precautions may exposé not
only you, but feliow workers as well, 10 serious injuries, Once
these rules are learned and kept in mind, proceed with maxi-
mum assurance,
1-2, WELDING CABLES
DON'T overload cables, {Figure 1-1)
Figure 1-1. Don't overload cables
NEVER use welding cables at currents in excess of their rated
capacity. It will cause overheating and rapid deterioration of
the insulation. It is also uneconomical.
DON'T use worn or poorly connected cables. (Figure 1-2)
Figure 1-2. Don't use worn or poorly connected cabies
inspect the cables frequently. Immediately repair all breaks
in the insulation with rubber and friction tapes. Tighten ай
cable connections and adequately insulate any joints where a
connector may have an exposed conductive part. |n addition
to the potential hazard to life, a hazard occurs when exposed
sections of cable come in contact with grounded metallic
objects, causing an arc. Unprotected eyes may be injured and
fire may result if combustible materials such as oii or grease
are in the vicinity. The efficiency and quality of welding will
be improved by elimination of these dangerous grounds, and
by keeping connections tight.
ELECTRODE HOLDER
DON'T use electrode holders with defective jaws. (Figure
1-3}
Keep the jaws of the electrode holder tight and the gripping
surfaces in good condition to provide close contact with the
electrodes. Defective jaws will permit the electrode to wob-
ble, making control of the welding operations difficult.
Figure 1-3. Don’t use Electrode Holder with defective jaws
1-4.
DON'T use electrode holder with loose cable connections.
Keep the connections of the electrode lead to the holder
tight at ali times.
Use only fully insulated electrode holders (and without pro-
truding screwheads.)
Never touch two electrode holders from two separate welding
machines at the same time.
CODE CONFORMANCE
The machine and its equipment must be installed and main-
tained in accordance with the National Electrical Code and
local requirements,
1-5. PARALLEL CONNECTIONS
See diagrams in the instruction manual applying to the weld-
ing machine used.
1-6.
1-7.
1-8.
1-9
POWER DISCONNECT SWITCH
if the welding machine does not include a power disconnect
switch, install one at or near the machine.
POLARITY SWITCH
DON'T operate the polarity switch under load.
The polarity switch (when supplied) is provided for changing
the electrode lead from positive (reverse polarity) to negative
(straight polarity}. Never move it while under the load of a
welding current. Operate this switch only while the machine
is idling and the welding circuit is open. The potential dan-
gers of opening the circuit while carrying high current are:
1. An arc will form between the contact surfaces of the
switch and severely burn them.
2. The person throwing the switch may receive a severe burn
trom this arcing.
RANGE SWITCH
DON'T operate the range switch under load.
The range switch (when supplied) is provided for obtaining
required current settings. It must never be operated while the
machine is under the load of welding current. Operate the
range switch only white the machine is idling and the welding
circuit is open. The potential danger of switching the circuit
while carrying high current is the formation of an arc be-
tween the contact surface which will severely burn them,
Repeated occurrences of this arcing will eventually prevent
operation of the contacts.
. EXHAUST GASES
DON'T use gas engine units in confined spaces without vent-
ing the exhaust gases. (Figure 1-4)
If gasoline or other fuel driven welding machines are operated
indoors, provide means to pipe the exhaust gases to the out-
side air to avoid carbon monoxide poisoning.
OM-340 Page 1
Figure 1-4. Vent exhaust gases
1-30. POWER CIRCUIT GROUND
DON'T use welding machine without grounding frame or
case. (Figure 1-5)
Figure 1-5. Ground frame or case
Ground the ground cable of every power circuit to prevent
accidental shock by stray current. The potential danger is
that development of a stray current may give a fatal shock
should a person, for example, place one hand on the welding
machine and the other on the switch box, or other grounded
equipment, Do not ground to pipelines carrying gases or
flammable iiquids and conduits carrying electrical conduc-
tors. Be sure conductors ¢an safely carry the ground current.
When connecting the welding machine, properiy ground the
machine frame or case.
1-11. CONTAINERS WHICH HELD COMBUSTIBLES
Page 2
DON'T weld on containers which have held combustible or
flammable materials or materials which, when heated, give
off flammable or toxic vapors without proper cleaning, purg-
ing, or inerting,
Welding containers which have held flammabie or combust-
ible materials may be extremely dangerous, To prevent a fire
or explosion of the container, follow the recommendations
of the American Welding Society Pamphlet A6.0 "Welding or
Cutting Cantainers Which Have Held Combustibles”.
DON'T depend on your eyes or nose to decide if it is safe to
weld on a closed container,
Find out what was in the container or use an explosimeter. A
very small amount of residual flammable gas or liquid can
cause a serious explosion,
NEVER use oxygen to ventiiate a container.
When you know the container held a gas or liquid which will
readily dissolve in water:
1. Flush out with water several times and then fill with
water as far as work permits, positioning container to
permit introduction of as much water as possible.
2. Before welding be sure there is a vent or opening to pro-
vide for release of air pressure,
1-12.
1-14.
When you know the container held a gas or liquid which will
not readily dissolve in water:
1. Clean out thouroughly with steam or a cleansing agent
and purge all air or inert with a gas such as carbon dioxide
or nitrogen before repairing. Carbon dioxide is heavier
than air and will tend to remain in the container if the
opening is at the top.
2. Use steam to clean out light material.
3. Use a strong caustic soda solution to ciean out heavy oils
or grease.
4. Be sure to purge all air or inert with a gas, such as nitro-
gen or carbon dioxide, no matter how well you have
cieaned. There may still be traces of oil, grease, or other
readily oxidizable material under the seams.
Be careful when cieaning with steam Or caustic soda wear
goggles and gloves.
DON'T clean where there is poor ventilation.
Ventilation is necessary to carry away harmful or explosive
vapors.
DON'T clean where there are open flames.
When scraping or hammering to remove heavy sludge or scale,
use a spark resistive tool and keep it wet to avoid sparks.
Keep your head and arms as far away from your work as
possible.
HOLLOW CASTINGS
DON'T weld on hollow (cored) castings that have not been
properly vented. The casting may explode. (Figure 1-6)
Figure 1-6. Don’t weld on hollow (cored) castings
1-13. EXPLOSION HAZARDS
NEVER weld in or near explosive atmospheres. Such atmos-
pheres can be created by flammable gas leaks or by vapors
from flammable liquids (gasoline, alcohol, etc.) or by com-
bustible dusts.
VENTILATION
DON'T weld in confined spaces without adequate ventilation.
When welding in confined spaces, provide ventilation in
accordance with United States of American Standard 249.1,
1967. Always provide adequate ventilation by blowers, air
lines, or other acceptable means. Never use compressed ax-
ygen. The depletion of the oxygen supply, the heat of weld-
ing, and the fumes given off may cause severe discomfort or a
serious illness.
When toxic fumes from lead or cadmium bearing materials or
any other substances are present in harmful concentrations,
always use an air supplied respirator,
1-15.
1-16.
1-17.
SOLVENTS
Do not weld where chlorinated hydrocarbon vapors from de-
greasing, cleaning, or spraying may reach or be drawn into air
surrounding the welding operation, The heat of the arc can
decompose solvent vapors to form phosgene, a highiy toxic
gas and other irritating decomposition products,
Do not weld where ultraviolet light from the electric arc can
penetrate air containing even minute amounts of vapors from
solvents such as trichloroethytene or perchioroethylene, Ul-
traviolet light can decompose the vapors to-form phosgene, a
highiy toxic gas and other irritating products,
FIRE HAZARDS
DON'T weld near flammabie or combustible materials.
Fires can be caused by the arc, by contact with the heated
metal, by slag, or sparks. Keep combustibles at least 35 feet
from the arc or suitably protected, If welding must be done
in a particular area, move the combustibles away. If they
cannot be moved, cover them compietely with fire resistive
screens, Cover cracks or openings in floors or walls; sweep
floor free of combustibles and wet down, if wood, being sure
welder wears insulation shoe coverings. Avoid welding on par-
tition walls in contact with combustibles. Heated metal on
the other side of partition wall being welded upon can ignite
combustibles in contact with the partition. Where other than
a minor fire might develop, have a fire watcher stand-by with
suitable fire extinguishing equipment for at least one-half
hour after the welding is completed.
ELECTRICAL SHOCK-VOLTAGE
OPEN power circuits before checking machines,
Before working on the wiring, switches, controls, etc., open
the power line disconnect switch. [п most welding shops the
power supply used for arc welding machines is 230 or 460
volts. Open circuit voltages are usually less than 100 volts and
welding or arc voitage drops are still lower. However, all of
these voitages are capable of developing a harmful or fatal
current to the body.
DON'T touch electrically “hot” parts,
NEVER touch any exposed or non-insulated part of the
cables, cable connectors, clamps, electrode holders, elec-
trodes, or the power supply equipment to prevent harmful or
fatal electric shock or burns,
. ELECTRICAL SHOCK-DAMPNESS
NEVER work in a damp area without suitable insulation a-
gainst shock. Keep hands, feet, and clothing dry at all times,
To.prevent harmful body shocks, keep hands, feet and cloth-
ing dry. Never stand or lie in puddles of water, damp ground,
or against grounded metal when welding without suitable in-
sulation against shock. Always find a dry board or rubber
mat to stand on when water, moisture, or perspiration cannot
be avoided. Dampness between the body and an energized or
grounded metatlic part lowers the resistance to the passage of
current to the body which may produce a harmful or fatal
shock. Salt in perspiration or sea water dangerousty lowers:
contact resistances.
Figure 1-7. Don't leave electrode in contact with grounded
metallic surface.
1-19. STARTING UNDER LOAD
DON'T leave an uninsulated electrode holder, or a “live”
1-20.
1-21.
electrode on the table top or in contact with a grounded
metailic surface. (Figure 1-7)
When it is not in use, never place an electrode holder in
contact with the tabletop or other metallic surface in contact
with welding ground. Provide an insulated hook or holder for
the electrode holder. A potential danger is that a holder in
contact with the ground circuit provides a dead short circuit
on the welding machine, If the machine should be started up,
this short circuit would cause an excessive load on the ma-
chine and may damage the insulation.
FACE PROTECTION
DON'T use cracked or defective helmets or shields.
Keep the helmet, hand shields, or face shield in good condi-
tion. If cracks occur in the fibre material, replace the shield,
since the ieakage of arc rays may cause serious burns.
EYE PROTECTION
NEVER under any circumstances, look at an electric arc
without eye protection.
Figure 1-8. Use eye protection at all times
Make sure that flash goggles are used under the weld-
ing helmet at all times, particularly while gas shielded-
arc welding.
E———;—[o———————
In some type of arc welding, such as gas shielded-arc welding,
ultra-viotet and infra-red radiation from the arc is particularly
intense and requires constant attention to avoid arc flashes to
the welder when striking an arc and to avoid exposure to
other welders.
NEVER strike an arc without ascertaining that nearby per-
sons either have the necessary protective equipment or are
looking in the opposite direction. a
For welding operations in open areas, provide portable, non-
reflecting screens to shield persons nearby from the rays of
the arc. Eye burns from the arc, through not generally per-
manent injuries, are exceedingly painful. Such burns fre-
quently referred to as flashes’, feel like hot sand in the eye.
if the eye is focused on the arc without filterglass protec-
tion, infra-red radiation can cause retinal scarring and im-
paired vision, For eye burns consult your first aid station or
doctor.
NEVER use cracked, ili-fitting, or defective piates.
The filter glass plate provided in the helmets and shields must
be of reputable manufacture conforming to the latest Ameri-
can National Standards institute, Standard Z2.1. Replace
cracked or ill-fitting filter plates promptly.
NEVER use filter plates without a protecting cover glass.
OM-340 Page 3
1-22.
Keep a ciean cover glass in front of the filter plate for the
protection thereof. Frequent renewal of these cover glasses is
necessary, since they become covered with spatter, reducing
vision,
CLOTHING
NEVER use poor, inadequate, or worn-out clothing. Wear
heavy shoes, tightly laced, Keep clothing dry.
" Proper and dry, oil-free clothing is essential for the welder’s
1-23.
protection. Clothing must not only keep off the spatter and
molten particles, but must also obstruct the rays of the arc
and, when necessary, insulate the body from harmful electsi-
cal currents,
Wear leather or asbestos gloves at ali times to protect the
hands and wrists, Dark colored shirts are preferred to light
ones because light ones reflect arc rays to exposed parts of
the body. In tha case of gas shielded-arc weiding, light colors
are more reflective and may cause eye burns due to the in-
tense ultra-violet rays given off by the process. Avoid cotton
fabrics when gas shielded-arc welding.
An arc burn on the skin resembles a sunburn, except that it is
usually more severe. Clothing can be made flame resistant by
treatment with a solution of 3/4 pound of sodium stannate in
1 gallon of water, then wrung out and dipped in a solution of
1/4 pound ammonium suiphate per gajion of water. Don't
wash clothing so prepared in water, but dry clean,
When welding operations are to be performed in vertical and
overhead positions, leather sieevelets, aprons, and in some
cases leggings and ear plugs should be used to prevent severe
burns from spatter and molten meta.
HOT METAL BURNS
NEVER pick up hot objects. (Figure 1-9)
Figure 1-9. Never pick up hot objects
NEVER pick up pieces of metal which have just been weided
or heateg, or the stub ends of electrodes which have been
. discarded.
1-24. GRINDING AND CHIPPING
NEVER do any chipping or grinding without protective
goggles. (Figure 1-10}
Figure 1-10. Never do any chipping or grinding without
protective goggles.
Page 4
Whenever it is necessary to grind or chip metal, wear protec
tive goggles specifically designed for this purpose. Serious eye
injuries may result from failure to wear protective goggies.
1-25. COMPRESSED GAS CYLINDERS
NEVER strike an arc on a compressed gas cylinder, Always
observe the following precautions in regards to compressed
gas cylinders:
1. Avoid accidental contact of the electrodes, electrode
holder, or other electrically energized parts with a
compressed gas cylinder or any other pressure vessel.
Serious accidents or fires may result.
2. Use I.C.C. or D.O.T. cylinders, They are manufactured
and maintained in accordance with D.O.T. require-
ments and are safe so long as they are properly
handied. Don't drop cylinders.
3. Identify gas content by the name marked on the cylin-
der. if the cylinder is unmarked, do not use it. Return
it to the supplier. Do not rely on a color code.
4. Never use a cylinder or its contents for other than
intended purposes.
5. Keep oil and grease away from oxygen cylinders and
cylinder valves.
6. Keep cylinders away from exposure to sparks, hot
slag, open flame and alt possibile sources of ignition or
excessive heat,
7. Be careful that cylinders are not placed so as to be-
come a part of an electrical circuit. Avoid third raiis,
wires and electric welding circuits.
8. When transporting cylinders by crane, use cradle plat-
form or other suitable support.
9, Never lift the cylinders by slings, by the caps or by
electric magnets.
10. Never use cylinders as supports or rollers.
11. Never try to mix any gases in a cylinder,
12. Never try to refill a cylinder.
13. Mark or tag empty cylinders “Empty” or "MT".
14. Send “Emptys” back to the supplier promptly. 15.
15. Keep “Emptys’ and “'Fulis” separate,
16. Never tamper with or alter cylinder numbers or other
markings. This is not only foolish but may be illegal.
17. Do not tamper with or change fittings on cylinders.
18. If valves cannot be opened by hand, do not use ham-
mer or wrench. Notify supplier.
19. Protect cylinder valves from bumps, falls, falling ob-
jects, and from weather. Keep them covered with
cylinder caps when moving cylinders.
20. Keep valves closed on empty cylinders.
21. See that your cylinders are clear of passageways and
active work areas and that they are secured against
failing.
27. If adapter is required between cylinder and regulator,
always use a standard adapter. These may be obtained
from your supplier. Where right and left hand threads
are used on adapter, use two wrenches to insure leak
proof connections,
23. Do not store cylinders in unventilated areas.
— SECTION 2 - INTRODUCTION ura
Open Amperes Input At Rated Load Overall
AC AC DE DC Circuit Output 60 Hz Single Phase Cabinet Weight
Ga Shielded Gas Shielded Voltage Amperes Size (Pounds)
Model | Tungsten-Arc| Metal-Arc | Tungsten-Arc | Metal-Arc | AC 8: DC | 208V | 230V | 460V | kva kw (Inches) Net | Ship
200 5-45 6-45 5-50 5-40 Height - 47-1/2
Ampere 12-125 10-155 10-160 10-130 80 80 72 36 16.5 | 14 |Width - 22-1/4 | 785 | 805
85-300 90-330 120-300 70-260 Depth - 33-1/8
300 5-48 548 5-60 5-45 Height - 47-1/2
Ampere 20-230 20-245 20-250 16-200 80 115 104 52 23.91 21.8|Width - 22-1/4 1870 | 890
190-435 200-470 230-460 150-350 Depth - 33-1/8
Figure 2-1. Specifications
P& A/B
CONTROL |
PANEL |
| |
CONTROL FUSE CONTROL . GAS & WATER
XMFR RECTIFIER VALVES
CONTACTOR START AMPERAGE HIGH WELDING
FAN MOTOR CONTROL CONTROL CONTROL FREQUENCY CONNECTION
PRI-SEC DC AC
INPUT PRIMARY RANGE MAIN
POWER CONTACTOR |- MER O [ CONTROL SWITCH RECTIFIER
Figure 2-2. Block Diagram T8-901 013-1
2-1. GENERAL tactor control receptacle and switch. A Start Control is pro-
This manual has been prepared especially for use in familiar-
izing personnel with the design, installation, operation, main-
tenance, and troubleshooting of this equipment. All informa-
tion presented herein should be given careful consideration to
assure optimum performance of this equipment.
RECEIVING-HANDLING
Prior to installing this equipment, clean all packing material
from around the unit and carefully inspect for any damage
that may have occurred during shipment. Any claims for loss
or damage that may have occurred in transit must be filed by
the purchaser with the carrier. A copy of the bill of lading
and freight bill will be furnished by the carrier on request if
occasion to file claim arises.
When requesting information concerning this equipment, it is
essential that Model Designation and/or Stock Number and
Serial (or Style) Number of the equipment be supplied.
DESCRIPTION
These single phase input welding power sources are designed
to be used for ac or dc Shielded Metal-Arc and Gas
Tungsten-Arc Welding. This series of welding power sources
come in either a 200 or 300 ampere version and either ver-
sion can be equipped in three different ways: basic; basic
with gas and water control; and basic with gas and water
control, and spot weld time capability,
. Basic Model
The basic model is provided with a Range Switch for select-
ing one of three coarse amperage ranges of either ac, dc
straight, or dc reverse polarity weld current. The Fine Cur
rent Control on this unit provides the capability of selecting
the exact desired weld current within the coarse range selec-
ted. Facilities are aiso provided for connecting a remote fine
current control. Facilities are also provided for on-off control
of the open circuit voltage through utilization of the con-
©
2-4.
vided for determining the amount of weld current present at
the initiation of the weld. High frequency is also built into
the welding power source for ease in arc starting when per-
forming Gas Tungsten-Arc Welding.
Water And Gas Control Model
The water and gas contro! model incorporates all the features
of the basic model plus the addition of a gas valve, water
valve, and post-flow timer.
Spot Time Model
The spot timer model incorporates all the features of the
basic and water and gas control models plus the addition of a
spot weld timer.
SAFETY
Before the equipment is put into operation, the safety sec-
tion at the front of this manual should be read completely,
This wiil help avoid possible injury due 10 misuse or improper
welding applications,
The following definitions apply to CAUTION, IMPORTANT,
and NOTE blocks found throughout this manual:
Installation, operating, and maintenance procedures,
practices, etc., which will result in personnel injury or
loss of life if not carefully followed.
OM-340 Page 5
IMPORTANT
installation, operating, and maintenance procedures,
practices, etc., which will result in damage to equip-
ment,
E— —G——Ñ dl
SECTION 3 - INSTALLATION —mmm
3-1. LOCATION
FOUR 7/16”
DIA. HOLES
A good installation is essential if the welding power source is
to provide satisfactory and dependable service,
The location should be such that 2 minimum amount of dust
and dirt will be drawn into the air stream. Preventive main-
tenance consists of removing the wrapper from the welding
power source and blowing out the dust accumulation inside
the unit. For this reason it is desirable to locate the unit so
that the wrapper can be removed without any difficulty,
IMPORTANT
The welding power source should be located so that
the panels with the air vents are clear of any obstruc-
tion, Cooling air is drawn through the lower area and
1 expelled out of the rear air vent. Г
rs || 47-1727
ST
1 30-1/8”
33-1/8”
LE
I — =f
nie — TA-901 034-1A
Figure 3-1. Dimensional Drawing
1-1/8
3-2. PRIMARY CONNECTIONS
Page 6
This welding power source is designed for and must be opera-
ted on a single phase, 60 Hertz, ac power supply, having a
voltage rating which corresponds to one of the voltages
shown on the welding power source nameplate. If there is
any question about the electrical system used locally, consult
the local public electric utility,
A. Primary Wire Connections
NOTE
ft is recommended that the primary wires be of the
heavy rubber covered type or be run in solid or flex-
ible conduit. Tabie 3-1 is provided as a guide tn selec-
| ting the proper primary wire and fuse size. I
Route the two primary line wires pilus one ground wire
through the inlet hole provided on the rear panel of the
welding power source. This inlet hole will accept standard
conduit and associated fittings.
NOTE
Installation, operating, and maintenance procedures,
practices, etc., which it is essential то emphasize.
KA оооананао винной
Table 3-1, Primary Wire And Fuse Sizes
Primary Wire Size - AWG Fuse Size In Amperes
Model [208 Y T230 Y Ta60 V | 575 V 1208 V | 230 V ] 460 V [575 V
200 Мо. 4 | No. 4 No.8 | No. 19
Amp | (No.8) | (No. 8) | (No. 8) | (No. a] 180 | 125 | 70 | 50
300 Мо, 2 Мо. 2 Мо. 6 No. 8
Amp | (No. 6) | (No. 6) | (No. 8) | (No. 8)| 200 | 175 90 70
( ) Indicates ground wire size.
NOTE
lt is recommended that the ends of the primary and
ground wires which are to be connected to the input
terminals have a terminal lug of suitable amperage
| rating attached, 3
A hinged door is provided on the rear panel for gaining access
to the primary terminal board. After opening the door, con-
nect the two primary line wires to the terminals on the pri-
mary terminal board labeled L or LINE. Connect the ground
wire to the terminal labeled GRD. The opposite end of the
ground wire should be connected to a proper ground. Use
whatever grounding method which is acceptable to the local
electrical inspection authority.
= LINE
DISCONNECT
SWITCH
GROUND
CONNECTION
CONTROL
LINE VOLTAGE: TRANSFORMER
CONNECTIONS LINK
NN | CONNECTION
#
PRIMARY VOLTAGE
JUMPER LINKS
Figure 3-2. Primary Line Voltage Connections
TA-900 959-5
. Primary Voltage Jumper Links
The primary voltage jumper links are provided on the pr-
mary terminal beard to permit the welding power source to
be operated from various line voitages. The voltages which
this welding power source may be operated from are stated
on the front panel nameplate and on the input voltage sticker
on the inside of the rear panel hinged door. This weiding
power source had the primary voltage jumper links set for the
highest voltage position at the factory. If the welding power
source is to be operated from a line voltage which is lower
than the highest voltage the unit was designed for, 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 jumper link positions that the jumper
links may be set for on the standard welding power source, If
the welding power source has input voltages different from
those of the standard unit, that is, if the primary voltage on
the welding power source nameplate differ from those shown
in Figure 3-3, the primary voltage jumper links should be
positioned as shown in the voltage sticker on the inside of the
rear panel hinged door.
208 VOLTS 230 VOLTS 460 VOLTS
TA-013 258
Figure 3-3, Primary Voltage Jumper Link Arrangement
3-3.
>
SECONDARY CONNECTIONS
The secondary terminals are located behind the lower front
access panel and are labeled ELECTRODE and WORK, See
Figure 4-3 for the location of these terminals.
Welding Cables
It is recommended that the welding cables be kept as short as
possible, placed close together and be of adequate current
carrying capacity. The resistance of the welding cables and
connections cause a voltage drop which is added to the volt-
age of the arc. Excessive cable resistance may result in over-
loading as well as reducing the maximum current output of
which the welding power source is capabie. The proper opera-
tion of any arc welding power source is to a great extent
dependent on the use of welding cables and connections that
are in good condition and of adequate size, An insulated
holder must be used to ensure the operators safety.
Table 3-2. Secondary Cable Sizes
WELDING "TOTAL LENGTH OF CABLE (COPPER) IN WELD CIRCUIT
AMPERES | “50 100 150 200 250 300 350 400
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 2 2 1 1/0 2/0 3/0 4/0 4/0
250 1 1 10 2/0 30 4:0 4:0 2-70
300 1/0 1/0 2.9 3/0 a-0 4/0 2-20 } 2-30
350 1/0 1/0 3/0 4/0 4:0 2.2/0] 2-3/0 1 2-3/0
400 2/0 2/0 3:0 4/0 27:05 2.301 3-2/0 24/0
500 | 3/0 70 4/0 22/0| 2-3/0 2-30) 24/0 | 3-3/0
TA-900 56 1-3
NOTE: *A. 50 feet or less
* 8. Cable size is based on direct current ide}, 60% 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 voitage rating to withstand the
open circuit voltage (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.
Use Table 3-2 as a guide for setecting the correct welding
cable size for the anticipated maximum weld current that will
be used. Table 3-2 takes into account the total length of
cable for the weld circuit. This means the length of the Elec-
trode cable that connects the Electrode Holder to the weld-
ing power source and the Work or ground cable between the
welding power source and the work piece. For example: If
the Electrode cable is 75 feet long and the work or ground
cable is 25 feet long, you would select the size cable from
Table 3-2 that is. recommended for 100 feet at the maximum
amperage that wili be used. In the case of a maximum anti-
cipated weld current of 300 amperes 1/0 weld cable would be
recommended for both the Electrode and Work cabies.
. GAS AND WATER CONNECTIONS (Figure 4-3)
The gas and water valves, located behind the lower front
panel door, provide on-off control of gas and water to the
gun. The gas valve fittings have right hand threads, while the
water fittings have left hand threads.
If a recirculating type of water cooling system is used, do not
connect the systern through the water valve as damage may
occur to the motor of the coolant system because the water
valve will shut off, thus blocking the water flow.
3-5. CONTACTOR CONTROL CONNECTIONS
The CONTACTOR CONTROL Receptacie, located on the
front panel of the welding power source, provides a junction
point for connecting a Remote Contactor Control to the con-
tactor control circuitry in the welding power source.
If normal contactor control connections are to be made,
(normal being when the remote contactor control switch
energizes the contactor when closed and de-energizes the
contactor when opened) a maintained contact switch should
be used for a remote contactor control switch. This type of
contactor control is the only type that can be obtained on
the Standard Models.
On Water and Gas Modeis and Spot Models connected for
water and gas panel operation, a momentary contact switch
should be used for contactor control, When this setup is used,
the contactor will de-energize whenever the arc is broken.
On Spot Models connected for spot welding operation, a
momentary contact switch is to be used as the remote
contactor control switch, Closing the momentary contactor
control switch in this operation will energize the contactor
and start the Spot Weld Timer as soon as an arc is initiated.
NOTE
If a Remote Contactor Control is to be used, the
CONTACTOR CONTROL Switch must be in the
REMOTE position. The complete operation of this
I switch will be explained in SECTION 4. I
To connect the Remote Contactor Control to the CON-
TACTOR CONTROL Receptacle, insert the two pole plug
from the Remote Contactor Control into the receptacie and
rotate it as far as it will tum in a clockwise direction, The
plug will now be locked in the receptacle and wiii not pull
out under stress.
3-6. REMOTE AMPERAGE CONTROL CONNECTIONS
The REMOTE AMPERAGE CONTROL Receptacle, iocated
on the front panel of the welding power source provides a
junction point for connecting a Remote Amperage Control
meostat to the amperage control circuitry in the weiding
power source.
To connect the Remote Amperage Control to the REMOTE
AMPERAGE CONTROL Receptacle, insert the three pole
plug from the Remote Amperage Control into the receptacle
and rotate the plug as far as it will turn in a clockwise direc-
tion. Once fully rotated, the plug will be locked in the recep-
tacle and will not pull out under stress.
If a Remote Amperage Control is to be used, the
STANDARD REMOTE AMPERAGE CONTROL
Switch must be placed in the REMCTE position. The
complete operation of this switch will be explained in
i SECTION 4. I
OM-340 Page 7
CONTROL RECEPTACLE
2 o
STANDARD-REMOTE “e LT
AMPERAGE CONTROL STANDARO 2 REMOTE
SWITCH
SECONDARY
AC ue
yours [LL] 16
180 150
DUTY CYCLE aly #0X
CONTACTOR CONTROL mr
CONTACTOR CONTROL
SECTION 4- FUNCTION OF CONTROLS
REMOTE AMPERAGE
REMOTE AMPERAGE
CONTROL
E
DUTY CTO EATEO OUTPUT 15% 73%
MAN, © м 40 80
WILOIRG EAMGE INERT §
POLARITY SWITCH 7
CONTACTOR CONTROL
-@
STANDARD-REMOTE "TE STANDARS
RECEPTACLE
REMOTE
SWITCH e
jr START ADJUSTMENT
CONTROL
START ADJUSTMENT
—— FINE CURRENT
OVERLOAD CONTROL
[13 OVERLOAD
CIRCUIT BREAKER
PRIMARY
VOLTS 20672307465
AMES, 15/452
K va 239
FREQUENT T 40 Hr,
DA SWITCH
— POWER SWITCH
AMT EEES YE AUN
CTS MEL DE MALL ACTUAL
EA RL HS
HIGH FREQUENCY
STAR
a”
COMICAS
HIGH FREQUENCY
SWITCH
AA-901 013-4A
Figure 4-1. Upper Controi Panel
4-1. CURRENT CONTROL (Figure 4-1)
Page 8
A. Range Switch
The Range Switch provides the capability of being able to
select from three ac or dc coarse amperage ranges. The
amperage range of each switch position is provided on the
welding power source nameplate. If the amperage desired
should fall in the overlapping area of two ranges, it is recom-
mended that the lower of the two ranges be used, as better
fine amperage adjustment will be obtained in the lower of the
two ranges.
Fine amperage adjustment within the coarse range selected is
to be accomplished by the Fine Current Control, The com-
plete function of this control will be explained in section
4-1B.
IMPORTANT
Do not change the position of the Range Switch while
welding or under load as this will cause the contacts of
the switch to arc. Arcing across the contacts will cause
the contacts to become pitted and thereby eventually
i to become inoperative, N
B. Fine Current Control
The Fine Current Control, [ocated on the center portion of
the upper front panel, provides a means of selecting the exact
amperage desired within the entire range being used. Rotating
the control in a clockwise direction will increase the am-
perage output,
NOTE
The contacts of the Fine Current Control are of the
continuous contact type, thereby making it possible to
adjust the amperage output while welding.
Las}
The scale surrounding the Fine Current Control is calibrated
in percentage and should not be misconstrued as an amperage
or voltage reading.
. Remote Amperage Control
'f a Remote Amperage Control is to be used, make connec-
tions from the Remote Amperage Control to the REMOTE
AMPERAGE CONTROL Receptacle as instructed in section
3-7.
When remote control of the amperage is desired, it is essential
that the STANDARD-REMOTE AMPERAGE CONTROL
Switch be placed in the REMOTE position. Likewise, if a
Remote Amperage Control is not to be utilized, the switch
must be in the STANDARD position. When in the STAND-
ARD position, the Fine Current Control on the front panel
will solely control the amperage.
When a Remote Amperage Control is being used, it should be
noted that the Remote Amperage Control is functioning as a
- fine amperage adjustment of the Fine Current Control setting
on the welding power source. For example: !f the Fine Cur-
rent Control on the welding power source is set at the 50%
position, the Remote Amperage Control will provide (from
its min. to max. positions) fine amperage adjustment of one
half of the weiding power source output for the current range
selected by means of the Range Selector Switch. If full ad-
justment thru use of the Remote Amperage Control of the
current range selected is desired, the Fine Current Control on
the welding power source must be set at 100% (max. posi-
tion).
Polarity Switch
The Polarity Switch provides a means of selecting either ac,
de straight, or de reverse polarity without having to change
the secondary cable connections.
Placing the Polarity Switch fully to the right will provide DC
STRAIGHT polarity; fully to the left will provide DC RE-
VERSE polarity; the center position will provide AC weld
current.
CAUTION À
: |
Do not change the position of the Polarity Switch
while weiding or under load as this wiil cause the con-
tacts of the switch to arc. Arcing across the contacts
will cause the contacts to become pitted and thereby
1 eventuaily to become inoperative. J
START ADJUSTMENT (Figure 4-1 & 4-2)
The Start Adjustment facility in this welding power source
permits the operator to select an amperage setting for arc
initiation which is different from the setting of the Fine Cur-
rent Control. The starting current which is selected will be in
effect for the first 35 to 40 cycles of the weld. After this
time period, the weld current will go to the setting of the
Fine Current Control.
A.
Start Circuit Switch
A two position toggle switch, located next to the gas valve on
the lower front control panel, is provided to determine
whether or not the start circuit will be functional, Placing the
START CIRCUIT Switch to the IN position will make the
START ADJUSTMENT Control on the upper front panel
operative, The QUT position will make the START ADJUST-
MENT Control inoperative and thereby causing the weid cur-
rent to go immediately to the setting of the Fine Current
Control at are initiation.
Start Adjustment Control
The START ADJUSTMENT Control provides fine current
selection within the minimum to maximum capabilities of
the range being used for the initial 35 to 40 cycle {approxi-
mately 2/3 of a second) time period of the weld. After this
initial time period, the weld current will either slope up or
down to the setting of the Fine Current Control.
CONTACTOR CONTROL RECEPTACLE &
SWITCH (Figure 4-1)
The CONTACTOR CONTROL Circuitry in this welding
power source provides a means of making weld output avail-
able whenever desired without having to position the POWER
Switch ON or OFF. Whenever 115 volts ac 1s applied to the
contactor cail, the coil will energize and thereby close the
contactor normally open contacts. Once the contacts have
closed, electrical power will be applied to the main trans-
former and in turn supply weid output. Likewise, whenever
the 115 voit ac circuit to the contactor coil is opened, the
coil will de-energize, open the contactor contacts and sus-
pend the weld output.
If a Remote Contactor Control is to be used, make con-
nections to the CONTACTOR CONTROL RECEPTACLE as
instructed in section 3-6.
Whenever it is desired to have weld output available and a
Remote Contactor Control Switch is not being used, it will
be necessary to place the CONTACTOR CONTROL Switch
to the STANDARD position. When in the STANDARD posi-
tion, weld output will be available as soon as and for as tong
as the POWER Switch is positioned to ON.
When a Remote Contactor Control Switch is to be used, the
CONTACTOR CONTROL Switch must be placed in the RE-
MOTE position. With a Remote Contactor Control Switch
weld output will be available whenever and for as long as the
Remote Contactor Control Switch is closed,
NOTE
When connected for spot welding operation, (Spot
Panel Models Oniy) the Remote Contactor Control
Switch need be only momentarily closed to energize
I the contactor and start the Weld Timer, I
. HIGH FREQUENCY SWITCH (Figure 4-1)
The HIGH FREQUENCY Switch, located on the upper front
panel, provides three positions which will determine whether
the high frequency will be on or off.
. Start Position
When in the START position, high frequency wili be present
at the welding electrode until the arc 15 initiated. Once an arc
is established, and even though the Remote Contactor Con-
trol Switch is closed, the high frequency will be de-energized.
High frequency will be present again only after the arc is
broken and restarted.
. Continuous Position
The CONTINUOUS position will provide high frequency for
as long as the Remote Contactor Control Switch is closed.
The high frequency and weld current may be shut off during
the weld by releasing the Remote Contactor Control Switch.
C.
Off Position
High frequency will not be available when in the OFF posi-
tion, even if the contactor is energized. This position must be
used when performing Shielded Metal-Arc Welding (Stick
Electrode).
Never try to use high frequency when performing
Shielded Metal-Arc Welding {Stick Electrode). Failure
to comply may result in the high frequency arcing
through the electrode holder and seriously injurying
I the operator. |
ON-OFF POWER SWITCH (Figure 4-1)
This weiding power source is equipped with an ON-OFF
POWER switch in order to eliminate the need of having to
engage and disengage the line disconnect switch whenever it
is desired to turn the welding power source on or off.
Placing the POWER Switch in the ON position will energize
the welding power source fan and control circuitry and place
the welding power source in a ready-to-weld status. Placing
the POWER Switch in the OFF position will shut the weiding
power source down.
CAUTION-
Even though the POWER Switch is in the OFF posi-
tion and the weiding power source is apparentiy elec-
tricaliy shut down, primary electrical power is still
present on all circuitry up to the POWER Switch, To
completely cut-off all electrical power to the welding
power source, it will be necessary to piace the line
disconnect switch in the OFF position or to discon-
nect the primary leads from terminal strip TE1 in the
i welding powver SOUTCE. I
. PRIMARY OVERLOAD CIRCUIT BREAKER (Fig
ure 4-1)
The PRIMARY OVERLOAD Circuit Breaker provides pro-
tection against overloading of the welding power source. In
the event of a continued overload or abnormal primary cur-
rent drawn, a current transformer {located in the primary
input lines to the main transformer) will detect this overload
condition and cause the circuit breaker to open, The internal
contacts of the circuit breaker are connected in series with
the primary contactor coil of the welding power source.
Thus, if the current transformer detects an overload condi-
tion, the opening or tripping of the circuit breaker causes the
primary contactor to open thereby suspending weid current
output. The Circuit Breaker must be positioned to ON before
the primary contactor of the welding power source can be
energized. If the Circuit Breaker shouid open or trip, it must
be manually re-set.
. WATER-GAS POST-FLOW TIMER (Figure 4-2)
An adjustable 0 to 60 second Water-Gas Post-Fiow Timer,
located on the center portion of the lower front panel, is
provided for controlling the period of time shielding gas and
water (coolant) will be allowed to flow after the arc is extin-
guished,
To select the desired portion of the maximum 60 second
post-flow period available, rotate the adjustable stop arm on
the timer until the appropriate setting is obtained.
As soon as the arc has been extinguished, the Fost-Flow
Timer will begin to time out the selected period of post-flow
time. Once the timer has timed out, the gas and water valve
will close and thereby cut off shielding gas and water flow.
The timer will then automaticaliy reset and be ready for
another weld cycle.
. HIGH FREQUENCY INTENSITY CONTROL (Fig
ure 4-2)
A High Frequency Intensity Control is provided on the {ower
front panel for controlling the strength of the high fre-
OM-340 Page 9
4-9.
4-10.
Page 10
SPARK GAP
ASSEMBLY
- HIGH FREQUENCY
INTENSITY CONTROL
e
BALANCING =
RESISTOR | Cam]
SWITCH |
- a “WNELD TIMER
| e (SPOT PANEL MODEL ONLY)
D ho = . | F START CIRCUIT SWITCH
WATER — 1" |
VALVE $
г ; I ; *SHIELOING
; | GAS VALVE
| |
|
o POST-FLOW*
GAS & WATER
VALVE TIMER
o 5
WOR K am _
TT 3 9 ‚9 © > —_— ELECTRODE
TERMINA
===
18 a | *NOT INCLUDED ON BASIC MODEL
Figure 4-2. Lower Front Control Panel
quency. Rotating the contro! in a clockwise direction will
increase the intensity of the nigh frequency.
As the high frequency intensity is increased, the pos-
sibility of causing interference with local radio and
television receivers also increases. It is recommended
that the High Frequency intensity Control be set at as
iow a position as possible in order to avoid receiver
L interference, i
BALANCING RESISTOR SWITCH (Figure 4-2)
The Balancing Resistor Switch will place the proper amount
of resistance in the welding power source necessary to pro-
vide proper weiding characteristics for either Shielded Мета!-
Arc or Gas Tungsten-Arc welding.
When Shielded Metai-Arc Welding (Stick Electrode) is to be
performed, the arm of the Balancing Resistor Switch must be
in the METALLIC (down) position, When performing Gas
Tungsten-Arc Welding {TIG), the arm of the switch must be
in the TIG (up) position,
FULL WAVE/HALF WAVE BALANCE (Figure 4-3}
Gas Tungsten-Arc Welding of magnesium and aluminum is
commonly done with ac welding current. Гл theory, half of
the total number of electrons in the welding current would
flow from the tungsten to the work and the other half would
flow from the work back into the tungsten.
In practice, however, this condition does not occur when Gas
Tungsten-Arc Welding is being done on oxide forming mater-
lais such as aluminum or magnesium. The oxides on the sur-
face of the metal make it easier for the welding current to
pass from tungsten to workpiece than in the opposite direc-
tion.
This unbalancing of the ac welding current can cause pro-
blems in extreme cases. Some of the results which may be
encountered are:
1. Poor cleaning action.
2. Porosity
TERMI
STRIP
TE3
TA-901 d13-6
3. Fluctuation in the arc
4. Uneven weld penetration
"is important to remember that different altoys of alumi-
num or magnesium may react differentiy and that variations
of temperature or technique play an important part, Gen-
eraliy speaking, problems caused by rectification may be cor-
rected with this welding power source by changing over to
the half wave circuit,
To change over to the half wave circuit, proceed as follows:
1. Remove the left side panel and locate terminal strip TES.
— See Figure 4-3.
Disconnect wire No. 27 at terminal A, No. 57 at terminal
B and No. 55 at terminal C.
Connect wire Na, 55 to terminal A.
. Connect wire No. 27 to terminal B.
Connect wire No, 57 to terminal C.
mn pe
Replace side panel.
;
Sora п
NAL
A Zn . a a
TC-901 013-2
Figure 4-3. Terminal Strip TE3 Location
4-11.
A.
A
MAINTAINED CONTACT
SWITCH OPERATION
|
Figure 4-4. Terminal Strip 1T Location And Jumper Link Arrangement
PANEL CONNECTION (Gas And Water Model And
Spot Model Only)
Maintained Contact Switch Operation
Whenever it is desired to start and stop the welding arc by
respectively closing and opening the Remote Contactor Con-
trol Switch, a maintained contact type switch must be used
as the Remote Contactor Control Switch and the jumper
links on terminal strip 1T must be positioned as shown in
section A of Figure 4-4,
When welding in this fashion, closing the Remote Contactor
Control Switch will provide weld current, high frequency,
and energize the Gas and Water vaives and thereby cause
shielding gas and coolant to flow. Ali of these items will
remain active {high frequency will remain on only if the
HIGH FREQUENCY Switch is in the CONTINUOUS posi-
tion) for as long as the Remote Contactor Control Switch 15
closed. Opening the Remote Contactor Control Switch wiil
shutoff the weid current and high frequency and also will
start the post-flow timer.
. Momentary Contact Switch Operation
When the jumper links on terminal strip 1T are positioned as
shown in section В of Figure 44, a momentary contact
switch may be used as the Remote Contactor Control Switch.
The Momentary Contact Switch need be closed only long
enough to initiate the arc and then it may be released. To
break the arc when welding in this manner, it will be neces-
sary to pull the TIG gun away from the workpiece. High
frequency wili be present and the Gas and Water valves will
energize and permit shielding gas and coolant ta flow as soon
as the Remote Contactor Control Switch is closed when
utilizing this type of operation. When the arc is broken by
pulling the TIG gun away from the workpiece, weld current
and high frequency will be cutoff and the Post-Flow Timer
will be started.
. Spot Panel Operation (Spot Panel Models Only)
In order to utilize the Spot Weld Timer, it will be necessary
to position the jumper links on terminal strip 1T as shown in
section C of Figure 4-4. When utilizing the Spot Weld Timer,
a momentary contact switch should be used as the Remote
Contactor Control switch.
Upon closure of the Remote Contactor Control Switch the
operator may proceed with establishing an arc. As soon as an
arc is struck, the Spot Weld Timer will begin timing out. Also
4-12.
B
MOMENTARY CONTACT
SWITCH OPERATION
с
SPOT PANEL OPERATION
{Spot Panel Models Only)
TC-901 013-13
upon closure of the Remote Contactor Control Switch, the
Gas and Water valves will energize and permit shielding gas
and coolant to flow and High Frequency will be present.
Once an arc is established, the Remote Contactor Control
Switch may be released as the weld current, high frequency,
and Gas and Water vaives will all be on until the time allotted
on the Spot Weld Timer has elapsed. When the Spot Weld
Timer has timed out, weld current and high frequency wii! be
cutoff and the Post-Flow Timer will be started.
AUTOMATIC-MANUAL WELD SWITCH (Figure 4-5
— Spot Panel Models Only)
AUTOMATIC-MANUAL
LL WELD SWITCH
(SPOT MODEL ONLY)
TA-901 013-5
Figure 4-5. Automatic-Manual Weld Switch
The AUTOMATIC-MANUAL WELD Switch will determine
whether the Spot Weld Timer or the Remote Contactor Con-
trol Switch wiil govern the amount of time that weld current
will be available when the jumper link on terminal strip 1T is
connected for spot panel operation.
When in the AUTOMATIC position the time of the weld wiil
be determined by the Spot Weld Timer.
When in the MANUAL position, weld time will be governed
by the Remote Contactor Control Switch. In this position,
weld current will be available for as long as the Remote Con-
tactor Control Switch is closed.
OM-340 Page 11
When in the MANUAL position the Spot Weld Timer
will start to time out as soon as an arc is initiated.
However, the timer will have no effect on when the
weld current will be cutoff, this will be solely deter-
mined by the opening of the Remote Contactor Con-
. 1 trol Switch. ]
4-13. SPOT WELD TIMER (Figure 4-2 — Spot Panel Mo-
4-14.
AC VOLTS
Page 12
dels Only)
The Spat Weld Timer provides a means of selecting the exact
period of time that weld current will be avaiiable when spot
welding is being performed.
NOTE
In order for the Spot Weld Timer to be functional the
WELD Switch must be in the AUTOMATIC position
and the jumper link on terminal strip 1T must be con-
I nected for spot panel operation. 1
The Spot Weld Timer will begin to time out and provide weld
current as soon as an arc is initiated. When the time set on
the Spot Weld Timer has elapsed, weld current will be cutoff
and the Post-Flow Timer will be started
DUTY CYCLE (Figure 4-6)
The duty cycle of the welding power source is the percentage
of the ten minute period that a welding power source can
safely be operated at a given output current setting. This
welding power source is rated at 200 or 300 ampere (depend-
ing on the model) amperes, 60 percent duty cycle. This
means the welding power source can be safely operated at
200 or 300 ampere (depending on the mode!) amperes weid-
ing current for 6 minutes out of every ten, If the welding
90
80
70
60
50
40
AC VOLTS
30
I { L i
4-15.
current is decreased, the duty cycle will increase. Figure 4-6
enables the operator to determine the safe output of the
welding power source at various duty cycles.
IMPORTANT
Exceeding the indicated duty cycle will cause the
machine to overheat thereby causing damage to the
machine.
RATED OUTPUT
500
-400
ъ Ч
700
—
~~
>
WELDING AMPERES
»
La
>
Led
o
o
150
70 80 90 100
DB-901 013-1
35 40 50 60
7% DUTY CYCLE
Figure 4-6. Duty Cycle Chart
VOLT-AMPERE CURVE (Figure 4-7, 4-8 8: 4-9)
The volt-ampere curve shows the output voltage available at
any given output current within the limits of the minimum
and maximum current control setting. Load voltage is pre-
determined to a large degree by arc characteristics, With the
use of the volt-ampere curve, it is possible to determine the
amperage required for a specific load voltage. With reference
to the volt-ampere curve, the curve shows the maximum and
minimum settings of the current control onty. Curves of
other settings will fall between the maximum and minimum
curves shown.
90
80
20 25 30
70
60
50
40
AC VOLTS
30
20
10
400
о 50 100 150 200 250 300 350 400 0 100 200 100 500 600
AC AMPERES lA AC AMPERES
-901 013-
E6-901 EB-901 034-1A
200 Amp Model 300 Amp Model
Figure 4-7. AC Gas Tungsten-Arc Volt-Ampere Curves
90 90
80 80
70 70
60 a 60
50 à 50
>
40 с y 40 с
“30
30
в a
20 20
A
10 10 E
| 1 1 i 1 1 1 1 1 1 k 1
o 50 100 150 200 250 300 350 400 450 o 100 200 1300 400 500 600
A C AMPERES AC AMPERE
EB-901 013-2A EB-901 034-2A
200 Amp Model 300 Amp Model
Figure 4-8. AC Shieided Metal-Arc Volt-Ampere Curves
90
80
70
с
+ ©
DC VOLTS
+ tn
D
50 100 150 200 250 300 350 400 450
DC AMPERES
EB-901 013-3A
200 Amp Model
Figure 4-9. DC Shielded Metal-Are Volt-Ampere Curves
SECTION 5 - SEQUENCE OF OPERATION
Never, under any circumstances, operate the weiding
power source with any portion of the wrapper re-
moved. in addition to a safety hazard, improper cool-
ing may result in damage to the welding transformer
and the welding power source components. Warranty
is void if the welding power source is operated with
the wrapper removed.
boormnemeannennennanaœannæannannnt
5-1. SHIELDED METAL-ARC WELDING
1.
10.
11.
12.
Make all necessary connections as instructed in Sec-
tion 3.
On ail models except the basic, connect the jumper
link on terminal strip 1T to the configuration shown
in section A of Figure 44,
Place the CONTACTOR CONTROL Switch in the
STANDARD position,
Place the Polarity Switch in the desired position.
If a Remote Amperage Control is not to be used, place
the REMOTE AMPERAGE CONTROL Switch in the
STANDARD position.
Place the START CIRCUIT Switch in the desired posi-
tion. If this switch is positioned to IN, rotate the
START ADJUSTMENT Control to the desired setting.
Piace the Range Switch in the desired position.
Rotate the Fine Current Control to the desired setting.
Place the HIGH FREQUENCY Switch in the OFF
position.
Place the Balancing Resistor Switch in the METALLIC
position,
Ensure that the PRIMARY OVERLOAD Circuit
Breaker is in the ON position.
Place the POWER Switch in the ON position,
13.
Prior to welding, it is imperative that proper protective
clothing (welding coat and gloves) and eye protection
{glasses and/or welding helmet) be put on. Failure to
compiy may result in serious and even permanent
| bodily damage.
Commence welding.
D C VOLTS
100 200 300 400 500 600 700
В С AMPERES EB-902 034-3A
300 Amp Model
5-2. GAS TUNGSTEN-ARC WELDING
1.
10.
11.
12.
13.
14.
Make all necessary connections as instructed in Sec-
tion 3.
Connect the jumper link on terminal strip 1T for
either momentary or maintained switch operation.
{This step does not apply to basic models.)
Place the CONTACTOR CONTROL Switch in the
REMOTE position.
Place the Polarity Switch in the desired position,
If a Remote Amperage Control is not to be used, place
the REMOTE AMPERAGE CONTROL Switch in the
STANDARD position.
Place the Range Switch in the desired position.
Rotate the Fine Current Control to the desired setting.
Place the START CIRCUIT Switch in the desired posi-
tion. If this switch is positioned to IN, rotate the
START ADJUSTMENT Control to the desired setting.
Place the HIGH FREQUENCY Switch in the START
or CONTINUQUS position and rotate the HIGH FRE-
QUENCY Intensity Control to the desired setting,
Place the Balancing Resistor Switch in the TIG posi-
tion,
Set the Post-Flow Timer for the desired amount of
time,
Connect for full or half wave operation as instructed
in paragraph 4-10.
Ensure that the PRIMARY OVERLOAD Circuit
Breaker is in the ON position.
Place the POWER Switch in the ON position.
15.
. GAS TUNGSTEN-ARC SPOT WELDING (Spot Panel
Prior to welding, :t is imperative that proper protective
clothing {welding coat and gloves) and eye protection
{glasses and/or welding helmet) be put on. Failure to
comply may result in serious and even permanent
odily damage.
E— ]——. ОНЕНннНННННиЙ
Commence welding.
Models Only)
1.
Make all necessary connections as instructed in Sec-
tion 3,
Connect the jumper link on terminal strip 1T for spot
panel operation.
OM-340 Page 13
Page 14
3. Place the CONTACTOR CONTROL Switch in the
REMOTE position.
4. Place the Polarity Switch in the desired position.
5. If a Remote Amperage Control is not to be used, place
the REMOTE AMPERAGE CONTROL Switch in the
STANDARD position,
6. Place the Range Switch in the desired position.
7. Rotate the Fine Current Control to the desired setting.
8. Place the START CIRCUIT Switch in the desired posi-
tion. If this switch is positioned to IN, rotate the
START ADJUSTMENT Control to the desired setting,
8. Place the HIGH FREQUENCY Switch in the START
or CONTINUOUS position and rotate the HIGH FRE-
QUENCY Intensity Control to the desired setting.
10. Place the Balancing Resistor Switch in the TIG posi-
tion.
11. Place the WELD Switch in the AUTOMATIC position.
— CAUTION + |
Ensure that the branch circuit or main disconnect
switch is open or primary input circuit fuses are
removed before attempting any inspection or work on
the inside of the welding power source. Placing the
welding power source on-off power switch in the OFF
position does not remove voltage from the power
1 terminals inside the welding power source, |
. RECTIFIER
tt is recommended that the rectifier be cleaned occasionally
by blowing it out with compressed air. This cleaning opera-
tion is necessary so that maximum cooling will be accom-
plished by the air stream. This should be done periodically
depending upon the location of the unit and the amount of
dust and dirt in the atmosphere.
. FAN MOTOR
AM modeis are equipped with an exhaust fan and rely on
forced draft for adequate cooling for high duty cycles and
overloads. The fan motor is manufactured with lifetime
lubricated sealed bail bearings and no attention should b
required. :
. RECTIFIER
It is recommended that the rectifier be cleaned occasionaily
by blowing it out with compressed air. This cleaning opera-
tion is necessary so that maximum cooling will be accom-
plished by the air stream. This should be done periodically,
depending upon the location of the unit and the amount of
dust and dirt in the atmosphere.
. SPARK GAP
The spark gaps can be readily inspected by opening the access
door on the front of the welding power source.
The spark gaps are normally set a .008" clearance at the
factory. It will be necessary to periodically readjust these
after extended operation. Usually inspection and adjustment
every three or four months will suffice. Readjustment is also
indicated when intermittent operation of the gaps is noted.
Usually this occurs when the setting has increased to .013” or
greater.
Generally speaking, the high frequency outputvaries directly
{up to a certain point) with the spark gap spacing. In extreme
cases where the greatest amount of high frequency is needed,
it may be necessary to adjust the spark gap setting to .010”
or even 013". This also increases the high frequency radia-
tion and it is suggested that the minimum gap setting (.004”
to .0087), consistent with good welding operation, be used.
12. Set the Spot Weld Timer for the desired amount of
time.
13. Set the Post-Flow Timer for the desired amount of
time.
14. Connect for full or half wave operation as instructed
in paragraph 4-10.
15. Ensure that the PRIMARY OVERLOAD Circuit
Breaker is in the ON position,
16. Place the Power Switch in the ON position.
eN
Prior to welding, it is imperative that proper protective
clothing {welding coat and gloves) and eye protection
(glasses and/or welding helmet) be put on. Failure to
comply may result in serious and even permanent
1 bodily damage. |
17. Commence welding.
5ЕСТ!ОМ 6 - МА!МЧТЕМАМСЕ == mena
Cleaning or dressing the points of the spark gaps is not
recommended, as the material at the points is tungsten
and is impossible to file, The entire point shouid be
replaced when the tungsten section is completely
1 disappeared. 1
TA-020 623-A2
Fiqure 6-1. Spark Gap Adiustment
To Adjust Spark Gaps, Proceed As Follows:
1. Loosen screw A on both sides,
2. Place feeler gauge of proper thickness between gaps C.
3. Apply slight pressure against point B so feeler gauge is
held firmiy in gap.
4. Tighten screws À.
CONTROL CIRCUIT FUSING
The control circuit fuse is a 600 volt, 6 ampere type fuse and
is mounted in the case next to the primary terminal board.
Do not use any fuse other than a 600 volt, 6 ampere size. The
purpose of this fuse is to provide protection to the control
rectifier and the circuit components,
The symptom of a blown fuse is complete loss of control of
6-6. THERMAL PROTECTION
the welding current but minimum output of each range 15
available. Before replacing the fuse, examine leads for short
circuit or other signs of trouble, especially at the point where
the leads enter the remote amperage control case. Examine
the Amperage Adjustment Control Rheostat in the welding
power source, and, if a remote amperage control is used, also
examine the rhegstat in the remote amperage control.
INTRODUCTION
The data collected here, discusses some of the common problems
which may occur in this welding power source. A little thought will
probably solve the problem involved through the information pro-
vided,
The assumption of this data is that a proper welding condition has
been achieved and has been used until trouble developed. In all cases
This welding power source is protected with one normally
closed overload thermostat located in the Right Secondary
Coil of the Main Weld transformer {TP1)., Any excessive over-
loading wili cause the Main Contactor to open, stopping the
welding power source output. If this occurs, stop welding and
allow the weiding power source about three minutes cooling
off time. Normai operation can then be resumed.
SECTION 7 - TROUBLESHOOTING =
of equipment malfunction, the manufacturers recommendations
should be strictly adhered to and followed.
If after performing the following procedures the trouble is still not
remedied, it is recommended that a serviceman be called.
It is recommended that the circuit diagram be used for reference
during the troubleshooting.
TROUBLE
PROBABLE CAUSE
REMEDY
Control of welding current with
Start Adjustment Control only.
High Frequency remains on when
Н.Е. Switch is in “START”
position.
CR1 relay remains energized after arc begins.
Examine CR1 relay. May be necessary to adjust
R? resistor.
Changing position of Start
Adjustment Control does not
affect starting current. High
_ [frequency does not turn on when
(switch is in “START” position.
| CR1 relay does not p.u. when welding machine
is turned on and no arc is established.
May be necessary to adjust R2 resistor to
increase voltage applied to CRT.
Start Control Switch in OUT position.
Place Start Control Switch in IN position if
starting current is desired.
Welding current very low -
increasing Weld Current Control
setting does not increase welding
current.
Blown control circuit fuse.
Replace if defective with a 6 amp, 600 volt
fuse,
Amperage Control Switch in the REMOTE
position with no remote amperage control
connected to receptacle.
Either place Amperage Control Switch in the
STANDARD position or connect a remote
amperage control to the Remote Amperage
Control Receptacle,
Using remote amperage control with Weld
Current Control on machine turned to
minimum.
Increase the setting of the ‘Weld Current
Control on the machine,
Welding current iow - Weld
Current Control does not control
current.
Low line voltage,
Check line voltage - if tow. Check with Power
Company to determine cause.
Use of welding cable which is too long or too
small for the welding current empioyed.
See Table 3-2 for cable size requirement for
current used,
Loose connection to workpiece or in welding
cable connections.
Check all secondary welding connections.
Machine deiivering welding
amperage more or less than
marked on nameplate.
Operating welding power source on incorrect
line voltage.
Check jumper links on primary line voltage
connections. See Figure 3-3.
Lack of high frequency, difficulty
in establishing are.
Spacing of spark gaps has increased.
Set spark gap points .008” to .010”.
Use of tungsten iarger than recommended for
welding amperage involved.
Use proper size tungsten.
Dissipation of high frequency from electrode
holder lead.
Make certain electrode holder cable is not in
close proximity to any grounded metal.
High Frequency Intensity Control setting too
low.
increase setting of Hign Frequency intensity
Controi.
Wandering arc - poor control of
direction of are,
Use of tungsten considerably larger than
recommended.
Use proper tungsten size.
Tungsten electrode oxidizing and
not remaining bright after
conclusion of weld.
Water lead in electrode holder.
Refer to gun parts list for parts Or parts
requiring replacement.
Loose gas fittings on regulator or gas line. This
will siphon oxygen into the weld zone,
Check all gas fittings and tighten.
Insufficient gas flow.
Increase gas flow setting.
Drafts blowing gas shield away from tungsten.
Shield weld zone from drafts.
Dirty filler rod or material.
Lise clean fitler rod or material.
Gas shutting off too quickly after end of weld.
Increase time delay setting of Post-Flow Gas
and Water Valve Timer, |
ОМ-340 Раде 15
Tungsten electrode oxidizing and
not remaining bright after com
clusion of weld.
Insufficient high frequency.
Control.
Increase setting of High Frequency intensity
Power switch on, no weld current,
and fan motor is not running.
F2 fuse blown.
Replace if defective.
High frequency unit has no
power.
F3 fuse blown.
Replace if defective.
SHIELDED METAL-ARC (STICK ELECTRODE) WELDING
Contactor Control Switch Standard”
H.F. Switch “Off”
Power Switch “On”
L
г
W-p.u.
Effective 80 Voits
CA1-o.u.
CR2-p.u.
CR4d oo.
RE
Operative
|
Gas & Water
Flow Starts
Gas & Water
Flow Stops
|
p.u. - picks up
d.o. - drops out
ТО1 +...
Begins Time Qut
TD1-Times Out
And Holds
|
L
Welding Arc
Established
CR1-d.o.
CR2d.o.
After Time Delay
CR4-p.u.
R7
Operative
Lui.
Welding Arc Extinguished
|
Effective
CR1-p.u.
CR2-p.u.
CR4-do.
RB
Operative
|
Раде 16
80 Volts
——
Figure 7-1. Shielded Metal-Arc Wel ding Flow Chart
TA-901 013-9
AC AND DC GAS TUNGSTEN-ARC (TIG) WELDING
Contactor Control Switch “Remote”
High Frequency Switch “AC-Continuous - DOC-Start”
Panel Selection “A”
Power Switch “On”
p.u. - picks up
d.o. - drops out
| | |
CR2-p.u. Gas & Water TO!-p.u.
Flow Starts Begins Time Qut
CR4-p.u. Zero | |
| O.C.V.
RE Gas & Water TO1-Times Out
Operative E. And Holds
Maintain Contactor Closed By
Operator Through RC2-Electrode A
Not In Welding Position
W-p.u.
Effective 80 Volts
| CR3-p.u.
HF. CR1p.u. |
On | | |
CR? - Held Gas & Water TD1d.o
Energized Flow Starts Ва
Effective BO Volts
H.F. “On
Gas Glow
Electrode In Welding
Position
Welding Arc Established
CR1d.0.
CRZ2-d.o.
CRA о. Н.Е, ОН
| (S3 - Start)
R7
Operative
| N -
Maintain Contact Switch
Through RCZ Opened By
Operator
W-d.0.
Welding Arc Extinguished
| CRId.o.
HF. Off Zero
(53 Continuous) OC.V. |
CR2-p.u. TDI-p.u.
| Begins Time Out
X CR4-p.u. TD1-Times Out
| And Holds
R8 Gas & Water
Operative Fiow Stops
Fiqure 7-2
|
|
ыы
. À Panel AC/DC Gas Tungsten-Arc Welding Flow Chart
TA-201 013-10
OM-340 Page 17
AC AND DC GAS TUNGSTEN-ARC (TIG) WELDING
Contactor Control! Switch “Remote”
High Frequency Switch “AC-Continuous - DC-Start”
Panel Selection “RB”
p.u. - picks up
d.o. - drops out
Power Switch "On"
| | | |
CR2-p.u. Gas & Water TD1-p.u.
Flow Starts Begins Time Out
CR4-p.u. Zero | |
| O.C.V |
RE Gas & Water TD1-Times Out
id
Operative Flow Stops a 5
Momentary Contactor Closed By
Operator Through RCZ-Electrode
Not In Welding Position
W-p.u.
Effective 80 Volts
| J
1 CR3-p.u
On | |
CR2 - Held Gas & Water TD1-d.0.
Energized Flow Starts
Effective 80 Volts
H.F. “On”
Gas Glow
Electrode In Welding
Position
Welding Arc Established
R1-do.
CR2-d.o. С |
After Time Delay CR3 . Locks in On
itself Through CR1
|
| W - Hoids In
CR4-do. H.F. Off |
| (S53 - Start) Momentary Contact Switch
R7 Through RC2 Opened By
Operative Operator
Electrode Removed From Work
Welding Arc Extinguished
CR1 - p.u.
i
- Wd.o.
Zero Q CV,
CR3-d.o.
CA1-do. Н.Е. ОН
Раде 18
{53 Continuous)
Figure 7-3, B Panel AC/DC Gas Tungsten-Arc Welding Flow Chart
|
CRZ-p.u. TD1-pu.
Begins Time Out
CR4-p.u. TD1-Times Out
And Holds
RE Gas & Water
Operative Flow Stops
La
—
TA-901 013-11
DC GAS TUNGSTEN-ARC (TG) SPOT WELDING
Contactor Control Switch “Remote”
High Frequency Switch “Start”
Automatic-Manual Switeh “Automatic”
Panel Selection $”
Power Switch “On”
p.u. - picks up
d.o, - drops cout
i
| |
CR2-p.u. TD2 Motor Runs Gas & Water TD1 p.u.
| Continuously Flow Starts Begins Time Out
CR4-p.u. e | |
а Gas & Water — TD1-Times Out
88 Fiow Stops And Holds
Operative | |
L — -
T.1.G. Spot Gun In
Welding Position
Maintain Contact Switch Closed
By Operator Through RC2
W-p.u.
Effective 80 Volts
| |
CRÍ-D.u. ur CR3-p.u.
If Arc Is Not 0 * rm |
Established n Gas & Water
a }
CR?-Held Ns
Energized Effective 80 Volts
H.F. “On”
Gas Flow
Welding Arc Established
CR2d.o. |
(S5 Automatic} {S5 Manual)
After Time Delay
CR4-d.o.
R?
Operative
Weld Time Generally
Completed Before
R7 is Operative
TD?-p.u.
Begins Time Out
|
TD2
Weid Time Controlled By
Operator Through RC?
|
TT Le LL
W-d.o.
||
1 1
Maintain Contact Switch Opened CR3d.0
Н.Е. By Operator Through RC2 |
Off | Г - ]
CR2-p.u. TDipu. TD2do.
| Begins Time Qut
|
R4-0.U. TD{-Times Out
CRAP. And Holds
|
RE . Gas é: Water
Operative Flaw Stops
Figure 7-4. DC Gas Tungsten-Arc Spot Welding Flow Chart
J
TA-901 013-12
OM-340 Page 19
GRD
C—b
L Cr
a
SEE INSTALCTION BOOK FOR
PROPER PRIMARY CONNECTIONS
L Or
ТЕ,
>
J5 © 3]
сет) — +
к
+
AA
73
Ca
| START ¢
START
CIRCUIT ——
ET
a CA
CONTACTOR _— 9 RE HACI EMETERS
CONTROL E COPTIOMNAL-EXTRAJ
AMT, т R
"Ss PANEL" 89 | AC 3 AVAILABLE ONLY WORK ELECTRODE
> e ! WITH 2 KyA TRANBFOPMER
ONLY |
AC GTAw=- Aa BALANCE SELECTION
CRa res BALANCE TERMINAL BALANCE
85 FRONT SELECTION POSITION E SELECTION
с 077 22 VIEW TOP FULL WAVE lets HALF WavE
AA — == bar EXTERNAL Me | * INTERNAL FE
! | FACTORY | 5057 OPTIONAL
1 GR-GAOUND (wHT; | of CONNECTED | 4027 | CONNECTION
| | B- BRASS (¥? È on
tod C-COPPERCX) | om 52
+ L dl ок = = == = = — de — == = =! 03
7 REMOTE CUNTROL 2702
i ! (OPTIONAL - EXTRA} a Ra
! O23 28 #
* oz OCST LÉ DCREV
"DELETE ON -
"PT MOGEL
3 Circuit Diagram Мо. СВ-901 013-101
Figure 7-5. Circuit Diagram For 200 Ampere Model
SAD, r
od
Lo 74
SEE Мате СТОН BOOK FOR
PROPER PRIMARY CONNECTIONS
ca
и“ 34
—
TE
р ь
de
B уст
пси a> С À — {Fig ——t
Y 37 are
TÉ3 AC.
“ x
"| i
À À
; T
4 Е CONT 5 Ta Ё 3
= OFF cas Co
| START © pad
START 1
CIRCUIT To
4 51
CONTRACTOR 17 ny o rE WRCAL METERS 5
CONTROL OPTIONAL EXTRA WORK ELECTRODE
ACA AVAILABLE ONLY
WITH 2 KYA TRANSFORMES
AC GTAW- Ra BALANCE SELECTION
5% BALANCE TERMINAL BALANCE
o SELECTION (POSITION | SELECTION
arr FULL WAVE TES HALF WAVE
AC $ EXTERNAL Ra | СОЗ INTERNAL Ag
2 | I PO FACTORY 2057 OPTIONAL
1 } GA - GROUND [WHT | cs | CONNECTED | 4027 | comNECTON
oo] B-BRASS (Y) 1 25 i 1
! i © - COPPER (Xi | эм
I li a == = — — — — я
REMOTE CONTROL ATO
' (OPTIONAL -EX TRAN 20
! =
' 02 28 OT, a
1 . 024 OCT oc REY
AC.
"DELETE ON
TP" MODEL Circuit Diagram No. CB-901 034-1A
Figure 7-6. Circuit Diagram For 300 Ampere Model
Page 20
=== SECTION 8 - CERTIFICATION FOR HIGH FREQUENCY ARC WELDING EQUIPMENT ===
8-1.
1
Ground
GENERAL
This following information is necessary to make a proper
installation of the high frequency arc welding equipment de-
scribed in this instruction manual. In order to comply with |
Part 18 of the Rules and Requlations of the Federal Com-
munications Commission, the certificate in front of this man-
.ual must be filled in completely and signed. The certificate
must be kept WITH THE EQUIPMENT AT ALL TIMES to
comply with the regulation. ;
The manufacturer of the equipment covered herein has con-
ducted approved field tests and certifies that the radiation
can reasonably be expected to be within the legal limits if the
correct installation procedures, as outlined, are followed.
The importance of a correct installation cannot be over-
emphasized since case histories of interference due to high
frequency stabilized arc Welding Machines have shown that
invariably an inadequate installation was at fault.
The user of the equipment must complete the certification
by stating that he has installed the equipment and is using it,
according to the manufacturer's instructions. The user must
sign the certification notice appearing in front of this instruc-
tion bookiet indicating that he has complied with the require-
ments.
In the event that interference with authorized services occurs,
in spite of the fact that the radiation from the welding equip-
ment is within the specified limits, the user is required to
take suitable steps to clear the situation. The factory person-
nel will assist the user by supplying technical information to
clear the situation.
In lieu of complying with the instaliation requirements and
the certification of each individual installation, the user may
elect to certify his entire plant by having a reputable engin-
eering firm make a plant radiation survey. In such cases, the
installation instructions incorporated in this instruction
booklet could very well serve as a guide in minimizing inter-
ference that might be contributed by the high frequency arc
welding equipment.
. GENERAL INFORMATION
In a high frequency stabilized arc Welding Machine installa-
tion, interfering radiation can escape in four distinct ways as
outlined below:
1. Direct radiation from the weiding machine. This is radia-
tion that escapes directly from the Welding Machine case.
This is very pronounced if access doors are left open and
unfastened and if the Welding Machine case is not pro-
perly grounded. Any opening in the metal Welding Ma-
chine case will allow some radiation to escape. The high
frequency unit of this certified equipment is adequately
shielded to prevent direct radiation of any consequences
if proper grounding is carried out.
2. Direct feedback to the power line. High frequency energy
may get on the power line by direct coupling inside the
equipment or the high frequency unit, the power line
then serving as a radiating antenna.
By proper shielding and filtering, direct coupling is pre-
vented in this certified equipment.
At least 50 feer
Solid Metallic Conduit |
Line Fuse and
~~ и, Switch Box
Good electrical joints be- Г) |
tween Box and Conduit
ing Machine or Osciliator
Good electrical contact.
Clean metal to metal,
Fiqure 8-1. Power Service Instaliation H.F. Stabilized
Arc Welding Machine
High Frequency Stabilized Weld-
3. Direct radiation from welding leads. Direct radiation from
the welding leads, although very pronounced, decreases
rapidly with distance from the welding leads. By keeping
the weiding leads as short as possible, the operator can do
a great deal to minimize interference from the source.
The intensity and frequency of the radiation can be
altered over wide limits by changing the location and rela-
tive position of the welding leads and work. If possible,
loops and suspended sections should be avoided.
4. Pick-up and reradiation from power lines. Even though
welding lead radiation falls off rapidly with distance, the
field strength in the immediate vicinity of the welding
area may be extremely high. Unshielded wiring and un-
grounded metallic objects in this strong field may pick up
the direct radiation, conduct the energy for some dis-
tance, and produce a strong interference field in another
area. :
This is. usually the most troublesome source of interfer-
ence, but careful adherences to proper installation pro-
cedure as outlined in this booklet will minimize this type
of interference.
8 - 3. POWER SERVICE
The specific installation instructions for making the proper
primary connections to the equipment as outlined in the in-
struction booklet furnished with the equipment, should be
followed carefully with one exception as notted in the
foliowing paragraph.
Frequently installation instructions specify that the primary
power service shall be run in solid or flexible metallic con-
duit. Ordinary helically wrapped conduit is designed for
mechanical protection and is not suitable for electrical shield-
ing. Only solid metallic conduit or conduit of “equivalent
electrical shielding ability” should be used to enclose the
primary power service leads.
Solid metallic shielding shall enclose the primary power ser-
vice to the equipment from a point 50 feet from the equip-
ment in a unbroken run.
This shielding shall be grounded at the farthest point from
the equipment and should make good electrical contact with
the casing of the equipment. The ground should be in accor-
dance with the specifications outlined in the section entitled
“GROUNDS” and .as shown in Figure 8-1. Care should be
taken that paint or corrosion at the junction of conduit and
case, does not interfere with good electrical contact.
There shall be no gap in this shielding run. This simply means
that within 50 feet of the equipment, no portion of the
power wires serving the equipment shall be unshielded. If
there is any question about the electrical efficiency of the
joints between individual conduit sections, outlet boxes and
the equipment case, bonding should be carried out by solder-
ing a copper strap or wire across the joint as shown in Figure
8-2.
Clean and bolt _
Soider Copper Strap o Solder
N |
(a) Demountable Bonding Strap for Conduit Joints
Co r Wire
Solder POr Solder
[b) Solid Bonding with Copper Wire for Conduit Joints
Figure 8-2. Two Recommended Methods For Electrical
Bonding Across Poor Conductivity Conduit Joints
8-4. WELDING MACHINE
The location of the equipment should be chosen with respect
to nearness to a suitable ground connection. The equipment
case, firmly banded to the power conduit, should be
grounded to the work terminai of the equipment with a
copper cable or braid with rated current carrying capacity
equal to or greater than that of the power service wires.
OM-340 Page 21
This “work” output terminal of the equipment should then
be grounded to a “good electrical ground” las defined in
section entitled “GROUNDS”) with a short length of welding
Sale of the same capacity as the “work lead”. (See Figure
Welding Machine Case firmly
bonded to Power Conduit
Work Terminal grounded 10 driven
heavy braided strap or cable
"Source of
Power
7
Case grounded to —
Work Terminal
Figure 8-3. Ground Connections At Welding Machine
Page 22
No change in the wiring or the location of parts inside the
equipment, other than power service tap changes ar other
adjustments specifically covered shall be made. The equip-
ment shall not be modified in any way since changes in the
equipment can affect the radiation characteristics and may
not be in accordance with the test data upon which the man-
ufacturer bases his certification.
While the equipment is in operation, all access and service
doors shall be closed and properly fastened.
Spark gap settings shall be maintained at the minimum separ-
ation consistent with satisfactory welding results.
. WELDING LEADS
in order to minimize direct weld lead radiation, the welding
leads {electrode lead and work lead) must be kept as short as
possible. Certification tests on this machine have been made
with leads 25 feet long. Considerable improvement in radia-
tion minimization can be had by shortening the leads as
much as possible.
Keeping the electrode {ead and ground or work lead as close
as possible and on the floor serves to reduce the radiation,
(See Figure 84),
Welding Machine
or Qscillator
Elec Hold
Keep leads on ground trode Holder
or boards and
3/4" té 1° apart
Keep leads as short as possible —
never in excess of 26 feet,
Figure 8-4. General Rules For Welding Leads
. WIRING IN THE VICINITY OF THE WELDING
AREA
As discussed in the general information section, the most
serious source of interference is reradiation from wires that
are located near the welding area.
Any ungrounded electrical conductor in the strong “directiy
radiated” field, produced by the welding leads, serves as a
pick-up device and may conduct the interference for some
distance and reradiate strongly at another location.
For purpose of simplification and standardization, the space
all around the weld zone at a distance of 50 feet in all direc-
tions is referred to as the High Field intensity (H.F.1.) zone.
{See Figure 8-5}.
To minimize radiation of this type all wiring in the H.F.I.
zone shall be in rigid metallic conduit, lead covered cable,
copper braid or material of eguivalent shielding efficiency,
Ordinary flexible helically wrapped metallic conduit, com-
monly referred to as "'B.X.” is not satisfactory for shielding,
and should not be used. The shield on all wiring should be
grounded at intervals of 50 feet and good electrical bonding
between sections shall be maintained.
This shielding requirement applies to ail wirtng, including tel-
ephone, Inter-communication, signai and controi and inciden-
tat service.
© ground rod or cold water pipe with
A TT
Va a Shielded Wires >.
G
rounded at ION
50 foot intervals L A
Welding
Machine E
Electrode |
A
«y Holder |
+ =. Work
Keep ALL unshielded and un- 7
grounded wires out of this
Migh Field Intensity Zone.
> —
в, ИН
N
Figure 8-5. General Requirements to Minimize Reradiation
Pick-Up In the Vicinity of the Weld Zone
Extreme precaution should be taken to make sure that the
location of the zone 15 chosen so that none of the conditions
are voided by unshielded wires off the premises but still with-
in the radial dimensions of the H.F.l. zone.
This 50 foot H.F.l. zone is a minimum that is imposed on the
installation. Certification tests by the manufacturer are based
on this limit.
Keeping unshielded wires farther than 50 feet from the weld
zone will materially aid in minimizing interference.
If it is impossible to relocate unshielded wires, that section
within the H.F.I. zone, should be placed in conduit and each
end of the conduit section grounded.
NOTE
It must be emphasized that all changes in power and
lighting wiring should be made by a qualified electri-
cian and comply with the National Electrical Code
requirements. Any shielding or relocation of telephone
or signal wires must be done either by the service com-
pany concerned or with the specific permission of said
[ company. i
. GROUNDS
pd
Frequent reference is made to a “good ground” in previous
sections, Although there is considerabie leeway in the Inter-
pretation of this term, for the purpose covered in this
booklet the following specifications apply:
A “ground” connection should be made to a driven rod at
least 8 feet long and driven into moist soil.
A cold water pipe can be used in place of the ground rod
provided it enters the ground within 10 feet of the equip-
ment to be grounded.
All leads connecting the point to be grounded to the ground
rod or pipe should be as short as possibile since the ground
tead itself can become an effective radiating antenna.
The effectiveness of a ground in reducing interference de-
pends upon the ground conductivity. In certain locations it
may become necessary to improve the ground conductivity
by treating soi! around the ground rod with a saít solution.
. METAL BUILDING
[t is frequently through that operating of high frequency
stabilized arc welding equipment in metallic buildings will
completely eliminate troublesome radiation. This, however, is
a false assumption.
A metallic building structure, if properly grounded, may
serve to reduce direct radiation from the weld zone but will
have no effect on conducted interference and reradiation. As
a result, all installation requirements necessary for certifica-
tion must be complied with.
8-10
. INDIVIDUAL
tf the metallic building is not properly grounded, bonding to
several good electrical grounds placed around the periphery
of the building will give reasonable assurance that the build-
ing itself is not contributing to the radiation.
INSTALLATION CERTIFICATION
Any or all of the above installation requirements may be
waived by the user if he desires to exercise the option of
making an individual field survey of the particular unit instal-
lation (or the complete installation if more than one unit is
involved), and certifying on that basis.
This survey shall be made by a competent engineer in accord-
ance with the test procedure requirements as set forth in Part
18 of the Rules and Regulations of the Federal Communica-
tions Commission,
Surveys of this nature can cover a single unit or multiple
units or may include the complete plant structure.
CHECK LIST
The following questions may be used by the installer as a
check to see if all instaliation requirements have been met:
1.. Has the equipment been located so that ground leads
can be kept short?
2. Are the power ieads, serving the unit, in conduit?
3. Is there good electrical contact between power con-
duit and case?
4. Do the conduit couplings make good electrical con-
tact? {If in doubt, use bonding).
5. Is there good electrical contact between conduit and
switch on service boxes?
6. If rigid metallic conduit is not used, is the shielding
used of equivalent shielding efficiency? {Copper sleev-
ing, lead covered cable, etc., is satisfactory. Spirally
wound flexibie metallic conduit is not suitable),
7. Is the conduit system grounded at a point at least 50
feet from the equipment?
8. Is the conduit run complete (without any gap) in the
H.F.. zone?
9, Is the equipment case connected to the work terminal
of the secondary?
10. Is the wire used for this connection of sufficient size?
11. Is the work terminal connected to a good electrical
ground?
12. Is the cable or copperbraid used for this connection
equal to or greater in current carrying capacity than
the welding lead?
13. ls this cable as short as possible?
14, Are thesparik-gaps set at .008” or less?
15. Are all service and access doors closed and bolted?
16. Are the welding leads less than 25 feet long?
17. Are they as short as possible?
18. Are the welding leads on the floor or placed on a
suitable board?
19. Are the weiding leads approximately 3/4" to 1°’ apart?
20. Have you visualized the H.F.l. zone, a sphere with a 50
foot radious centered on the weld zone? :
21. Have the unshielded power and light wires originally in
this H.F.I. zone been placed in grounded shields or
been relocated outside the zone?
22. Have all large metallic objects and any long guy or
supporting wires in the H.F.]l. zone been grounded?
23. Have you checked so that no external power or tele-
phone lines off the premises are within the zone?
24. Arethe grounds driven ground rods?
25. Is a cold water pipe used as ground?
26, If so, does it enter the ground 10 feet or less from the
connection?
27. Are the connections to the ground clean and tight?
28. If operated within a metal building, is the building
properly grounded?
If your answer is “yes” to the above questions, you can certi-
fy the installation by signing the certificate.
- OM-340 Page 23
September 1973 FORM: OM-340
Effective with serial No. HD684370
Ц 3
MODEL/STOCK NO. SERIAL/STYLE NO. DATE PURCHASED
PARTS LIST
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OM-340 Page 1
TD-901 048
Figure A — Main Assembly
Quantity
Model
Item Dia, Factory 200 | 300
No. Mkgs. PartNo. Description Amp | Amp
Figure A Main Assembly
1 014607 PANEL, side ........oecoeceorororarnmanmonmravresxormnnmarcerrenora, 2 2
2 014 604 COVER, top ............ maracas eae 1 1
3 016 608 CONTROL PANEL, master (See Fig. DPage 4) ....... coins, 1 1
4 018752 BASE, mounting - capacitor .......e.o.er.eraerervesorneraenmneoaaon, 1 1
5 C1 025 315 CAPACITOR, paper-oil 30 uf 460volt ..... RAA ф бк н ня неа неее 1 2
6 025 143 BRACKET, mounting-capacitor ............... recreo eens 1
6 025 142 BRACKET, mounting - capacitor .......cw..reresrenesceocormereeos. 1
7 R4 030 6038 RESISTOR, WW fixed 10 watt 10K ohm ............ chien nn а 1
8 038 461 TERMINAL ASSEMBLY, connecting-resistor (consisting of) . ........... 1 1
9 023 001 .BUSBAR ......eosmesedcarmarmaraoen0ocare., PA 1 1
10 038 323 . TERMINAL BOARD ......oo_roncodoroorervarmerocavvecnercarere 1 1
11 019177 , BRACKET,mounting.......2..24.41444 000000 00010000 00 00000000 2 2
12 038888 .STUD, brass 1/4-20 x 1-1/2 w/hex collat ......0.0.00000000 000000 K EG 3 3
13 016876 BASE ........22220000 0400 00e 0 a aa ua eu au 0 000 8 0010001 00 0000006 1 1
14 010 494 BUSHING, snap-in 1-3/4 dia hole ..,........e.esorocecnrecarerevo.. 1 1
15 014630 BAFFLE, air - vertical .....eeeocoorearercorocatrermanovdcorecmrreaa 1 1
16 SRI 037 324 RECTIFIER, silicon diode (See Fig. BPage 3) ....... cocina. 1
16 SRI 037111 RECTIFIER, silicon diode (See Fig. B Page 3) ......e.e.erreoovervova 1
17 014 628 BAFFLE, air - horizontal .......oeoreererrasrareormecárocereacear. 1
17 015548 BAFFLE, air - horizontal ,.........eceserecaarrererorrecmerveraraa 1
18 010 493 BUSHING, snap-in 7/8 dia hole ......eoreorcorrsecoraecarrormederera 1 1
19 R10 030636 RESISTOR, WW adj 50 watt 4 ohm .......... cities 1 1
20 R11 030640 RESISTOR, WW adj 100 watt 5 ohm ......._eeoorecvernvoreorerocoras 1 1
21 R6 030 608 RESISTOR, balance (See Fig. CPage 3d)... ..... cians. 1
21 R6 030 609 RESISTOR, balance (See Fig. C Page 3) .........eecrenoroorerecccaco 1
22 Figure E PANEL, rear w/components (See Page 5) ........e.ececerororecaeoo. 1 1
23 R12 030 965 RESISTOR, WW fixed 100 watt 100 ohm ........—.—_—e-—eeoxververersa 1 1
24 CT 036 208 TRANSFORMER, current 200/5 ........e..reaveccaaarmerveorerv a 1 1
25 022 027 LINK, jumper - contactor (Allen Bradley Contg) or
25 038 264 LINK, jumper - contactor (Furnas Contg) ......00.2400000 0000000000 4 4
26 W 034 653 CONTACTOR, size 1-4 pole 115 volt (Allen Bradley) or
26 W 034 820 CONTACTOR, size 1-3/4 - 4 pole 115 volt (Furnas)(See Fig. F Page 5) . . .. 1 1
27 012638 HOLDER, fuse-carfridge 600 volt. .... ....... 0 iii 1 1
28 F2 *012 639 FUSE, cartridge 6 amp 600 volt ..........ecere—morevosorecencoven. 1 1
28 F2 +*012 641 FUSE, cartridge 10 amp 600 volt ........._—-—e__eeceeresorereeoroave. 1 1
29 Tel 038 442 TERMINAL ASSEMBLY, primary (See Fig, K Page 9) ................ 1 1
30 T2 036 629 TRANSFORMER, kva 1/2 1.122444 06404011 10e 000 883 ea 1 101 40000 8 1 1
30 T2 +036 646 TRANSFORMER, kva 2... ..... cities scsi 1 1
31 100 917 BRACKET, mounting-xfmrkva ........o_r_esoarenerrvrocearerevrvea 2 2
32 017998 BAFFLE, air & mounting component ...... 7e.rrrevorearearmerevara 1 1
33 Ti **022 519 TRANSFORMER, power - main (See Fig, G Page 6) .................. 1
33 TI **022 520 TRANSFORMER, power - main (See Fig. GPage6) .................. 1
34 MAI *022 521 AMPLIFIER, magnetic (See Fig. HPage 7) ........ cc. coin, 1
34 MAl **022 522 AMPLIFIER, magnetic (See Fig. HPage 7) ........ coins. 1
35 Z 023 060 STABILIZER ....422040 040004 0 00 0 0 0 0 a aa eau 00 RAA AAA EE 1
36 Z 023061 STABILIZER ...1..14 04444000 044 434 a 0 a 0 a ea 0e 10e 1 001 A0 40 0200000 1
36 -020 846 HF PANEL (See Fig. dPage 8) ...... coi iii inna 1 1
37 020665 BRACKET, mounting - HF Panel .......oo_eremcresrorceereartececne. 1 1
38 010957 TUBING, steel 1/20D x17 Ga. wallx 1-3/4 .... ceive 2 2
39 Figure N PANEL, front w/components (See Page 12) .-......re.e.rresoracarvoo 1 1
40 020100 CONTROL PANEL, start (See Fig. L Page 10) or
40 018 563 CONTROL PANEL, gas & water (See Fig. LPage 10} ................. 1 1
41 Figure M TIMER & RHEOSTAT (SeePage 10} ........ oii 7. 1 1
Al +025 603 METER, amp de 0-300 scale. ........e_erreresreeocrvertecaaerece. 1
Al +025 608 METER, amp de 0-500 scale ............eo0crenvrreasreorvocarcaret 1
A2 7025 601 METER, amp ac 0-300 scale .....1222400 0000 a eee 1e 000402 1 ea 0e 000 6 1
A2 +025 617 METER, amp ac 0-500 scale .........oe coer_enasroretsversrovveerares 1
CT2 +036 609» TRANSFORMER, current 300/5 ...........ecemmmoeseradarer rice. 1
СТ +036 611 TRANSFORMER, current 500/5 ....... onan 1
Pl +025 701 FILTER, HF Li iia a a ea a 00 a 10500 3 3
Р2 +025 700 FILTER, HF ............. ee a ee ee a a 4 a a ee 4 88 a ea re ua ee 0000800 1 1
V1 +025 604 METER, volt de 0-100 scale .. 224424040082 0 0401001 a 0 ea a 0 0000 1 1
V2 +025 602 METER, voltac(-100scale ....... citer RAR KK EEG 1 1
011 751 SWITCH ASSEMBLY, normally open ..........¢ ccna... 1 1
011754 SWITCH ASSEMBLY, maintained ........... ccna. 1 H
*Recommended Spare Parts,
**Replace At Factory or Authorized Service Station
FOptional Parts
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENTPARTS. OM-340 Pace 2
- age
Quantity
Model
Item Dia. Factory 200 | 300
No. Mkgs. Part No. Description Amp | Amp
Figure B Rectifier, Silicon Diode (See Fig. A Page 2 Item 16) © ©
E o
51 Did4 037305 DIODE, 150 amp 300 volt straight polarity ........................— eee. 4
51 D1-4 037956 DIODE, 275 amp 250 voltstraight polarity ............... iii, 4
52 010014 CLAMP, mounting - capacitor ........oeeeeresorecererrarorroreorca 1 1
03 C9 031 683 CAPACITOR, paper-cil 5uf200voltde ........ iii 1 1
54 C58 031689 4 4
CAPACITOR, ceramic .01l uf wfleads & terminal ........................
Figure B — Rectifier, Silicon
_—
© о
В
e >
© | ©
L— i
TB-037 110
тс-030 609
Figure C — Resistor, Balance
я Quantity
Model
Item Factory 200 | 300
No. Part No. Description Amp | Amp
Figure © Resistor, Balance (See Fig. A Page 2 Item 21) 9 >
61 102552 BUS BAR ot ie et te ea a 14 88 0010 0 1 1
62 102551 BUS BAR oot it te ee eee ea eae aa 1 1
63 026 932 INSULATION ..........0c_—mrerereaoerereaarorerevoredarore diem 1 1
64 **030 612 BAND, mMichrome . Loot ite titties aaa 3 4
65 038671 TERMINAL BOARD ......21100000 4400 4 0 4 4 4 ae a a a aa 0e 48 10000000 2 2
66 026 616 SPOOL, insulating-band ....... Lie 0 7 7
67 014 629 BRACKET, mounting (consistingof) ..........c.... vin, 1 1
68 018 744 .BRACKET, mounting - frame section. ........ cnn. 1 1
69 018764 FRAME ... ii ee iti ies tae a 1 1
**Replace At Factory or Authorized Service Station.
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 3
Item Dia. Factory
No. Mkgs. PartNo. Description Quantity
Figure D 016 608 Control Panel, Master (See Fig. A Page 2 Item 3)
77 019 829 PANEL, mounting - COMPonent......._omecccarareaorrarerearrarerora. 1
78 SR24 *037 568 RECTIFIER, signal (consisting Of)... 202220000000 0 0 00 a 00 aa 24 14 0e 0 ae = 2
79 102 363 .BRACKET, mounting .......eeeonororanonordndanereenameorearocavecnra 2
80 601242 .WaASHER, insulating .....12 448242021010 1 2 40 a Le a a a 0 a 8e 01 001 000 8 2
81 603 115 STRIPPING, weather (order by foot) ......... acaso ranarardarroasonmenoo 4 ft.
82 013867 LABEL, CRI ............ aa aa anne tienen aa ea ee a ea ea as 000 1
83 013868 LABEL,CR2 ............. aeocooarenrenmaroerorearenyeararorecaene a. 1
84 026 844 STRIP, insulating - resistor.......o..oeresonoocxcanoraroaaronroreaoneneneao 1
85 R2 *030 601 RESISTOR, WW adj 25 watt 1000 ohm .......o.erreceaacersvesreorecoe. 1
86 CR1 034 601 RELAY, medium duty 24 volt de DPDT ............ La a 4e 8 80 014 10000000 1
87 CR2 034 612 RELAY, medium duty 110 volt de DPDT ..........e._e.resrevevocaromena 1
88 038 620 LINK, jumper - terminal block .........oer_e.—rerareraczxovroresarecvarevona i 2
89 013 535 LABEL, CR3 ........—.—.esesrermognerarocosoordayorarcavceorearanar e, 1
90 013 534 LABEL, link arrangment .......?oerevmosrcorrerodrcreorronóoocarerme 1
91 014118 COVER, dust - relay: .........ee-em—r—enocmororererecoccronocarane ere. 1
92 CR34 034615 RELAY, medium duty 115 voltac DPDT ........-r—reeroereosorearecarero 2
93 018 536 LABEL, CRA ........c-—odesercorerenomocaceceroereanneravooacareras 1
94 038 867 CONNECTOR, 45 degree 2 side ...........eceresvroraasererereenareoe.. 1
95 601 218 CONNECTOR, 45 degree 1 side ..........._—renoseonacerecarereren em. 1
96 1T,2T 038646 BLOCK, terminal 30 amp 10 pole .......eoeeerereovrorocoorermarmeonee 2
97 013 532 LABEL, teminal marking ......eooor_re-rroomaeracvoserecrecoarorcaraaer. 1
98 R9 030 615 RESISTOR, WW fixed 2 watt 1000 ohm ..........rogerernesvevesacene. 1
99 C4 031610 CAPACITOR, electrolytic 4Q uf 250 voltde ........ iin. 1
100 026 845 STRIP, insulating - capacitor 1
101 013533 LABEL, terminal marking .......ee.ecerervrervrcresresaereoeroerrecóreres 1
д
SZ
LA
>.
TC-016 608
*Recommended Spare Parts
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Figure D — Contro! Panel, Master
OM-340 Page 4
Quantity
Model
Item Dia. Factory 200 | 300
No. Mkgs. PartNo. Description Amp | Amp
Figure E Panel, Rear With Components {See Fig. A Page 2 Нет 22}
111 FM 032603 MOTOR, 230 voltsac {consisting of) ....... cities 1 1
*024 601 .BEARING iit iit ee ere area ae. 2 2
112 016 258 CHAMBER, plentum o.oo 2 a ea ee ea a a 4 a a a ea ee a ea aa a a 12e 6 1 1
113 032604 BLADE, fan 60 Hz i4in. 3 wing ........e.—erxreeseraconarerevarecec. 1 1
113 +032 611 BLADE, fan 50 Hz 14 in. Swing ........ocosaraararoorenaaramearerva. 1 1
114 022 025 PANEL, real ......eeecrersonorenaroneaeroverdaaocarorarteCraarenoea 1 1
Li
LL
TC-022 518
Figure E — Panel, Rear With Components
TC-034 652
Figure F — Contactor
Item Factory
No. Part No. Description Quantity
с) 5
Figure F Contactor (See Fig. A Page 2 Item 26) 5 3
o ©
121 033675 СОНЬ, 115 мо! ас ‚2..2... 27...25 ie ttt tates a a ea a 0 4 aaa anaes 1
121 033410 COIL, 115 voltac ,........ oe r=eneoroorvenrrteriarererereresorerermea. 1
122 *034 662 KIT, contact points ......... _—eeaacorroerrererredreverererrorarvrvreata 1
122 *034 825 KIT, contact points .. iit tiie esis ies sansa nese 1
*Recommended Spare Parts
+Optional Parts
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 5
Quantity
Model
Item Dia. Factory 200 | 300
No. Mkes. PartNo. Description Amp | Amp
Figure G Transformer, Power-Main (See Fig. A Page 2 Item 33) : :
Q =)
142 **036 877 TRANSFORMER SUBASSEMBLY, power-main (consisting of} ......... 1
142 **036 878 TRANSFORMER SUBASSEMBLY, power-main {consisting of) ......... 1
143 602 242 .WASHER, fat - steel 5/16 standard .......er_eo_rrernerorocoresocoo 4 4
144 602195 .WASHER, flat - fibre 3/8 ID x 7/8 OD x 3/32 .....r—...ereecoasereve. 4 4
145 018342 .BAR, clamping- core ,.....c.ecoesorrarccarorecrmerersrararcecr. 2 2
146 032157 .STRIP, glastic 1/16 x 2-33/64 x 6-1/8 ........erercorervrorerverato 2
146 032108 .STRIP, glastic 1/16 x 2-33/64 x 7-3/8 ........rer-rcrecorarecoorna 2
147 026 955 . TUBING, vinyl - No. 2x 6-1/2 .....42440000 01000 000000000000 20005 2
147 026 950 . TUBING, vinyl - No, 2x 7-5/8 1.201000 0 0001 0e 00000 00 0011000000 2
148 103 923 .BRACKET, mounting-terminal assembly primary +... к ноннн ео 2 2
149 601 800 .BOLT, machine - steel hex head 1/4-20 X 7 ......_r_eeerooraorenorecos 2
149 601 802 .BOLT, machine - steel hex head 1/4-20x 8 ......._c-evecrosorcormero 2
150 602819 .STRIP, phenolic 1/4 x 3/8 x 10-1/2 .......e.rererorearacerermrea»ro 2 2
021499 .STRIP, phenolic 1/4 x 3/8 x 5-1/4 .......re-erevresovreorormarcerve 2
151 010371 . WEDGE, hardwood 1/4x 1X 2 4.224200 0 00 8000000 0001000800 0 8 8
152 021099 WEDGE, glastic 1/8 x 5/8 х 2......e.cemmeancoreccorodorerarecer> 4 4
153 Pr **033 629 COIL, primary - right hand .......eeecsorerroresrreecrvororarmerere 1
153 Sec **033497 COIL, secondary - right hand .......oeescererevecsoreereasere ved. i
154 Sec **033 529 COLL, secondary ......_eereerrecorecerareonsernroararenrecarrarE. 1
154 Pri **033 630 COIL, primary - right hand ......_.erooocrravcrrrerroteororeracerI 1
155 Sec **033 529 COIL, secondary ......ooorescarmecoreroarcoreat vere neraceoenedeo 1
155 Pri **033 631 COIL, primary -left hand .......o_recerdoroarerverecsrerecarece.. 1
156 Pn **033 628 COIL, primary -lefthand .......... iii ein 1
156 Sec **033 496 COIL, secondary -lefthand .......... crea. 1
TP! 026 181 THERMOSTAT normallyopen ......0.202000 00000400 00 eau 00080000 1 1
>
x
X
J
=i
0
)
|
va
y
J
f
rs
a
;
y
x
/
\
стен
AZ i > Se EX)
AT > Ad 56
SD BEZ)
Be = 77 il ii Nes” >
NES ZZ ; i] N № E
DS | | | = Z
~ << | | i SI |
~~ | A >
Figure G — Transformer, power-main
**Replace At Factory or Authorized Service Station. |
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
TB-022 519
OM-340 Page 6
Quantity
Model
Item Dia, Factory 200 | 300
No. Mkgs. Part No. Description Amp | Amp
Figure H Amplifier, Magnetic {See Fig. A Page 2 Нет 34) с м
o oc
171 **036 459 AMPLIFIER SUBASSEMBLY, magnetic (consisting of) ............... 1
171 **()36 882 AMPLIFIER SUBASSEMBLY, magnetic (consisting Of) ............... 1
172 026966 .WEDGE, hardwood1/4x 1x6 ..........—eesrerverveorrevecrcr ere 2 2
173 026 931 .STRIP, fibre .020 x 4-1/2x T-1/2..........ememvererareo. een 2
173 026934 . STRIP, fibre .025 x 4-1/2 x 7-1/2 111420412080 40 43 031 31 0 ee eee 06 2
174 026 967 í. WEDGE, hardwood 5/16 x 1x6 ..........ereoseerevra recam. 2 2
175 032082 .STRIP, glastic 1/16 x 2-1/2x5 ,............ererrervrovesarecerees 4 4
176 010371 .WEDGE, hardwood 1/4x 1x2 .......eereonvererereocarmovarecra 4 4
177 021 807 .WEDGE, hardwood 5/16 Xx 1X2 .......e.r_eemesreesoorocoreoreee. 4 4
178 010 372 .STRIP, glastic 1/8x 1x 6.........200 010000003000 1 010 00000000 4 4
179 CWD **033645 COIL, control de ..........eee.reveorereraretrerec rare enrer.. 4
179 CWD **033 640 COLL, control de ..........eoemrearvacneroorecearoerveracrmercao. 4
180 CWA **033 530 COIL, control ac - right hand ......._reewerereorereoreamorecarereeo 1
180 CWA **033498 COLIL, control ac- right hand ,........eeereagesrverereo0cterenre 1
181 CWA **033 531 COIL,controlac-lefthand ............ iii. 1
181 CWA **033 499 COIL, confrolac-lefthand ............ rine 0 sa 15000 1
includes
Нет 178
TC-022 522
Figure H — Amplifier, Magnetic
**Replace At Factory or Authorized Service Station
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 7
Item Dia. Factory
No, _Mkgs. Part No. Description Quantity
Figure J 020846 HF Panel (See Fig. A Page 2 Item 36)
206 R3 030602 RESISTOR, WW fixed 100 watt 10 ohm ........ _eerecxermerocaresmerros 1
207 010 884 STRIP, conductor, ......e_.._e_-—eererererecorcerereravrevrrecarerrecrios 1
208 C2 031602 CAPACITOR, mica .002 uf 6000 volt .........e_eeeeweorscerecoracereres 2
209 016 601 !MOUNTING BOARD, component ......re.e.rriec0oresetrcosoonvyeaaneneca. 1
210 R4 036 865 TRANSFORMER, high voltage 115 volt primary .....e.eeoreresrnacvorre> 1
211 T3 033601 COIL, coupling ........eeeeerardracoarereorotroorracereraerecrame 1
212 601 838 NUT, hex-jam3/8-16brass .................... Meter es ean ma rare ea 4
213 601835 NUT, hex - reg 10-32 brass ..........eecsoracoo PP ENEE 7
214 038 887 STUD, brass 10-32 x 1-3/8 with hex collar .........—e.eeoreaernerosrere.. 2
215 603 737 SCREW, machine round hd 3/8-16 x 1-3/4 brass ....... Era ere aa 14014 110000 2
216 G 020 623 SPARK GAP ASSEMBLY (See Fig. Jl Page 9)........crrreccscrorrevóca, 1
217 010 885 STRIP, conductor ...........eeoonoseeaoccoarnararanaeareróconavo.. | 1
218 Er кн нк н нау бея вол во нон ж нк кке ное о 1
219 R1 030 603 RESISTOR, WW fixed 10 watt 10K ohm ......er—e-—e-—e-—revrsoraresmoreroo i
220 C3 *031 601 CAPACITOR, paper-oi 10 uf 600 voit ..........2.040000 00021400 000000 0 1
221 014 159 BRACKET, mounting - capacitor 1
TC-020 612
Figure J — HF Panel
*Recommended Spare Parts.
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-340 Page 8
Item Dia. Factory
No. Mkgs. Part No. Description Quantity
Figure J1 020 623 Spark Gap Assembly (See Fig. J Page 8 item 216)
226 602 023 £SCREW, cap - socket head 10-24 x 3/4 ..... ......e-—c20esaarrracerre rente. 4
227 ; 604 772 WASHER, flat No. 8 SA 2ER RR RR eae 4
228 010888 CONNECTOR, hoider 112401200014 44 14 11 4 6 a 8 4 20 14 a 8 0 40 au au a 11 ea a» 1
229 020622 HOLDER, points ......122244 04444424 4 408 a 4 4 ea ae er 4 ee a a aa a 1 0 20 0 4
230 G *020 603 POINT, spark gap (setof 4) © out iii ies ieee eee cana 1 set
231 010913 WASHER, flat - brass 3/161D .......e...eeoronexeooreavearooranre a oa 8
232 020621 BASE ...,.....e.eeoceciarerecorecarecoennacoaraceraroe, ee 1
233 602 204 WASHER, lock external tooth No. 10 .........oeeoocoQ.«—esvearcoerane neon. 8
234 602101 SCREW, machine round head 10-24 x 5/8 ...........ee.eseda.oermede aten. 8
TA-0Z0 6 23
Figure J1 — Spark Gap Assembly
TB-038 442
Figure K — Terminal Assembly, Primary
Item Dia. Factory
No. Mkgs. Part No. Description Quantity
Figure K 038442 Terminal Assembly, Primary (See Fig. A Page 2 Item 29)
241 601 835 NUT, hex - brass 10-32 .........e..eoeenerzo9reorereoreroreare or rare. 8
242 026 754 INSULATION, stud - barrier ........eoerrednvoeranedareroreréd ec serereuana 6
243 038618 LINK, jumper - terminal ,.........emreonracveresenrercdere re rerorerveraxa 2
244 038 662 TERMINAL BOARD. mounting - component ......._—..ee_rerverecovreereeces 1
245 010913 WASHER, flat - brass 3/16 ID .......e.eredereresvosroreoreervarernecn. 6
246 038 620 LINK, jumper - terminal block .........e_reeeraoesirererortorreerrtace, 1
247 TE2 038622 BLOCK, terminal 30 amp 5 pole 22.244200 0 0446446 64 00 es ea a ee 410000 0 l
248 038 887 STUD, brass - 10-32 x 1-3/8 with hex collar ..... PS 6
249 601836 NUT, hex - brass 1/4-20 112242100424 ea 0 4 a 4 0 0 a 8 Le 0 a a 4 a a ea sa ca 508000 0 4
250 038 888 STUD, brass - 1/4-20 x 1-1/2 with hex collar .......200200 000000550000 0000 0 2
*Recommended Spare Parts
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 9
Quantity
Model
Item Dia. Factory P A/B Panel
No. Mkgs, Part No. Description Panel | Spot Timer
Figure L Control Panel, Gas & Water (See Fig. A Page 2 Item 40) 020 100 018 563
256 010 295 ELBOW, street - brass 1/4 MPT 5/8-18 left hand thread .......... 2
257 GS1,WS1 035601 VALVE, 115 volt ac 1/4 IPS port (consistingof) ............... 2
033050 .COIL,1i5voltac...... _rrw—eae2oemmeoutdosa ro rarereremaneoo 1
258 010 286 ELBOW, street - brass 1/4 MPT 5/8-18 right hand thread ...... ... 2
259 87 011620 SWITCH, toggle SPST ........eom.erm0nmveoravroeeresvoecameao. 1 1
260 022 159 LABEL, start circuit-In-Qut .......... LIL a a 4 40 sa a ea aa aa 140 0 1 1
261 013983 LABEL, In-Gas-Out 1.222144 44 4000 0 4e aa 0e 14 0 eu aa a 0 00 00 0 i
262 TDI *(334 701 TIMER, 60 second 115 volt ac or |
262 TD1 +034 836 :TIMER, 60 second 115 voltac............440 1000000 su 00000 1
263 013982 LABEL In-Water-Qut ......o_oererrorearocorervarvarcecera 1
264 014 627 PANEL, mounting-components .......... ccc. 1 1
265 — 010853 SCREW, NO. 2 .......eomeseaxrrartarrasaro recareasvercnro 4 4
266 ° 010 855 WASHER, retainer ,,....eecoecwoesoaranararrrovssccorremat> 4 4
TB-018 563
Figure L — Control Panel, Gas And Water
TB-001 873
Figure M — Timer and Rheostat
Quantity
Model
Item Dia. Factory P| A/B | Spot
No. Mkgs. PartNo. Description Panel | Panel | Timer
Figure M Timer & Rheostat (See Fig. A Page 3 Item 41)
271 TD2 034712 TIMER, gsecondII15voltac .......e.ec_e.errecorererrereceros 1
272 024 366 KNOB, pointer 1-1/8 OD x 1/4 bore ..........ee.-enerrecrvermen> 1 1 1
273 013518 PLATE, indicator HF intensity ..........eceenanoerc0serecmamev. 1 1 1
274 R55 603 942 RHEOSTAT, WW 150 watt 5 ohm .......... crv, 1 1 1
275 042 211 STRIP, mounting- component ......... e rerreervorerevecrone 1 1
275 042212 STRIP, mounting - component ..........eereorereorererereonm 1
276 013331 LABEL, high frequency ......e.em_eerosesororareceorerorevrar: 1 1 1
277 S5 011611 SWITCH, toggle DPDT ...........eeoeorecorocrormererreore ete. 1
*Recommended Spare Parts
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-340 Page 10
TD-022 517
3
nd
y
Figure N — Panel, Front With Components
Page 11
Quantity
_— Model _
Item Dia. Factory 200 | 300
No. Mkgs. PartNo. | To Description Amp | Amp
Figure N Panel, Front With Components (See Fig. A Page 2 item 39)
281 015110 DOOR, access - fronfb .....—_eemmoenracarerooarr recon varvesrrrrmaa 1 1
282 019602 KNOB, pointer 2-3/8 OD x 3/8 bore .........oeerrecoreraerecirere. 1 1
283 NAMEPLATE (order by stock, model, and serial number) .......... e. 1 1
284 019609 KNOB, pointer 1-5/80D x 1/4 bore .....e....er_emerecarveryenerena 1 1
285 Fl *012 601 FUSE, plug 10 amp 250 volt ......0420000 0050000000 0e 0510000000 0 1 1
013206 LABEL, fuse 10 amp ......oremxoroaanmmonarsvcororonarrcoratceco. 1 1
286 012602 HOLDER, fuse - plug 250 volt .......... caoraserenrrnoresardenarm e 1 1
287 RCI 039607 RECEPTACLE, twistlock 3P3W .................. RAR 1 1
288 582 011609 SWITCH, toggle SPDT .......... e nandonrosoreccororerrocoornacena 1 1
289 030 655 SHAFT, rheostat .......r—ee-_eceesraorcoreoreeeórecer vor rAve. 1 1
290 031 897 CONTROL CORE RESET (consisting of) .......04402420000 00000000 0 - 1
D5 037906 .DIODE, 12 amp 400 volt ,........oeococcecoaoyrortreesereammvereo 1
R13 030 947 .RESISTOR, WWfixed40wattbohm .......... ccna. 1
031 889 . MOUNTING BOARD, component ......o_o_e_._er_eeroescerresvoconmo 1
031890 .HEATSINK ......orocosaxramavorareooreavarecoreresreraecarar. 1
291 010876 HANGER, minerallicNo. 1 ......._orroevroovoooorrnenerevrárerreare. 1
291 010926 HANGER, minerallic No. 2 ........ecoscornganrocoserenvareammarne.o 1
292 010926 HANGER, minerallic No. 2 .....o_erenonorsvsotecorcarmanréveoeco 1 1
293 89,10 011 726 SWITCH ASSEMBLY, range & selector (See Fig, N1 Page 13) ........... 1 1
294 011660 2BRACKET, support - switch ........e_eereanmeorarrorermerrcarona. 1 1
295 RT 030041 RHEOSTAT, WW 150 watt 15 ohm ........_—.e_rereosresrecosrecrmas 1 1
296 602 355 PIN, cotter 3/32 x 2 .......0410 02000000» RAA AA AAA AA AAA AS 1 1
297 SR5 037615 RECTIFIER, selenium - control .......o_enmmerseorrorererrerodrora 1 1
298 SR3 *037 601 RECTIFIER, selenium - control ..........ererorereeeeoregermecróna 1 1
299 S4 011611 SWITCH, toggle DPDT ,..........eoseonoraorravrearocrecaremaroo.. 1 1
300 RC2 039 602 RECEPTACLE, twistlock 2P2W ......... anccnarcacerrereeracr ena 1 1
301 RB 030653 RHEOSTAT, WW 150 watt 15 ohm ......ooomeonreesvrerresermermacoo 1 1
302 CB 011914 CIRCUIT BREAKER, 1 pole 5 amp 250 volt .......o.eroeosrrversroeeno 1 1
308 si #011813 SWITCH, topele 3PST ........nceeconnmodmoamrevercarvacanrnaacanar. 1 1
304 $3 011 610 SWITCH, toggle SPDT with centeroff ............ ccc iii. 1 1
305 F4 *012 601 FUSE, plug - 10 amp 250 volt ......oeoceereroosrcesrrnovesereerenmas 1 1
305 F4 +*012 606 FUSE, plug- 15 amp 250 volt (with duplex receptacle) ................ 1 1
306 012602 HOLDER, fuse- plug 250 voit ..... i.e, 1 1
RC3 +604 176 RECEPTACLE, duplex grounded straight 2P3W ..................... 1 1
307 038630 TERMINAL, power output (See Fig, N3Page 16) ............ conte. 1 1
308 020 299 PANEL, front,......o._reonoroanares»ararocarrareoreranraanerono 1 1
309 S6 011 787 SWITCH, changeover - Tig Metallic (See Fig. N2Page 16) ............... 1 1
310 019603 KNOB, ball 1-1/4 OD x 1/4-20 female thread ......r_e-—ecesooreoreras 1 1
*Recommended Spare Parts
+Optional Parts
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS,
OM-340 Page 12
Item Dia, Factory
No. Mkgs, Part No, Description Quantity
Figure N1 011726 Switch Assembly, Range 8: Selector (See Fig. N Page 12 Мет 293}
316 011 654 BRACKET, mounting - switch (consisting of) ...........ece.e.rrereoerec.. 1
317 010671 .SPRING .......e.ecoraeoronoeravveraareeoorerierr ore raceraonver ear. 2
318 019605 HANDLE, switch - selector ........e._eoneamereroarorevsd0envvrraretercóaao 1
819 019604 HANDLE, switch - range .....er_eeecscrereredererenrvarecercoarervecrea, 1
320 759 011635 PLATE ASSEMBLY, switch - range (See Fig. N1APage 14) .................. 1
321 011 657 SPACER, 1x 2x 2 withhole ,......10000 00000000 au eee a sa 10 iia eae 1
322 011 826 TUBING, steel 5/8 OD x 12 Ga. wall x 2 ..........—r-vecerorenvcari earn. 1
323 011659 SHAFT, control - switch ........._eerer-oreoonvarerrrana re recerereone. 1
324 S10 011604 PLATE ASSEMBLY, swtich - selector (See Fig, N1BPage 156) ................. 1
325 011643 BRACKET, mounting - switch .....eo..e.xeeerecarvonerecrervore rr tear e 1
326 011 826 TUBING, steel 5/80Dx12Ga. wallx 2 (Li iia ices 1
327 011671 SPACER, 1x1Xx2.......eremervecarorcronacrararerenarvorerrenrane 1
Figure NT — Switch Assembly, Range and Selector
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 13
TD-011 726
Item Factory
No. Part No. Description Quantity
Figure NTA 011635 Plate Assembly, Switch - Range (See Fig. N1 Page 13 Item 320)
331 010080 SPACER, copper ..........eceoreorconmernmoaeareovrecareenaommaracreere 2
332 011079 SPRING, pressure - center front ........eee.orrercaosoroconmoecrrocanerev oo 1
333 011371 CONTACT, segment........_eoemecorcormoaomenmivorteoreeanmerarenocane» 2
334 011968 MOUNTING BOARD, component - stationary .......ee_ceeeceornenconevecae.. 1
335 100622 SHIM, guide - rotor ,.,........e_eeereesreacararararacoreorenananernetrecZ»o. As Req.
336 100623 СОТОЕ, хобот... . к... 5..5... кво акне, anarconeudcoro nera arado. 3
337 011078 SPRING, pressure - center real .........oeecadadoconosroerowronareroreo 1
338 011 049 SPRING, pressure - rear ........ _renerverorararrrer rar nonareroarcovnanra 2
339 100 747 ROTOR, switch ....... _e.eorosrvascrecrvaorenvanenerceeareecawronmarvo, 1
340 011644 CONTACT, copper - stationary ......_.._eeeeeceorecocoo eonarac ia acecaroeo, 11
341 011645 CONTACT ASSEMBLY, copper - movable (consistingof) .................... 3
342 011075 SPRING, pressure - tear .....rer-—ereacocangoresorcerenverererecce nena _ 1
343 011074 _SPRING, pressure - front ......o.-ecroonerarvovareresereosromanmedreacao 1
344 011953 .CONTACT, copper-movable ........20400 0000000000 ea 00000000 0000000 2
345 011048 SPRING, pressure - front .......o_eooorecaroneoracrrvresrrorcereoarereave. 2
TC-011 635
Fiqure NTA — Plate Assembly, Switch Range
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-340 Page 14
Item Factory
No. Part No. Description Quantity
Figure NIB 011 604 Plate Assembly, Switch - Selector (See Fig. N1 Page 13 Item 324)
351 100621 BAR, shorting.........ec_.eresrororqaareorerenoóraeroreerererdenne cren. 6
352 011 968 MOUNTING BOARD, component-stationary . .........c. cove. 1
353 011969 ROTOR, switch .........edrescereyarervovderaraveonoreracmorvoravroca, 1
354 100623 CUIDE, rotor ........e .-eeoearaesnaorecaoooranmervrestnareaaaroonartoaea, 3
355 100622 SHIM, guide - rotor ........qec_eerrerrororarervonmarerreren. hee As Reg.
356 011 644 CONTACT, copper - stationary ....eqoo reecxeccoroorarorracvorecacer vor, 13
357 011645 CONTACT ASSEMBLY, copper - movable ........__—.ese-e-ressaceeoerveaeeo. 5
358 011075 .SPRING, pressure - real ........eceeererocaraarroneore0rarerecanmorr. 1
359 . 011953 ‚CONTACT, Copper ......e.emresvrredosroenrvorerevo ieee aaa 2
360 011074 SPRING, pressure - front .....ee—esacorarrorooerererecrrrrreóvenrarano 1
358
К
3
TC-011 604
Figure N1B — Plate Assembly, Switch Selector
BE SURE TO PROVIDE STOCK, MODEL, AND SEETAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 15
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