Miller MILLERMATIC 200/MIGMATIC 200 User manual

December 1982 FORM: OM-1303F — Effective With Serial No. JC849243 - MODEL MILLERMATIC 200 MILLER ELECTRIC MFG. CO. 718 S. BOUNDS ST, Р.О. Вох 1079 APPLETON, Wi 54912 USA NWSA CODE NO, 4579 PRINTED IN U.S.A. 3 a : EFFECTIVE: JUNE 1, 1979 lo + This warranty supersedes all previous MILLER warranties ant 1s ex- a? clusive with no other guarantees or warranties expressed or implied, С У LIMITED WARRANTY - Subject to the terms and conditions As a matter of general policy only, Miller may honor claims м hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants submitted by the original user within the foregoing periods. a to its Distributor/ Dealer that all new and unused Equipment e А furnished by Miller is free from defect in workmanship and In the case of Miller's breach of warranty or any other duty 5 y material as of the time and piace of delivery by Miller. No war- with respect to the quality of any goods, the exclusive remedies a ranty is made by Miller with respect to engines, trade ac- therefore shall be, at Miller's option (1) repair or (2) replacament . cessories or other items manufactured by others. Such or, where authorized in writing by Miller in appropriate cases, (3) A engines, trade accessories and other items are sold subject to the reasonable cost of repair or replacement at an authorized 6 y the warranties of their respective manufacturers, If any . Ali Miller service station or (4) payment of or credit for the purchase у + engines are warranted by their manufacturer for one year from price {less reasonable depreciation based upon actual use) upan ‚ date of original purchase. return of the goods at Customer's risk and expense. Upon receipt й | of notice of apparent defect or failure, Miller shail instruct the clai- fe L Except as specified below, Miiler's warranty does not apply mant on the warranty claim procedures to be followed. i a to components having normal usetfui lite of less than one (1) 5 A ment to the original user: ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX- | ff 4 CLUDED AND DISCLAIMED BY MILLER. x A 1. Arc welders, power sources and components .. | year А 2. Original main power rectifiers ................ 3 years EXCEPT AS EXPRESSLY PROVIDED BY MILLER iN uv N (labor - 1 year only) WRITING, MILLER PRODUCTS ARE INTENDED FOR & 3 3. Allwelding guns and feeder/guns. ........... 90 days ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL i A 4. Allother Millermatic Feeders.................. Iyear — USERS AND FOR OPERATION 8Y PERSONS TRAINED AND — N? | 5. Replacement or repair parts, exclusive of labor . 60 days EXPERIENCED IN THE USE AND MAINTENANCE OF ; Ч 6. Batteries. ...... a 6 months WELDING EQUIPMENT AND ЛОТ FOR CONSUMERS OR 5 4 year, such as spot welder tips, relay and contactor points, MILLERMATIC parts that come in contact with the welding wire including nozzles and nozzle insulators where failure does not result from defect in workmanship or material. Miller shall be required to honor warranty claims on warranted Equipment in the event of failure resuiting from a defect within the following periods from the date of delivery of Equip- provided that Miller is noufied in wnting within thirty (30) days of the date of such fadure. 5 LIMITED WARRANTY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA- TION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION, MIGHT ARISE 8Y IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO CONSUMER USE. MILLER’ WARRANTIES OO NOT EXTEND TO, AND NO RESELLER 1S AUTHORIZED TO EXTEND MILLERS WARRANTIES TO, ANY CONSUMER. «я y x + VS EST Ty, A A NA e A Е E Aa Se 0 The nameplate of this unit uses international symbols for labeling the front panel controls. The following definitions should help the operator become familiar with the symbols and their meanings. The symbois also appear at the appropriate section in the text. SYMBOL . DEFINITION SYMBOL DEFINITION | SYMBOL DEFINITION €) INPUT | ON V VOLTAGE (> OUTPUT O OFF — y POWER OO) WiRESPEED | - + POSITIVE SPOOLMATIC GUN ® / DO NOT SWITCH | TRIGGER I WHILE WELDING NEGATIVE ERRATA SHEET February 23, 1983 FORM: OM-1303F After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to data appearing later in this manual. | — Effective With Serial No. JD663203 Page Dia. Part Replaced | No. Mkgs. No, With Description - Quantity 2 <TP1 084680 088592 THERMOSTAT, N.O. ...........eerearvereves PE SA 1 BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. WESEN TABLE OF CONTENTS — —————————— Section No. — | | ‘ . Page No, SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1-1. Introduction PS 1 1-2. General Precautions ......... PI ee eae 1 1-3. Arc Welding.............esccr.e.cereneoó. nera. sean» + 7 0 1 - 4. Standards Booklet index ............. e. ee. 000000. ce 1 SECTION 2 - INTRODUCTION 2-1. General Information And Safety ..............e..0.200c0000000. 12 2-2. Receiving-Handling ............o eee. 0 vda d0ea a a adore aer 12 2-3. Description ............. re eee eae 12 2-4. OQutputCurves................ ea decana, rodar eo 12 2-5. Supplied Equipment...... J e. 13 2-6. Additional Required Equipment arnero rare av eoraververeroo a da 13 2-7. Optional Equipment ...................0.00000000 AA 2. 14 2-8. ConsumableParts........................ PEE ... 14 SECTION 3 - INSTALLATION. 3 - 1. Installation Of The Welding Power Source On Running Gear ..... .. 15 3-2. Installation Of Optional SKP-35 Panel ............... e... 15 3-3. Electrical input Connections ........ ee 16 3 - 4. installation Of Shielding Gas ..... eee rea 17 3-5. Work Cable Assembly E installation ..................000e. A 17 3-6. Drive Roll And Wire Guide Instaliation .....0000 0 vein... 18 3-7. GA-20C Or Optional GA-40C Welding Gun Connections RAS 18 3-8. Installation Of Welding Wire Spool.............. avalan ea 19 3-10. Installation Of Optional Spooimatic1 Gun....................... 19 SECTION 4 - OPERATOR CONTROLS 4 1, Power Switch .......... ao PAS 20 4 - 2. Voitage Control... 01050414 44 4 ae da 4 da aa ed A dd de aa ann 20 4-3. Wire Speed Adjustment Control ................ enn, 21 4-4, Polarity Selector Plug... . oi .e.rarcec, .. 21 4-5. FanControl .............. ii nea aóon acarreo. 21 4 - 6. Optional Spot Panel Controls ........... ee enana ar a 21 4-7. Overload Protection ..................0000 0. eniacerrade, 21 SECTION 5 - SEQUENCE OF OPERATION 5-1. Welding Wire Threading ................. 0/00. e... ... 22 5-2. Gas Metal Arc Continuous Welding ................_..oerexcere. 22 5-3. GasMetal Arc SpotWelding...................... eee 23 5-4. (as Metal Arc Pulsed Continuous Welding. ..................... 24 5-5. Shutdown ..000000004004 00ER a ae AAA a a a a a Aa a ea aa 24 SECTION 6 - MAINTENANCE & TROUBLESHOOTING 6-1. FanMotor 1101214 a ae da ea ee da Ada aa aa aa nana 24 6 - 2. Internal Cleaning ...............2..00 00 aa a ana aa a aaa 24 6 - 3. Drive Housing Realignment. ................ Ce eee 25 6-4. Troubleshooting The Wire Feeder System ...................... 25 6-5 Troubleshooting The Gas Metal-Arc Welding Process. ............ 29 SECTION 1- SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE ~ SECTION 1 - RÈGLES DE SÉCURITÉ POUR LE FONCTIONNEMENT DU POSTE DE SOUDAGE À L'ARC 1-1, INTRODUCTION - We learn by experience. Learning safety through personal experience, like a child touching a hot stove is harmfui, wasteful, and un- wise. Let the experience of others teach you. Safe practices developed from experience in the use of welding and cutting are described in this manual. Research, development, and field experience have evolved reliable equipment and safe installation, operation, and servicing practices. Accidents occur when equipment is improperly used or maintained. The reason for the safe practices may not always be given. Some are based on common sense, others may require technical volumes to explain. It is wiser to follow the rules, Read and understand these safe practices before at- tempting to install, operate, or service the equipment. Comply with these procedures as applicable to the particular equipment used and their instruction manuals, for personal safety and for the safety of others. Failure to observe these safe practices may cause serious injury or death. When safety becomes a habit, the equipment can be used with confidence. These safe practices are divided into two Sections: 1 - General Precautions, common to arc welding and cutting; and 2 - Arc Welding (and Cutting) {only}. Reference standards: Published Standards on safety are also available for additional and more complete procedures than those given in this manual. They are listed in the Standards Index in this manual. ANS! 249.1 is the most completa. The National Electrical Code, Occupational Safety and Health Administration, local industrial codes, and local inspection requirements also provide a basis for equip- . ment installation, use, and service. 1-2. GENERAL PRECAUTIONS A. Burn Prevention Wear protective clothing - gauntlet gloves designed for use in welding, hat, and high safety-toe shoes. Button shirt collar and pocket flaps, and wear cuffiess trousers to avoid entry of sparks and slag. Wear helmet with safety goggles or glasses with side shields underneath, appropriate filter lenses or plates (protected by clear cover glass). This is a MUST for welding or cutting, {and chipping) to protect the eyes from radiant energy and flying metal. Replace cover glass when broken, pitted, or spattered. See 1-3A.2. Avoid oily or greasy clothing. A spark may ignite them, Hot metal such as electrode stubs and workpieces should never be nandled without gloves. -1, INTRODUCTION - Contrairement à l’apprentissage de la vie, l'apprentissage de la sécurité par ex- périence personnelle, comme l’enfant qui touche un poêle chaud, est dangereux, imprudent et inutile. Instruisez-vous donc de l'expérience d'autrui. Des méthodes de sécurité issues de l'expérience du soudage et du coupage sont décrites dans le manuel. La recherche, le progrès et l'expérience dans ce domaine ont développé un matériel fiable et des méthodes de sécurité pour l'installation, le fonctionnement et l'entretien. Des accidents se produisent lorsque le matériel est inadéquatement utilisé ou entretenu. La raison de ces méthodes de sécurité peut ne pas être toujours donnée. Certaines sont fondées sur le sens commun, d'autres demanderont à être expliquées par des livres techniques. Il est plus sage de suivre les règles. Lisez et comprenez ces méthodes de sécurité avant d'essayer d'installer, de faire fonctionner ou de réparer l'appareil. Pour votre sécurité personnelle et celle d'autrui, conformez-vous à ces règies et aux manuels d'instructions. | Manquer d'observer ces méthodes de sécurité pourrait entrainer des blessures graves ou mème la mort. Quand la sécurité devient une habitude, le matériel peut alors être utilisé en toute confiance. Ces méthodes de sécurité sont divisées en deux sections: 1 - Précautions générales, communes au - Soudage et au coupage à l'arc, et 2 - Soudage à l'arc {et coupage} (uniquement). Normes de référence: Des publications des normes américaines de sécurité sont aussi à votre disposition pour d'autres modes opératoires plus compiets que ceux du présent manuel. Elles sont données dans I'In- dex des Normes de ces règles de sécurité. ANSI Z49-1 est la plus complète. Les codes de l'ACNOR, les codes provinciaux et municipaux donnent aussi les exigences pour une installation, une utilisation et un entretien sûrs. 1-2. PRÉCAUTIONS GÉNÉRALES Â. Prévention des brûlures Portez des vêtements de protection - des gants à crispin spécialement désignés pour le soudage, un casque et des chaussures de sécurité. Boutonnez le col de votre chemise et les pattes de vos poches, et portez des pan- talons sans revers pour éviter que des étincelles et du laitier ne s'y introduisent. Portez un masque avec lunettes de sécurité ou avec écrans laté-raux de protection, des lunettes filtrantes ou des couvre-lentilles (potégés par un verre clair}. Pour le soudage ou ie coupage (et le burinage), il est. OBLIGATOIRE de protéger ses yeux contre l'énergie de rayonnement et les éclats de métal. Remplacez le verre protecteur lorsqu'il est brisé, piqué ou qu'il a reçu des projections. Voir 1.3A.2. Evitez de porter des habits imprégnés d'huile ou de graisse. Une étincelle pourrait les enflammer. Ne manipulez jamais sans gants un métal chaud tel que des chutes d'électrode et des pièces à souder. ОМ-1303 Раде 1 Medical first aid and eye treatment. First aid facilities _ and a qualified first aid person should be avaitable for each shift unless medical facilities are close by for im- - mediate treatment of flash burns of the eyes and skin ‘burns. Ear plugs should be worn when working on overhead or in a confined space. A hard hat should be worn when others work overhead. Flammable hair preparations should not be used by persons intending to weld or cut. B. Toxic Fume Prevention Adequate ventilation. Severe discomfort, illness or death can result from fumes, vapors, heat, or oxygen enrichment or depletion that welding (or cutting) may produce. Prevent them with adequate ventilation as described in ANSI Standard 249.1 listed 1 in Standards index. NEVER ventilate with oxygen. Lead -, cadmium -, zinc -, mercury -, and beryllium - bearing and similar materials, when weided (or cut) may produce harmful concentrations of toxic fumes. Ade- quate local exhaust ventilation must be used, or each person in the area as well as the operator must wear an air-supplied respirator. For beryllium, both must be us- ' ed. Metals coated with or containing materials that emit toxic fumes shouid not be heated unless coating is removed from the work surface, the area is well ven- tilated, or the operator wears an air-supplied respirator. Work in a confined space only while it is being ven- tilated and, if necessary, while wearing an air-supplied respirator. Gas leaks in a confined space should be avoided. Leaked gas in large quantities can change oxygen concentration dangerously. Do not bring gas cylinders into a confined space. Leaving confined space, shut OFF gas supply at source to prevent possible accumulation of gases in the space if downstream valves have been accidently opened or left open. Check to be sure that the space is safe before re-entering it. Vapors from chlorinated solvents can be decomposed by the heat of the arc (or flame) to form PHOSGENE, a highly toxic gas, and other lung and eye irritating products. The ultraviolet {radiant} energy of the arc can also decompose trichloroethylene and per- chloroethylene vapors to form phosgene. DO NOT WELD or cut where solvent vapors can be drawn into the welding or cutting atmosphere or where the radiant energy can penstrate to atmospheres containing even minute amounts of trichloroethylene or per- chloroethylene. C. Fire and Explosion Prevention Causes of fire and explosion are: combustibles reached by the arc, flame, flying sparks, hot slag or heated Page 2 Premiers soins et traitement des yeux: Tout atelier devrait avoir à sa disposition un poste de premiers soins ainsi qu’une personne compétente, à moins qu'ur, service médical ne soit à proximité pour soigner immédiate- ment les brûlures des yeux et de la peau. Portez des bouche-oreilles lorsque vous travaillez au plafond ou dans un espace restreint. Portez un casque lorsque d’autres personnes travaillent au plafond. Les personnes devant souder ou couper ne doivent pas employer des préparations inflammables pour leurs cheveux. 8. Prévention des gax toxiques Ventilation adéquate: Les gaz, les vapeurs, la chaieur, un enrichissement ou un manque d'oxygène peuvent entraîner un malaise, une maladie ou même la mort. Remédiez-y par la ventilation décrite dans ta Norme AN- Si Z49.1 paragraphe î de l'index des Normes. NE ven- tilez JAMAIS à l'oxygène. En soudant ou en coupant, les plomb, cadmium, zinc, mercure et béryilium ou autres matériaux semblables peuvent créer des concentrations nocives de gaz toxiques. On doit avoir recours à une ventilation aspirante adequate du local, ou alors toute personne sur les Неих, de même que le soudeur, doit porter un masque à adduction d'air. On doit employer les deux pour le béryllium, Les métaux enrobés ou composés de matériaux émet- tant des gaz toxiques ne doivent pas être chauffés à moins que l'enrobage ne soit ôté de la surface à travailler, que le local ne soit bien ventilé, ou que le soudeur ne porte un masque a adduction d'air. Ne travaillez dans un espace restreint que s’il est bien ventilé et, si nécessaire, portez un masque à adduction d'air. On doit éviter les fuites de gaz dans un espace restreint. Les fuites de gaz en grande quantité peuvent transformer dangereusement la concentration d'ox- vgene. N'amenez pas de bouteilles de gaz dans un espace restreint. | En quittant un espace restreint, FERMEZ le robinet d'alimentation de gaz de la boutéille. Ainsi on pourra rentrer en toute sécurité dans la piece, mäme sí les robinets “aval” ont été ouverts par accident, ou si on les a laissés ouverts. Les vapeurs de dissoivants chlorés peuvent être décom- posées par la chaleur de l'arc (ou de la flamme) et former du PHOSGENE, gaz très toxique, et d'autres produits irritant les poumons et les yeux, L'énergie ultra-violette de l'arc peut aussi décomposer les vapeurs de trichioroéthyiéne et de perchloroéthylène pour former du phosgéne. NE SOUDEZ PAS ou ne coupez pas dans des endroits où les vapeurs de dissoivants peuvent être attirées dans l'atmosphère de soudage ou de coupage et où l'énergie de rayonnement peut pénétrer dans des atmosphères contenant des quantités même minuscules de trichioroéthylene ou de per- chloroéthylene. C. Prévention des incendias et des explosions Les causes d'incendie et d'explosion sont les com- bustibies atteints par arc, la flamme, les étincelles, le laitier chaud ou les matériaux chauffés, ie mauvais material; misuse of compressed gases and cylinders; and short circuits. , BE AWARE THAT flying sparks or falling siag can pass through cracks, along pipes, through windows or doors, and through wall or floor openings, out of sight of tha goggled operator. Sparks and slag can fly 35 feet. To prevent fires and explosion: Keep equipment clean and operable, free of oil, grease, and (in electrical parts) of metallic particles that can cause short circuits. If combustibles are in area, do NOT weld or cut. Move the work if practicable, to an area free of combustibles. Avoid paint spray rooms, dip tanks, storage areas, ven- tilators, If the work cannot be moved, move combustibles at least 35 feet away out of reach of sparks and heat; or protect against ignition with suitable and snug-fitting, fire-resistant covers or shieids. Walls touching combustibles on opposite sides should not be welded on (or cut). Walls, ceilings, and floor near work should be protected by heat-resistant covers or shields. Fire watcher must be standing by with suitable fire ex- tinguishing equipment during and for some time after welding or cutting if: a. appreciable combustibles {including building construction) are within 35 feet | b. appreciable combustibles are further than 35 feet but can be ignited by sparks с. openings (concealed or visible) in floors or wails within 35 feet may expose combustibles to sparks | d. combustibles adjacent to walls, ceilings, roofs, or metal partitions can be ignited by radiant or conducted heat. Hot work permit should be obtained before operation to gnsure supervisor's approval that adequate precautions have been taken. After work is done, check that area is free of sparks, glowing embers, and flames, An empty container that held combustibles, or that can produce flammable or toxic vapors when heated, must never be welded on or cut, unless container has first been cleaned as described in AWS Standard A6.0, listed 3 in Standards index. This includes: a thorough steam or caustic cleaning {or a solvent or water washing, depending on the combustible’s solubility) followed by purging and inerting with nitrogen or carbon dioxide, and using protective equipment as recommended in À6.0. Watertilling just below working level may substitute for inerting. A container with unknown contents should be cleaned (see paragraph above). Do NOT depend on sense of smell or sight to determine if it is safe to weld or cut. emploi des gaz comprimés et des bouteilles a ainsi que les . Courts-Circuits. Sachez que les éclats d'étincelles ou la chute du iaitier peuvent s'infiltrer dans les fissures, le long des tuyauteries, par les fenêtres et les portes et par les couvertures des murs ou du sol, sans que ie soudeur portant des lunettes ne les voie. Les étinceiles et les scories peuvent voler jusqu'à 35 pieds. Pour prévenir les incendies et les explosions: Veillez à ce que votre appareil soit propre et en état de marche, dénué d'huile et de graisse, et de particules de métal sur les pièces électriques qui pourraient entraîner des courts-circuits, Si des combustibles se trouvent á proximité, ne soudez pas, ne coupez pas. Si possible, dépiacez votre travail loin des combustibles. Evitez les ateliers. de peinture au pistolet, les cuves d'immersion, les entrepôts, les ven- tilateurs. Si cela n'est pas possible, placez les combustibles à au moins 35 pieds des étincelles et de la chaleur et protégez-les des étincelles avec des couvertures ou des écrans protecteurs adéquats, bien ajustés et ignifugés. On ne doit pas souder (ou couper} le côté opposé. des murs touchant les combustibles. Les murs, plafonds et planchers proches du travail doivent être protégés par des couvertures ou écrans protecteurs ignifugés. Un surveillant doit se tenir à proximité avec un matériel de lutte contre l'incendie adéquat, pendant et queique temps après le soudage ou le coupage si: a. Des quantités appréciables de combustibles {y compris une construction en chantier) se trouvent à rnoins de 35 pieds. b. Des quantités appréciables de combustibles sont à plus de 35 pieds mais peuvent être enfiammées par des étincelles. c. Des ouvertures {cachées ou visibles) sur les planchers ou les murs à moins de 35 pieds peuvent exposer. des combustibles aux étincelles. d. Les combustibles adjacents aux murs, plafonds, toits ou cloisons métalliques peuvent être enflammés par une chaiïeur rayon- nante ou transmise. Avant de commencer, avisez le contremaître pour qu’il s'assure que les précautions adéquates soient prises. Une fois le travail terminé, vérifiez qu'il n'y ait pas d'étincelles, de cendres ardentes ou de flammes dans le local. On ne doit jamais souder ni couper sur un récipient ayant contenu des combustibles, ou pouvant produire des vapeurs inflammables ou toxiques à la chauffe, à moins que le récipient n'ait été lavé au préalable, comme décrit dans la Norme AWS A6.0, figurant au paragraphe 3 de l'index des Normes. Cela comprend: un nettoyage à fond à la vapeur ou au caustique (ou un lavage avec dissoivant ou eau selon la solubilité du combustible) suivi d’une purge et d'une in- jection d'azote ou de gaz carbonique, en utilisant un équipement de protection comme recommandé dans l’'A6-0. L'atmosphère inerte peut être remplacée par un niveau d'eau arrivant au-dessous du travail à effectuer. Vous devez laver un récipient dont la nature de contenu est inconnue (voir paragraphe ci-dessus}. NE vous fiez PAS à Годога{ оч & la vue pour dire si l'on peut le souder ou le couper en toute sécurité. OM-1303 Page 3 la я ны + Hollow castings or containers must be vented before welding or cutting. They can explode. . Expiosive atmospheres. Never weld or cut where the air may contain flammable dust, gas, or liquid vapors (such as gasoline). О. Compressed Gas Equipment Standard precautions. Comply with precautions in this manual, and those detailed in CGA Standard P-1, PRECAUTIONS FOR SAFE HANDLING OF COM- PRESSED GASES IN CYLINDERS, listed 6 in Stan- dards index, t. Pressure Regulators Regulator relief valve is designed to protect only the regulator from overpressure; it is not intended to pro- tact any downstream equipment. Provide such protection with one or more relief devices. Never connect a regulator to a cylinder containing gas other than that for which the regulator was designed. Remove faulty regulator from service immediately for repair {first close cylinder valve). The following symp- toms indicate a fauity regulator: Leaks - if gas leaks externally. Excessive Creep - if delivery pressure continues to rise with downstream valve closed. Faulty Gauge - if gauge pointer does not move off stop pin when pressurized, nor returns to stop pin after pressure release. Repair. Do NOT attempt repair. Send faulty regulators for repair to manufacturer's designated repair center, ‘where special techniques and tools are used by trained personnel. 2. Cylinders Cylinders must be handled carefully to prevent leaks and damage to their walls, valves, or safety devices: Avoid electrical circuit contact with cylinders including third rails, electrical wires, or welding circuits. They can produce short circuit arcs that may lead to a serious accident. {See 1-3C.) ICC or DOT marking must be on each cylinder. itis an assurance of safety when the cylinder is properly handled. Identifying gas content, Use only cylinders with name of gas marked on them; do not rely on color to identify gas content. Notify supplier if unmarked. NEVER DEFACE or alter name, number, or other markings on a cylinder. It is illegal and hazardous. Page 4 Vous devez pratiquer un évent sur les piéces ou réci- pients creux avant de les souder ou couper: ils peuvent exploser. Atmosphères explosives: Ne soudez ni ne coupez jamais dans des lieux où l’air peut contenir des poussières, gaz ou vapeurs liquides inflammables (tels que l'essence). | D. Gaz comprimé Précautions générales: Suivez les précautions de ce manuel, et celles décrites à la Norme CGA P-1 (Précau- tions de sécurité pour la manipulation de gaz comprimés en bouteilles), paragraphe 8 de l'index des Normes. 1. Détendeurs de pression La soupape de sûreté d'un détendeur est destinée à pro- téger seulement ie détendeur de la surpression, Elle n'a pas pour but de protéger les boyaux et le chalumeau: on protège ceux-ci par des soupapes de retenue conçues spécialement pour cette fonction. Ne montez jamais un détendeur sur une bouteille cante- nant un gaz différent de celui pour lequel le détendeur a été conçu. Enlevez immédiatement un détendeur défectueux pour le faire réparer (d'abord, fermez le robinet‘ de la bouteille). Les symptômes suivants dénotent la défec- tuosité du détendeur: Fuites - si le gaz fuit extérieurement. Ascension excessive - si la pression de débit continue à monter, le robinet du chalumeau étant fermé. — Manomètre défectueux - si l'aiguille du manomètre ne s’écarte pas de la goupille de butée lors de la mise en pression, ou ne revient pas sur la goupille après l'échap- pement de la pression. Réparation. N'ESSAYEZ PAS de réparer vous-mêmes. Envoyez les détendeurs défectueux à réparer aux ateliers de réparation agréés du fabricant, où des techniques et des outils spéciaux sont utilisés par un person- nei formé. 2. Bouteilles Les bouteilles doivent être manipulées avec soin pour prévenir les. fuites ou dégâts à leurs parois, robinets ou systèmes de sûreté. Évitez qu'un circuit électrique soit en contact avec les bouteilles, y compris les rails de contact, les fils électriques ou les circuits de soudage. Cela pourrait créer des arcs courts-circuits pouvant entraîner des accidents graves (Voir 1.3C.). Chaque bouteille doit porter les inscriptions ICC ou DOT. C’est un gage de sécurité pourvu que la bouteille soit bien manipulée. Identification du gaz: N'utilisez que les bouteilles indi- quant la nature du gaz; ne vous fiez pas à la couleur pour reconnaître la nature du gaz. Adressez-vous à votre fournisseur si cela n'est pas indiqué. N'EFFACEZ ou ne modifiez JAMAIS les noms, Numéros ou autres indications sur une bouteille. Cela est illégai et dangereux. Empties: Keep valves closed, replace caps securely; mark MT; keep them separate from FULLS and return promptly. Prohibited use. Never use a cylinder or its contents for other than its intended use, NEVER as a support or roller, Locate or secure cylinders so they cannot be knocked over, Passageways and work areas. Keep cylinders clear of areas where they may be struck. Transporting cylinders, With a crane, use a secure sup- - port such as a platform or cradle. Do NOT lift cylinders off the ground by their valves or caps, or by chains, slings, or magnets. Do NOT expose cylinders to excessive heat, sparks, siag, and flame, etc. that may cause rupture. Do not allow contents to exceed 130°F. Cool with water spray where such exposure exists. Protect cylinders particularly valves from bumps, falls, falling objects, and weather. Replace caps securely when moving cylinders. Stuck valve. Do NOT use a hammer or wrench to open a cylinder valve that can not be opened by hand. Notify your supplier. Mixing gases. Never try to mix any gases in a cylinder. Never refill any cylinder. Cylinder fittings should never be modified or exchang- ed. 3. Hose Prohibited use. Never use hose other than that designed for the specified gas. A general hose identification rule is: red for fuel gas, green for oxygen, and black for inert gases. Use ferrules or clamps designed for the hose {not or- dinary wire or other substitute) as a binding to connect hoses to fittings. No copper tubing splices. Use only standard brass fittings to splice hoss. Avoid long runs to prevent kinks and abuse. Suspend hose off ground to keep it from being run over, stepped on, or otherwise damaged. Coil excess hose to prevent kinks and tangles. Protect hose from damage by sharp edges, and by - sparks, slag, and open flame. Examine hose regularly for leaks, wear, and loose connections. Immerse pressured позе in water: bubbles indicate leaks. Repair leaky or worn hose by cutting area out and splic- ing (1-2D03). Do NOT use tape. | Vides: Maintenez les robinets fermés, replacez bien les chapeaux; inscrivez “Vides”; séparez-les des “Pleines et retournez-les rapidement. Emploi interdit: N'utilisez une bouteille ou son contenu que pour ce à quoi elite est destinée, mais JAMAIS comme support où rouleau. Placez les bouteilles pour qu’elles ne tombent pas. Lors- qu'un détendeur (et un boyau) est monté sur elles, placez les.ou attachez-les debout. Passages et lieux de travail. Enievez les bouteilles d'un endroit où l'on pourrait les frapper. Transport des bouteilles. Avec une grue, utilisez un support fiable tel qu'une plate-forme ou un cadre. NE SOULEVEZ PAS des bouteilles du sol par leur robinet ou chapeau, ou avec des chaînes, élingues ou aimants. N'EXPOSEZ PAS les bouteilles à une chaleur excessive, aux étincelles, au laitier et aux flammes, etc., pouvant causer leur rupture, Le contenant ne doit jamais dépasser 55°C. Refroidissez en puivérisant de l'eau si nécessaire. Protégez les bouteilles et particulièrement les soupapes contre les chocs, les chutes, les chutes d'objets et la température. Remettez bien les chapeaux lorsque vous déplacez les bouteilles. Robinet coincé, N'UTILISEZ PAS un marteau ou une clé metallique pour ouvrir un robinet de bouteille que Fon ne peut pas ouvrir à la main. Avisez votre fournisseur. | Mélange de gaz. N'essayez jamais de mélanger des gaz dans une bouteilie. Ne rechargez jamais une bouteille. Les éléments de la bouteille ne doivent jamais être modifiés ou remplacés. 3. Boyau Utilisation interdite. N'utilisez jamais un boyau autre que celui approprié au gaz indiqué. La règle générale d'identification est: rouge pour les gaz combustibles, vert pour l'oxygène, et noir pour les gaz inertes. Utilisez des bagues ou colliers appropriés au boyau (et non du fil ordinaire ou autre substitution) pour brancher les boyaux à l'appareiilage. N'utilisez pas des raccords en cuivre. N'utilisez que des accessoires standard en laiton pour raccorder un boyau. Utilisez une petite longueur de boyau. Cela évitera les noeuds et l'usure prématurée. Suspendez le boyau au- dessus du sol pour éviter qu'il ne soit écrasé, piétiné ou endommagé. Enroulez le surplus de boyau pour éviter les noeuds et emméêlements. Évitez que le boyau ne soit endommagé par des tranchants, étincelies, laitier et flamme nue. Vérifiez régulièrement les fuites, l'usure et les rac- cordements lâches. Plongez le boyau sous pression dans de l’eau; les bulles indiqueront les fuites. Réparation. Coupez la partie percée ou Usée, et rac- cordez (1-2D3). N'UTILISEZ JAMAIS de ruban adhésif. ОМ-1303 Раде 5 4, Proper Connections Clean cylinder valve outlet of impurities that may clog orifices and damage seats before connecting reguiator. Except for hydrogen, crack valve momentarily, pointing outlet away from people and sources of ignition. Wipe with a clean lintless cloth. Match regulator to cylinder, Before connecting, check that the regulator label and cylinder marking agree, and that. the regulator inlet and cylinder outlet match. NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas. Tighten connections. When assembling threaded connections, clean and smooth seats where necessary, Tighten. If connection leaks, disassemble, clean, and retighten using properly fitting wrench. Adapters. Use a CGA adapter (available from your supplier) between cylinder and regulator, if one is required. Use two wrenches to tighten adapter marked RIGHT and LEFT HAND threads. Regulator outlet (or hose) connections may be iden- tified by right hand threads for oxygen and left hand threads (with grooved hex on nut or shank) for fuel gas. 5. Pressurizing Steps: Drain regulator of residual gas through suitable vent before opening cylinder (or manifold valve) by turning adjusting screw in (clockwise). Draining prevents excessive compression heat at high pressure seat by allowing seat to open on pressurization. Leave adjusting screw engaged slightly on single-stage regulators. Stand to side of regulator while opening cylinder valve. Open cylinder valve slowly so that regulator pressure increases slowly, When gauge is pressurized {gauge reaches regulator maximum) leave cylinder vaive in following position: For oxygen, and inert gases, open fully to seal stem against possible leak. For fuel gas, open to less than one turn to permit quick emergency shutoff. Use pressure charts (available from your supplier} for safe and efficient, recommended pressure settings on regulators. Check for leaks on first pressurization and regularly there-after. Brush with soap solution (capful of Ivory Liquid* or equivalent per galion of water). Bubbles indicate leak. Clean off soapy water after test; dried soap is combustible. E. User Responsibilities Remove teaky or defective equipment from service immediately for repair. See User Responsibility statement in equipment manual. *Trademark of Proctor & Gamble Page 6 4. Branchements corrects Avant de brancher le détendeur, nettoyez la sortie du robinet de la bouteille des impuretés qui peuvent obstruer les orifices et endommager les sièges. Sauf pour l'hydrogène, ouvrez momentanément le robinet, en éloignant la sortie des personnes et des sources inflammables. Essuyez avec un tissu propre et non graisseux. 3 Appareiliez le détendeur à la bouteille. Avant de brancher, vérifiez que la marque du détendeur et la description de la bouteille concordent, et que forifice d'entrés du détendeur et orifice de sortie de la bouteille aillent ensemble. NE BRANCHEZ JAMAIS un détendeur conçu pour un gaz spécial (ou des gaz spéciaux) a une bouteille contenant d'autres gaz. Serrez les branchements. Lorsque vous assemblez des branchements filetés, nettoyez et polissez les sièges où c'est nécessaire. Serrez. Si les branchements perdent, démontez-les, nettoyez et ressarez avec une clef adé- quate. Adaptateurs. Placez, si besoin est, un adaptateur CGA {en vente chez votre fournisseur) entre la bouteille et le détendeur. Avec deux clefs, serrez l’adaptateur fileté À DROITE et À GAUCHE. On peut reconnaître les branchements de sortie du détendeur (ou boyau) à l’aide du filetage à droite pour l'oxygène et à gauche (identifié par un écrou cannelé) pour les gaz combustibles. 5. Démarches de mise en pression Purgez le détendeur de résidu de gaz avant d'ouvrir la bouteille (ou le robinet de canalisation} en serrant la vis de réglage (dans le sens des aiguilles d‘une montre). Cette opération permet au siège de haute pression de s'ouvrir à la mise en pression, supprimant ainsi toute surchauffe de compression. Maintenez la vis de réglage des détendeurs à simple détente légèrement engagée. Avant d'ouvrir le robinet de la bouteille, assurez-vous que les Doyaux sont branchés et que les soupapes aval sont fermées. Tenez-vous latéralement au détendeur en ouvrant le robinet de la bouteille. Ouvrez-le lentement pour que la pression du détendeur monte progressivement. Lorsque le manomètre est mis sous pression (indique ie maximum) le robinet de la bouteille de gaz inerte ou d'ox- ygène devra être ouvert à fond pour assurer l'étanchéité et cetui de la bouteille de gaz combustible ouvert de moins d'un tour pour pouvoir le refermer rapidement en cas d'urgence. Référez-vous aux tableaux de pression (distribués par votre fournisseur) pour Un réglage recommandé de pression sûr et efficace sur les détendeurs. Vérifiez les fuites à la première mise en pression puis régulièrement, brossez avec une solution savonneuse (un bouchon d'ivory Liquid* ou semblable par gallon d'eau}. Les bulles indiquent une fuite. Enlevez l’eau savonneuse après examen: le savon sec est inflammable. Е. Responsabilités de l'usager Ôtez immédiatement les parties percées ou défec- tueuses. Voir les Responsabilités de l‘Usager du manuel de l'appareil. *Marque de Commerce de Proctor & Gamble F. Leaving Equipment Unattended Close gas supply at source and drain gas. С. Rope Staging-Support Rope staging-support should not be used for welding or cutting operation; rope may burn. 1-3. ARC WELDING - Comply with precautions in 1-1, 1-2, and this section. Arc Weiding, properiy done, is a safe process, but a careless operator invites trouble, The equipment carries high currents at significant voltages. The arc is very bright and hot, Sparks fiy, fumes rise, ultraviolet and infrared energy radiates, weldments ara hot, and compressed gases may be used. The wise operator avoids unnecessary risks and pro- tects himself and others from accidents. Precautions are described here and in standards referenced in index. A. Burn Protection | Comply with precautions in 1-2. The welding arc is intense and visibly bright, its radiation can damage eyes, penetrate lightweight clothing, reflect from light-colored surfaces, and burn the skin and eyes. Skin burns resemble acute sunburn, those from gas-shielded arcs are more severe and painful. DON'T GET BURNED, COMPLY WITH PRECAU- TIONS. 1. Protective Clothing Wear long-sleeve clothing [particularly for gas-shielded arc) in addition to gloves, hat, and shoes (1-2A). As necessary, use additional protective clothing such as leather jacket or sleeves, flame-proof apron, and fire- resistant leggings. Avoid outergarments of untreated cotton. Bare skin protection. Wear dark, substantial clothing. Button collar to protect chest and neck and button pockets to prevent entry of sparks. 2. Eye and Head Protection — Protect eyes from exposure to arc. NEVER look at an electric arc without protection. Welding helmet or shield containing a filter plate shade no. 12 or denser must be used when welding. Place over face before striking arc. Protect filter plate with a clear cover plate. Cracked or broken helmet or shield should NOT be worn: radiation can pass through to cause burns. Crackad, broken, or loose filter plates must be replaced IMMEDIATELY. Replace clear cover plate when broken, pitted, or spattered. F. Appareil laissé sans surveillance Fermez l'alimentation de gaz à la source et purgez. G. Liens et supports temporaires Pour vos travaux de soudage ou des coupage, n'utilisez - pas de la corde comme soutien, elie est inflammable. 1-3. SOUDAGE A L'ARC - Conformez-vous aux précautions des paragraphes 1.1 et 1.2 de cette section. Le soudage à l'arc bien exécuté est sûr, mais Un soudeur négligent est un danger. Le poste de soudage transporte des courants élevés sous de fortes-tensions. L'arc est très vif et chaud. Les étincelles volent, les vapeurs montent, l'énergie ultra-violette et infrarouge rayonnent, !es soudures sont chaudes, et des gaz com- primés peuvent être utilisés. Le soudeur prudent évite les risques inutiles, se protège et protège autrui contre. les accidents. Les précautions sont décrites ici et dans les normes données dans l'index. A. Protection contre les brûlures Conformez-vous aux précautions du paragraphe 1.2. L'arc de soudage est intense et visiblement vif. Son rayonnement peut blesser les yeux, traverser les habits légers, se réfléchir sur les surfaces claires, et brûler la peau et les yeux. Les brûlures de la peau ressemblent à un gros coup de soleil. Celles d'arcs sous gaz protecteur sont plus graves et plus douloureuses, NE VOUS BRULEZ PAS - SUIVEZ LES PRECAUTIONS. 1. Vétements de protection Portez des vêtements à manches longues (surtout pour l'arc en atmosphère inerte) avec gants, masque et chaussures {1.2A.). Si nécessaire portez en plus une veste ou des manches en cuir, un tablier et des guétres ignifugés. De préférence ne portez pas de vétements en coton non traité. Protection de la peau, Portez des vêtements épais foncés, Boutonnez le col pour protéger la poitrine et le cou, et boutonnez les poches pour prévenir l‘infiltration d'étincelles. 2. Protection des yeux et de la téte Évitez que vos yeux soient exposés a l'arc. NE regardez — JAMAIS un arc électrique sans protection. Lorsque vous soudez, portez un écran ou masque avec verre filtrant teinté N° 12 ou plus foncé. Mettez-le sur le visage avant d'amorcer l'arc. Protégez le verre filtrant d'un couvre-verre clair. NE PORTEZ PAS un masque fendu ou brisé; le rayonnement peut s'infiltrer et causer des brúlures. Les verres filtrants fendus, brisés ou láches doivent étre remplacés IMMÉDIATEMENT. Rempiacez un couvre- verre brisé, piqué ou taché par des projections. OM-1303 Page 7 Flash goggles with side shields MUST be worn under the helmet to give some protection to the eyes should the heimet not be lowered over the face before an arc is struck. Looking at an arc momentarily with unprotected eyes (particularly a high intensity gas-shielded arc) can cause a retinal burn that may leave a permanent dark area in the field of vision. 3. Protection of Nearby Personnel Enclosed welding area. For production welding, a _separate room or enclosed bay is best. In open areas, surround the operation. with low-reflective, “hon. combustible screens or panels. Allow for free air circula- tion, particularly at floor level. Viewing the weld. Provide face shields for all persons who wilt be looking directly at the weld. Others working in area. See that all persons are wearing flash goggles. Before starting to weld, make sure that screen flaps or bay doors are closed. B. Toxic Fume Prevention Comply with precautions in 1-28. Generator engine exhaust must be vented to the outside air. Carbon monoxide can kill. C. Fire and Explosion Prevention Comply with precautions in 1-2C. Equipment’s rated capacity. Do not overload arc welding equipment. It may overheat cables and cause a fire. Loose cable connections may overheat or flash and cause a fire. Never strike an arc on a cylinder or other pressure vessel, It creates a brittle area that can cause a violent rupture or lead to such a rupture later under rough handling. D. Compressed Gas Equipment Comply with precautions in 1-2D, E. Shock Prevention Exposed hot conductors or other hare metal in the welding circuit, or in ungrounded, electricaliy-HOT equipment can fatally shock a person whose body becomes a conductor, DO NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wet surface when welding, without suitable protection. Page 8 Vous devez portez des lunettes 3 écrans latéraux sous le masque pour proteger les yeux dans le cas ou ie masque ne serait pas abaissé sur le visage avant l'amorçage de l’arc. Regarder momentanément un arc sans protection (principalement un arc en atmosphère inerte à haute in- tensité) peut brûler ta rétine et laisser un point sombre permanent dans ie champ de vision. 3. Protection du personnel à proximité Local de soudage fermé. Pour fe soudage de production, il vaut mieux utiliser une saile séparée ou une baie fermée. Dans les locaux ouverts, entourez les travaux d'écrans ou panneaux peu réfléchissants et ininflam- mables. Laissez l’air circuler librement, particutièrement au niveau du sol. Donnez des masques aux personnes qui regarderont directement la soudure, Autres personnes travaillant sur les lieux. Veillez à ce que toutes les personnes portent les lunettes de protection. Avant d'attaquer la soudure, assurez-vous que les rebords d'écran ou les portes soient fermés. B. Prévention des gaz toxiques Suivez les précautions du paragraphe 1.2B. L'échappe- ment du moteur de la génératrice doit être ventilé à l'air extérieur. L'oxyde de carbone peut tuer. C. Prévention des incandies et das explosions Suivez les précautions 1.2C. Puissance nominale de l'appareil. Ne surchargez pas le poste de soudage ä l’arc. Cela peut surchauffer les câbles et causer un incendie. Les branchements lâches de câble peuvent surchauffer ou faire des étincelles et causer un incendie. N'amorcez jamais un arc sur une bouteille ou autre réci- pient sous pression. Cela créerait un point de rupture entraînant à plus ou moins longue échéance l'explosion du réservoir. D. Gaz comprimé Suivez les précautions 1.2D. E. Prévention des décharges électriques Des conducteurs chargés ou métal nu incorporés au circuit de soudage ou à un appareil chargé sans mise à la terre peuvent donner une décharge fatale à la personne dont le corps devient conducteur. NE SOUDEZ PAS DEBSOUT, ASSIS, COUCHE, PENCHE sur une surface humide ni en contact avec une telle surface sans protection appropriée. To protect against shock: Keep body and clothing dry. Never work in damp area - without adequate insulation against electrical shock. Stay on a dry duckboard, or rubber mat when damp- ness or sweat can not be avoided. Sweat, sea water, or moisture between body and an electrically HOT part - or grounded metal - reduces the body surface electrical resistance, enabling dangerous and possibly lethal currents to flow through the body. 1. Grounding the Equipment When installing, connect the frames of each unit such as welding power source, control, work table, and water circulator to the building ground. Conductors must be adequate to carry ground currents safely, Equipment made electrically HOT by stray current may shock, possibly fatally. Do NOT GROUND to electrical conduit, or to a pipe carrying ANY gas or a flammable liquid such as oil or fuel. Three-phase connection. Check phase requirements of equipment before installing. if only 3-phase power is available, connect single-phase equipment to only two wires of the 3-phase line. Do NOT connect the equipment ground lead to the third (live) wire, or the equipment wilí become electrically HOT - a dangerous condition that can shock, possibly fataily. Before welding, check ground for continuity. Be sure conductors are touching bare metal of equipment frames at connections. If a line cord with a ground lead is provided with the equipment for connection to a switchbox, connect the ground lead to the grounded switchbox. if a three- prong plug is added for connection to a grounded mating receptacle, the ground lead must be connected to the ground prong only, If the line cord comes with a three-prong plitg, connect to a grounded mating receptacle. Never remove the ground prong from a plug, or use a plug with a broken off ground prong. 2. Electrode Holders Fully insulated electrode holders should be used. Do NOT use holders with protruding screws. 3. Connectors Fully insulated lock-type connectors should be used to join welding cable lengths. 4, Cables Frequently inspect cables for wear, cracks and damage. IMMEDIATELY REPLACE those with axcessivaly worn or damaged insulation to avoid possibly - lethal shock from bared cable, Cables with damaged areas may be taped to give resistance equivalent to original cabie. Keep cable dry, free of oil and grease, and protected from hot metal and sparks. Pour vous protéger contre les décharges électriques, maintenez votre corps st vétements secs. Ne travaillez jamais dans un endroit humide sans isolation adequate contre les décharges électriques. Lorsque vous ne pouvez éviter l'humidité ou la sueur, placez-vous sur un caillebotis sec ou un tapis en caoutchouc. La sueur, l'eau de mer, ou l'humidité entre le corps et une pièce CHARGÉE, ou une pièce de métal à la masse, réduisent la résistance électrique de la surface du corps, permet- tant l'entrée de courants dangereux, voire mortels. 1. Mise à la terre de l'appareil À l'installation, branchez les châssis de chaque élément {source de courant, commande, établi et circuit d'eau) à la terre. Les conducteurs doivent pouvoir conduire ies courants teiluriques en toute sécurité. L'appareil chargé par les courants vagabonds peut donner une décharge ° risquant d'être mortelle. NE BRANCHEZ PAS VOTRE PRISE DE TERRE à une conduite électrique, ou à un tuyau de gaz ou de liquide inflammable tel que l'huile ou un combustible. Connexion triphasée. Avant l'installation vérifiez la phase nécessaire à l'appareil. Si seul le triphasé est disponible, ne branchez l'appareil monophasé qu'à deux des fils de la ligne triphasée. NE BRANCHEZ PAS le conducteur de terre de l'appareil au troisième fil (sous | tension), autrement l'appareil. serait chargé: condition dangereuse pouvant donner une décharge fatale. Avant le soudage, vérifiez si la prise de terre est uniforme. En branchant, assurez-vous que les conducteurs touchent le-métal nu du châssis de l‘appareil. Lorsqu'un appareil doit être alimenté à partir d’un cof- — fret d'alimentation, le conducteur de terre doit être relié à celui-ci. Si vous avez en plus une fiche à trois broches pour la terre, ne branchez le conducteur de terre qu'à la broche de terre. Si le cordon d'alimentation a une fiche à trois broches, reliez-le à une prise femelle tripolaire reliée à la terre. N'enlevez jamais la broche de terre d'une fiche ou n‘utilisez jamais une fiche dont la broche de terre serait brisée. 2. Pince-électrodes Utilisez des pince-électrodes bien isolées. N'UTILISEZ PAS des pince-électrodes avec vis saitlantes. | 3. Connecteurs Utilisez des connecteurs à verrouillage bien isolés pour assembler de longs câbles. 4, (Cables Vérifiez fréquemment l’usure, les fissures et l'altération des câbles. REMPLACEZ IMMÉDIATEMENT ceux dont. l'isolation serait trop usée ou aitérée pour prévenir les décharges mortelles provoquées par un.cäble dénudé. - Vous pouvez enrouler les parties endommagées de ruban adhésif en épaisseur suffisante pour donner une résistance de cáble neuf. Maintenez les cábles secs, dépourvus d'huile et de graisse et mettez-les à l'abri du métai chaud et des étinceiles, OM-1303 Page 9 5. Terminals And Other Exposed Parts. Terminals and other exposed parts of electrical units should have insulating covers secured before operation. 6. Electrode Wire Electrode wire becomes electricaily HOT when the power switch of gas metal-arc welding equipment is ON and welding gun trigger is pressed. Keep hands and . body clear of wire and other HOT parts. 7. Safety Devices Safety devices such as interlocks and circuit breakers should not be disconnected or shunted out. Before installation, inspection, or service, of equipment, shut OFF all power and remove line fuses (or lock or red-tag switches) to prevent accidental turning ON of power. Disconnect all cables from welding power source, and pull all 115 volts line-cord plugs. Do not open power circuit or change poiarity while welding. If, in an emergency, it must be disconnected, guard against shock burns, or flash from switch arcing. Leaving equipment unattended. Always shut OFF and disconnect all power to equipment. Power disconnect switch must be available near the welding power source. 1-4. STANDARDS BOOKLET INDEX - For more information, refer to the foliowing standards or their latest revisions and comply as applicable: 1. ANSI Standard 249.1, SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society, 550 Le Jeune Rd, Р.О. Вох 351040, Miami, FL 33135. 2. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents, U.S, Government Printing Office, Washington, D.C. 20402. 3. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the U.S. Govern- ment Printing Office, Washington, D.C. 20402. 4. ANSI Standard 287.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018. 5. ANSI Standard Z41.1, STANDARD FOR MEN'S SAFETY -TOE FOOTWEAR obtainable from the American National Standards ‘Institute, 1430 Broadway, New York, NY 10018 Page 10 5. Tétes de cábles et autres parties dénudées Avant la mise en marche, les tétes de cábles et autres parties dénudées d'un appareil électrique doivent étre munies de leurs couvrefils isolants. 6. Fils-électrodes Le fil-électrode est chargé lorsque lorsque l'interrupteur d'alimentation du poste à souder au MIG est sur MAR- CHE et que l'on appuie sur la gâchette du pistoiet. Evitez que les mains et le corps soient en contact avec le fil et autres éléments chargés. 7. Dispositif de sécurité Le dispositif de sécurité-verrouillage et coupe-circuit ne doit pas étre débranché ou déshunté. Avant l'installation, l'inspection ou la réparation de l'appareil, mettez l'alimentation sur ARRET et enievez les fusibles généraux (ou verrouillez les interrupteurs) pour éviter une remise en MARCHE accidentelie. Débran- chez tous les câbles de la source de courant ainsi que les prises des cordons d'alimentation en 115 voits. Lors du soudage, n'ouvrez pas le circuit d'alimentation et ne changez pas la polarité. S'il est débranché au cours d'une urgence, faites attention aux brûlures de décharge ou aux jaillissements d'étincelies. Appareil laissé sans surveillance. Mettez toujours sur ARRET et débranchez l'appareli. L'interrupteur d'arrêt doit toujours se trouver à prox- imité de la source de courant. 1-4. INDEX DES NORMES - Pour plus de renseignements, référez-vous aux normes de l'ACNOR ou aux normes américaines suivantes: 1. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING distribué par l'American Welding Society, 550 Le Jeune Rd, Р.О. Вох 351040 Miami, FL 33135 2. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING distribué par le Superintendent of Documents, U.S. Government Printing Office, Washington D.C. 20402 3. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, distribué par U.S. Government Printing Office, Washington, D.C. 20402. 4. ANSI Standard 287.1, SAFE PRACTICES FOR QCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION distribué par l'American National Standards Institute, 1430 Broadway, New York, NY 10018. 5. ANSI Standard Z41,1, STANDARD FOR MEN'S SAFETY - TOE FOOTWEAR distribué par l’addresse donnee en 4. 10. 11. 12. 13. 14, 15, ANS! Standard 249.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PRO- CESSES obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018. . AWS Standard A6.0, WELDING AND CUT- TING CONTAINERS WHICH HAVE HELD COM- BUSTIBLES obtainable from the American Welding Society, 550 Le Jeune Rd., P.O. Box 351040, FL 33135. NFPA Standard 51, OXYGEN - FUEL GAS SYSTEMS FOR WELDING AND CUTTING obtainable from the National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210. NFPA Standard 70-1978, NATIONAL ELEC- TRICAL CODE obtainable from the National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210. NFPA Standard 518, CUTTING AND WELDING PROCESSES obtainabie from the National Fire Protection Association, 470 Atlantic Avenue, Boston, MÁ 02210, CGA Pamphiet P-1, SAFE HANDLING OF COM- PRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association, 500 Fifth Avenue, New York, NY 10036, CSA Standard W117.2, CODE FOR SAFETY IN : WELDING AND CUTTING obtainable from the Canadian Standards Association, Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Standards Canada M9IW 1 R3. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103. American Welding Society Standard AWSF4.1 “Recommended Safe Practices for the Prepara- tion for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, obtainable from the American Welding Society, 550 Le Jeune Rd., P.O. Box 351040, Miami, FL 33135. ANSI Standard 288.2 “Practice for Respiratory Protection” obtainable from the American Na- tional Standards Institute, 1430 Broadway, New York, NY 10018. 10. 11. 12. 13. 14, 15. ANS! Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PRO- CESSES distribué par l’addresse donnee en 4. AWS Standard A6.0, WELDING AND CUT- TING CONTAINERS WHICH HAVE COM- BUSTIBLES distribué par l’addresse donnee en 1. | | NFPA Standard 51, OXYGEN - FUEL GAS SYSTEMS FOR WELDING AND CUTTING distribué par ta National Fire Protection Associa- tion, 470 Atlantic Avenue, Boston, MA 02210 NFPA Standard 70-1978, NATIONAL ELEC- TRICAL CODE distribué par l’addresse donnée en 8 NFPA Standard 51B, CUTTING AND WELDING PROCESSES distribué par l’addresse donnée en 8 CGA Pamphiet P-1, SAFE HANDLING OF COM- PRESSED GASES IN CYLINDERS distribué par la Compressed Gas Association, 500 Fifth Avenue, New York, NY 10036. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING distribug par la Cana- dian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada MSW TR3. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY distribué par Welding Supply Association, 1900 Arch Street Philadelphia, PA 19103. American Welding Societe Standard AWSF4.1 "Recommended Safe Practices for the Prepara- tion for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, distribué par I' American Welding Societe, 550 Le Jeune Rd., P.O. Box 351040, Miami, FL 33135 ANSI! Standard 288.2 “Practice For Respiratory Protection” distribué par l'American National Standards Institute, 1430 Broadway, New York, NY 10018. OM-1303 Page 11 la Nationai DEE SECTION 2 - INTRODUCTION eu in A ed M Input At Rated Load Output с electrod clectrod Weight at ax. 50 Hz. Single-Phase antro sctrode ectrode - - - Welding | Open o AL ° Circuit Wire Wire Mahou fn on Current Circuit pares Voltage Feed Diameter un un un Amparas | Volts | 200Y 1 230V | 460V | 575V kva kw At Gun Speed Capability Dimensions Net Net Ship 023/.025-.045 in. Height - 30 in. 28 Volts 42 48 40 20 16 9.15 8.3 24 om, Hard Wira Width - 13-1/2 in. { 191* bb. 228* Ib. | 239"* Ib, 60% Duty Volts (1.5-14.8 mom} 062 & 1/16 in. (343 mm) (87 kg) (103 kg) | (108 kg} Cycle oT {1.3 & 1.8 mm} Length - 26-1/2 in. Flux Cored Wiret (673 mm) *Add 2-3/4 pounds {1.25 kg) far units with spot panal, *=Add 5 pounds (2.27 kg) for units with spot panal. tUsing GA-40C Gun Figure 2-1. Specifications - 1. GENERAL INFORMATION AND SAFETY A. General information presented in this manual and on various labels, tags, and plates provided on this unit pertains to equipment design, installation, operation, maintenance and troubleshooting which should be read, understood and followed for the safe and effective use of this equipment. B. Safety The installation, operation, maintenance, and troubleshooting of arc welding equipment requires practices and procedures which ensure personal safety and the safety of others. Therefore, this equipment is to be installed, operated and maintained only by qualified persons in accordance with this manual and all applicable codes such as, but not limited to, those listed at the end of Section 1 - Safety Rules For Operation Of Arc Weiding Power Source. Safety instructions specifically pertaining to this unit appear throughout this manual highlighted by the signal words WARNING and CAUTION which identify different levels of hazard. LLG] statements include installation, operating, and maintenance procedures or practices which if not carefully followed could result in serious personal injury or loss of life. CAUTION BE statements include installation, operating and maintenance procedures or practices which if not carefully followed could result in minor personal injury or damage to this 5 equipment. A third signal word, HVIPORTANT , highlights instructions which need special emphasis to obtain the most efficient operation of this equipment. 2-2. 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 Page 12 by the purchaser with the carrier. A copy of the bill | of lading will be furnished by the manufacturer on re- quest if occasion to file claim arises. When requesting information concerning this equipment, it is essential that Model Description and Serial (or Style) Number of the equipment be supplied. 2 - 3. DESCRIPTION - This unit is a constant potential dc arc welding power source and wire feeder system. lt is designed for Gas Metal-Arc Welding with short circuit or spray transfer. Rated weld output is 200 amperes, 28 volts dc, at 60% duty cycle. The duty cycle is the percentage of a ten minute period that the unit can be operated safely at a given output. Since this unit is rated at 80% duty cycle, it can be operated at rated load for six minutes out of ten. During the remaining four minutes, the unit should idle to permit proper cooling. If welding amperage is decreased the duty cycle can be increased. Figure 2-2 enables the operator to determine the duty cycie at various welding amperages. RATED OUTPUT == 300 . MODEL 250 TN | ory Wd x & 200 < ba о Da 2 `` Q 150 a | = | { 1 100 A 20 25 30 35 40 so 60 70 80 90 100 % DUTY CYCLE 08-900 810-18 Figure 2-2. Duty Cycle Chart 2-4. QUTPUT CURVES (Figure 2-3) - The volt- ampere curves show the minimum and maximum voltage and amperage output capabilities of the unit from the minimum and maximum settings of the WIRE SPEED ADJUSTMENT control. cl o I DC VOLTS hd o b — 4 E | | Q 50 100 150 200 250 300 DE AMPERES - pm ue ee g-049 424 Figure 2-3. Volt-Ampere Curves | 2-5. SUPPLIED EQUIPMENT - Equipment supplied with the welding power source and requiring customer installation or assembly is listed below: A. Running gear B. Wall receptacle C. Work cable € jack plug D. GA-20C gun with 5/8 inch (16 mm) nozzle and two contact tubes for each wire size (Unit can be ordered without GA-20C gun). E. .030 inch {0.8 mm), .035 inch (0.9 mm), and .045 inch {1.1 mm} drive rolls. The welding power source is factory equipped with an 8 ft. (2.4 m) power cord {with plug on 200/230 volt models), gas valve, and facilities for a Spoolmatic gun. 2-6. ADDITIONAL REQUIRED EQUIPMENT - The additional equipment required to complete the Gas Metal Arc Welding setup is listed below and can be obtained from your local welding supplies distributor. A. Cylinder of shielding gas - Most commonly used gases are 756 AR 25C0O2 and welding grade CO». Other welding grade gas mixtures can be used depending on the application. | В. Regulator and flow meter for the specific shielding gas used. | С. Approximately 8 ft. (2.4 .m) of 5/8 in. (18 mm) gas hose with fittings. D. 8 or 12 inch spool wire - Most commonly used hard wires are E70S-6 and E70S-3. Other hard wires can be used depending on the application. 045, .052, and 1/16 flux cored wires can be used with a GA-40C welding guns. E. Welding helmet, safety glasses, and welding gloves. | | F. Work clamp. Figure 2-4. Supplied Equipment IM-1303 Page 13 Page 14 Figure 2-5. Additional Required Equipment 2-7. OPTIONAL EQUIPMENT - The equipment listed below can be obtained to extend the capabilities _of the basic unit or to suit special applications: A. m DO OO 0 A Ir © J. SKP-35, Spot, Pulser, Continuous Panel (includes three spot nozzles) (For installation see Section 3-2). Spoolmatic |! gun Spoolmatic | gun extension hose E cable kit GA-40C gun Offset/ punching tool .023/.025 drive rol! kit CRM cylinder rack Gun cable hoider 25 ft cord extension (7.6 m) power 2-8. CONSUMABLE PARTS - The parts listed below are subject to wear under normal usage or damage: A. Contact tubes B. Nozzles C. Gun liner D. Drive rolls - —z—_—_—_——————————m—————_—_—_— SECTION 3 - INSTALLATION meme sms Cylinder Bracket _- Handle Spreader Bar Dn Wheels Tas Safety Chain Cylinder Rack ‘Wheel Coitsr И Flat Washer TC-049 808-8 _ Figure 3-1. Running Gear Installation | 3-1. INSTALLATION OF THE WELDING POWER SOURCE ON RUNNING GEAR (See Figure 3-1) UNCONTROLLED TILTING OR TIPP- ING of unit can result in personal injury or equipment damage. e Use equipment of adequate capacity to lift the unit. | e [fusing lift forks to handle this unit, be sure the lift forks are long enough to extend out of the opposite side of the base. ® Do not place any part of the body under the unit while it is suspended, Place blocks under frame of unit before attaching running gear. 1. Install the two 4 in. swivel wheels and the spreader bar on the front corners of the welding power source base as shown in Figure 3-1 using 3/8 in, hardware. 2. Block the unit up securely in middle to ease installation of rear wheel/gas cylinder rack assembly. 3. Slide axle through cylinder rack and install a wheel on each end of axle with a 3/4 in. flat washer on each side of wheel, Secure the wheels in place with cotter pins, 4. Install cylinder rack on welding power source base using 5/16-18 x 3/4 cap screws and associated hardware (see Figure 3-1). 5. Remove the two front cap screws in top of welding power source wrapper and discard. In- stall running gear handle to wrapper using 1/4-20 x 3/4 cap screws as shown in Figure 3-1. 6. Install cylinder bracket to rear panel of welding power source as shown in Figure 3-1 using 1/4-20 x 3/4 cap screws and existing holes in rear panel. 7. Set gas cylinder in rack and lock in position with safety chain. Cylinder must be secured at all times, 3-2. INSTALLATION OF OPTIONAL SKP-35 PANEL RILUDINTSE ELECTRIC SHOCK can kill e Disconnect input power and employ “lockout/tagging procedures” before internally Inspecting or servicing. Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or tagging circuit breaker or other disconnecting device. OM-1303 Page 15 1. Remove module cover plate from upper righthand corner of front panel, Retain securing Screws, 2. Locate wiring harness clamped to air baffle. Remove wiring harness from first clamp and carefully pull end of wiring harness with connectors through opening in front panel - it will come through approximately 2 in. (51 mm). 3. Disconnect jumpered connector from plug PLO2. 4. Connect receptacle RC2 from SKP-35 panel to PLG2. Be sure the connectors are locked together, 5. instali SKP-35 panel in front panel using securing screws removed in Step No. 1. Figure 3-2, SKP-35 Panel Installation 3-3. “ELECTRICAL INPUT CONNECTIONS A. Electrical Input Requirements This welding power source is designed to be operated . from single-phase, 60 Hertz, ac input power which has a voltage rating that corresponds with one of the electrical input voitages shown on the nameplate. Consult the local electric utility if there is any question about the type of electrical system available at the installation site : or how proper connections to the welding power source are to be made. Page 16 B. Matching The Welding Power Source To The Available Input Voltage This unit is equipped with input voitage jumper links on the primary terminal board which allow operation from different line voltages. This unit is shipped with the jumper links positioned for the highest voltage stated on the nameplate. If the unit is to be operated from the lower input voltage, remove the wrapper and reposition the jumper links to correspond to the available line voltage {see input voltage label on primary terminal board). KÉTITUUONE INCORRECT INPUT VOLTAGE JUMPER LINK PLACEMENT can damage unit. ® Position jumper links as shown on the input voltage label located on primary terminal board. o WYER Store unused jumper links across link- ed terminals, Primary Terminal Board . Stabilizer | TA-048 331 Welding Power Source Right Side Figure 3. 3. | Input Vi Voltage Jumper Lin! Links Location C. input Conductor Connections КОДОВ ELECTRIC SHOCK can kill. ® [tis recommended that a fusible line disconnect switch be installed in the input circuit to the welding power source. This would provide a safe and convenient means to completely remove all electrical power from the welding power source whenever it is necessary to internally inspect or service the unit. ® Employ “lockout/tagging procedures” on input line before making input connections to the welding power source, Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or tagging circuit breaker or other disconnecting device. Models with 200 or 230 volts primary input are equipped with a power cord that has a three-prong polarized plug. The corresponding wall receptacle is also provided. The wall receptacle should be instalied and connected to a line disconnect switch by a competent elec- trician. Install the receptacle with the grounding terminal at the top so that the power cable can hang downward without bending or twisting. Models with primary input above 230 volts have a power cord without plug. This power cord should be connected to line power at the line disconnect switch. Table 3-1 provides guidelines for selecting the proper size input conductors and line fuses. The input conductors should be covered with an insulating material that meets local electrical standards. EZLN ELECTRICAL SHOCK can kill. e Do not connect an input conductor to the ground conductor from the unit, ® Do not connect the ground conductor to an input conductor. Incorrect input connections can result in an electrically energized welding power source chassis. The ground terminal is connected to the welding power source chassis and is for grounding purposes only. Table 3-1. Input Conductor And Fuse Size input Conductor Size - AWG* Fuse Size In Ampesres 200V 230V 460V 575V 200V 230V 460V 575V 8 (10) 8 (10) 12 (14) 12 (16) 60 50 25 20 “Input conductor sizes are based on National Electrical Code specifications for allowable ampacities of insulated copper conductors, having a temperature rating of 75°C, with not more than three conductors in a raceway or cable. Numbers in { } are equipment ground conductor sizes. 3 -4. INSTALLATION OF SHIELDING GAS A. Gas Cylinder Secure the gas cylinder to the running gear with the supplied chain, If the running gear is not to be used, chain the cylinder to a wall or other stationary support to prevent the cylinder from falling over and breaking off the valve. КОДЕ СА5 UNDER PRESSURE is ex- plosive. ® Keep open flame and smoking materials away from shielding gas. ® Always store cylinders in upright position. ® Ensure that cylinders are chained to stationary support or running gear. B. Regulator Flowmeter (Customer Supplied) {Figure 3-5) 1. With the cylinder correctly placed, remove the cylinder cap, then stand to one side of the cylinder valve and open the vaive slightly. When gas is emitted from the cylinder, close the valve. This procedure will help to get rid of any dust that may have accumulated around the valve seat. 2. Regulator flowmeter must be properly equipped with a stem, nut connectors and gasket for use with either CO2 cylinders or inert gas type cylinders. 3. Attach gas regulator to gas cylinder valve; keep the face of the regulator flowmeter gauge in ver- tical position and tighten stem nut securely to gas cylinder valve. Gas Hegulator Stem Cap CO» - CO» "Washer: | | Stan - Use For | ‘Gas Cylinder Argon/ CO. Valve _Cylindars | 18-057 469-15 Figure 3-4. Typical Regulator Flowmeter installation IMPORTANT J gasket should be installed to prevent leaks. Do not use lubricants or sealing agents. 4. A shielding gas output fitting with 5/8-18 right hand threads is provided at the rear of the welding power source for making gas connections. Connect the gas hose to this output fitting. Attach other end of the gas hose over barbed stem located on the bottom of the regulator flowmeter. Ensure that the hose extends over at least two barbs. No clamp is necessary since only low gas pressure is present. ~ B. Use a wrench to loosen the lock nut on the regulator flowmeter adjustment handle one turn. 6. Ensure that the regulator flowmeter adjustment handle is in the closed (clockwise) position, then slowly turn the gas cylinder valve (counterclockwise) until it is completely open. 7. Depress gun trigger and turn regulator flowmeter adjustment handle counterclockwise until the regulator flowmeter gauge reads 6 pounds. LR ANI Some regulator flowmeter gauges are calibrated in C.F.H. (cubic feet per hour). Set flow rate depending on type of shielding gas and welding conditions. 8. Release gun trigger and tighten locknut on adjustment handle of regulator flowmeter. 3-5. WORK CABLE ASSEMBLY & INSTALLA- TION (Figure 3-5) - A ten foot cable and twistlock plug are provided with this unit to assemble for use as the work cable. A work clamp must be obtained to complete the assembly. A. Assembly 1. Secure terminal lug to work clamp. 2. Remove one inch of insulation from remaining end of cable. OM-1303 Page 17 3, Wrap copper strip around wire. 4. Place metal piece on copper strip and slide plug onto wire so that the set screw hole is over the metal piece. Set Screw Pin Ш e Insulator Plug | A Sp» Copper Strip E | | TD-083 264-A 5. Slide insulator over plug. 6. Secure plug by inserting and tightening set — screw. Secure insulator by inserting pin into plug. B. installation POSITIVE NEGATIVE ELE LLIDICE ELECTRIC SHOCK can kill. e Do not touch live electrical parts. e Do not change the position of the jack plug while welding. 1. Insert plug into the NEGATIVE output receptacle for dc reverse polarity or POSITIVE output receptacle for dc straight polarity with flat side towards receptacle key. 2. Rotate plug 1/4 turn clockwise. The drive rolls supplied with this unit are of the double usage type: When the grooves become worn, reverse each drive roll, locating the unused groove in position to feed the wire. 3-6. DRIVE ROLL AND WIRE GUIDE INSTALLA- TION (Figure 3-6) Upon initial installation, or as a result of changes in wire size, it is necessary to instal! the required drive rolls and wire guides. Open the hinged door on the left side of the welding power source by turning the two wing-headed screw fasteners in a counterclockwise direction, Install the appropriate drive roils and wire guides as follows: A. Drive Roll Installation 1. Loosen pressure adjustment wing nut {item 1, Figure 3-8) and pivot it free of the cover, Page 18 Jk | ; TA-049 804 Figure 3-6. Drive Rolis And Wire Guide Installation 2. Pivot gear cover (4) away until it is in an open position. mes marge lan Se A ON TOTO E a a 3. Slide drive roll (2) on pressure gear (3) with drive rofl size facing out. Align holes, insert securing screws (5) and tighten. 4, Slide remaining drive roll on drive gear (10) with drive roll size facing in. Align holes, insert securing screws and tighten, B. inlet Wire Guide Installation 1. Loosen the inlet wire guide securing screw (12). IMPORTANT E Wire guides should be installed so that the tip of the guide is as close to the drive roll as possible without touching. 2. insert the inlet wire guide (13) into the drive assembly as illustrated in Figure 3-6. Secure by tightening screw (12). WILEY VAR Behind the drive gear are spring washers. To obtain proper alignment of the drive гой оп the drive gear with the wire guides rotate the drive gear securing bolt (11) thereby moving the drive roll in or out to the desired position. The drive roll on the pressure gear will locate itself on the wire when the gear cover is replaced and the gears mesh together. If further adjustment is necessary to obtain proper align- - ment of wire guides and drive rolls, see Section 6-3. 3-7, GA-20C OR OPTIONAL GA-40C WELDING GUN CONNECTIONS A. Gun/Feeder Connector Installation (Figure 3-6) Wa SAW The outlet guide is provided as part of the gun assembly. 1. Loosen the gun/feeder connector securing knob (7), Wi NIE Wire guides should be installed so that the tip of the guide is as close to the drive roll as possible without touching. 2. insert the gun/feeder connector (6) which includes the installed outlet guide, through the access hole in the welding power source front panel and into the drive assembly opposite the inlet wire guide as illustrated in Figure 3-6 & 3-7. 3. Tighten the gun/ feeder connector securing knob 7). ‚В. Gun Switch Connection (Figure 3-7) — — GUN Cee 0 TRIGGER The GUN TRIGGER receptacle is provided for making switch control connections. Align the keys on the gun switch connector with the keyway on the GUN TRIG- GER receptacle; insert the connector and rotate: clockwise. When the switch connected across this receptacle is closed, the contactor in the welding power source will. energize, shielding gas will flow and wire will feed. 3 - 8. INSTALLATION OF WELDING WIRE SPOOL (Figure 3-6) 1. Remove the retaining ring (18) by pressing the two spring loaded pins inward. Remove compression spring (17) from the welding power source wire spool hub (14), 2. Place the wire spool {16) on the wire spool hub so that the wire feeds from the bottom of the spool into the inlet wire guide as shown in Figure. 3-6, Ensure that the smali pin of the spool hub fits into the small hole of the wire spool. 3.. Compression Spring (17) not required for 12” spools. For 8” spools, use compression. spring. Replace the retaining ring on the hub. 3-9. ADJUSTMENT OF HUB TENSION (Figure 3-6} - Check the hub tension by slowly pulling the wire toward the feed roll. The wire should unwind freely, but the hub tension should be sufficient to keep the wire ‘taut and prevent backiash when the wire feeding ceases. If adjustment is required, loosen or tighten the hex nut {158} on the end of the spindle support shaft ac- cordingly. 3-10. INSTALLATION OF OPTIONAL SPOOLMATIC 1 GUN | A. Shielding Gas Connections DECIAN Pure argon shielding gas is used for alumunum wire welding. Connect the shielding gas hose from the Spoolmatic 1 to the gas regulator - flowmeter on the shielding gas supply. B. Welding Cable Connections (Figure 4-1) Insert Spoolmatic 1 welding cable plug into POSITIVE weld output receptacle with flat side facing the recep- . tacle key. Rotate plug ciockwise 1/4 turn. Figure 3-7. Weiding Gun Connections OM-1303 Page 19 C. Trigger Control Connections {Figure 4-1) SPOOLMATIC ww | control connections. Insert the plug from the Spoolmatic 1 into the receptacle and rotate plug threaded collar clockwise. When the gun switch is closed, the contactor energizes, shielding gas flows and wire feeds, D. Cannister Brake Connections {if Applicable) 1. Remove welding power source left side panel. 2. Locate hole in lower portion of front panel. 3. Cut a hole of equal size in the nameplate. 4. Slide a grommet or similar device over ieads from cannister, 5. Insert cannister leads through hole in front pane! until they reach the two-pole terminal strip 1T on bottom of welding power source. 6. Connect the green colored lead with larger ring terminal to ground stud below terminal! strip 1T. 7. Connect two remaining leads to the terminals on terminal strip 1T. 8. Press grommet or similar device into hole in front panel, 9. Replace left side panel. SUN SECTION 4 - OPERATOR CONTROLS asst css nas Spot Timer/ Pulse On Time Control* —____ || High Range Receptacia |_~ Selector Switch* — Burnback Time Соптго!* —— Duise Off Time Controi* —Eusg Wire Speed Adjustment Controi Gun Trigger Receptacle Voitage Range Selector Plug Low Range Receptacle Positive Weld Qutput Receptacie Polarity Selector Plug Negative Wald Output Receptacie Power Switch y A Voltage Adjustment Contral 9 AT — Spoolmatic Power Receptacle TB-049 807-8 *Modals with SKP panel only Figure 4-1. Front Panel View 4 - 1. POWER SWITCH (Figure 4-1) ON POWER e (С) от Placing the POWER switch in the ON position energizes the welding power source, making the unit operational. Placing the POWER switch in the OFF position shuts the unit down. 4 - 2. VOLTAGE CONTROL (Figure 4-1) ANAL AI IE ARCING can damage contact surfaces, Page 20 e Do not change VOLTAGE ADJUSTMENT switch or VOLTAGE RANGE SELECTOR plug position while welding or under load, о ШО Arcing can damage contact surfaces which can even- tually make the switch or selector plug inoperable, The VOLTAGE RANGE selector plug and VOLTAGE ADJUSTMENT switch provide selection of twelve welding voltages ranging from 10 to 30 voits dc in approximately 2 volt steps with position 6 on the LOW range and 1 in the HIGH range overlapping. Use Table 5-1 to set initial voltage conditions. WGI EWE Give the selector plug a quarter turn when inserting into the receptacle. To remove the plug, give a quarter turn in the opposite direction while withdrawing. | 4 - 3. WIRE SPEED ADJUSTMENT CONTROL: (Figure 4-1) WIRE SPEED ADJUSTMENT do The WIRE SPEED ADJUSTMENT contro! provides selection of the speed at which welding wire feeds into the weld. The wire feed speed range is 60-585 inches . per minute (0.6 - 14,8 meters per minute}. Rotating the : WIRE SPEED ADJUSTMENT control clockwise increases wire feed speed. The scale around the WIRE SPEED ADJUSTMENT control is calibrated in percent and does not indicate the actual wire feed speed. 4 - 4. POLARITY SELECTOR PLUG {Figure 4-1) CAUTION : ARCING can damage contact surfaces. ® Do not change plug position while welding or under load, | Arcing can damage plug contact surfaces which even- tually makes the plug inoperable. The Polarity selector plug provides selection of either de reverse polarity (selector plug in POSITIVE output receptacle, work cable in NEGATIVE output receptacle), or dc straight polarity {selector plug in NEGATIVE output receptacle, work cable in POSITIVE output receptacle). Insert plug into receptacle with flat side facing receptacle key. Rotate plug one quarter turn clockwise. 4-5. FAN CONTROL - The fan motor is ther- mostatically controlled to provide fan cooling of the transformer and rectifier if these components require cooling. Under normal loading, the fan may not run. 4-6. OPTIONAL SPOT PANEL CONTROLS > (Figure 4-1) IZAN /n the PULSE mode, the WIRE - SPEED ADJUSTMENT control must be set at 50 percent or less. Exceeding the 50 percent control setting may trip the circuit breaker in the motor control circuit suspending wire feed. | A. Selector Switch The Selector switch enables the operator to select continuous, spot, or pulsed wire feed operation. Placing the Selector switch in the CONTINUQUS position and depressing the gun trigger feeds welding wire for as long as the gun trigger remains closed. Placing the Selector switch in the SPOT position and depressing the gun trigger feeds welding wire for the length of time sat on the SPOT TIME control. Placing the Selector switch in the PULSE. position and depressing the gun trigger feeds welding wire for the length of time set on the PULSE ON TIME control. At the end of pulse on ‘time, welding wire feeding stops for the length of time - set on the PULSE OFF TIME control. Welding wire feeding continues to pulse on and off for the selected times until the gun trigger. is released. The pulse option provides better control of the heat input to the weld on thin gauge metals, thereby decreas- | ing distortion and the likelihood of melt-throughs, a B. Spot Time/Pulse On Time Control The SPOT TIME/PULSE ON TIME control enables the operator to select from 0.5 to 4 seconds of weld time for spot operation or 0.25 to 2 seconds of pulse time for puise operation. Rotating the control clockwise increases spot/pulse on time. The control scale is calibrated in percent and does not indicate actual spot/ pulse on times. | С. Pulse Off Time Control The PULSE OFF TIME control enables the operator to select from 0.25 to 1 second of pulse off time for pulse operation. Rotating the control clockwise increases pulse off time. The control scale is calibrated in percent and does not indicate actual puise off time. D. Burnback Time Control The BURNBACK TIME control enabies the operator to select the amount of time the electrode wire remains electrically hot after the wire stops feeding. The correct burnback time allows the wire to burn back just free of the weld puddle. If the burnback time is too long the wire could burn back into the contact tube. Rotating the BURNBACK TIME control clockwise increases burnback time from 0 to 0.25 seconds, The control scale is calibrated in percent and does not indicate actual burnback times, 4 -7. OVERLOAD PROTECTION A. Wire Drive Motor A circuit breaker CB1, located immediately above the drive roll assembly on the center baffle, provides protection to the wire drive motor. Shouid the motor be placed in an overload condition, the breaker would trip and suspend all output. It would then be necessary to manually depress the circuit breaker to reset it. B. Main Rectifier À normaily-closed thermostat, wired in series with the contactor, provides protection to the main rectifier. The thermostat opens if the main rectifier is overloaded or if the fan control circuitry fails to activate, suspending all output. The thermostat resets after a cooling period of approximately fifteen minutes. C. Control Circuitry (Figure 4-1) A fuse F1 provides protection to the 115 volts ac control winding on the transformer. The fuse opens if the 115 volis ac winding is overloaded, suspending all output. OM-1303 Page 21 ME SECTION - SEQUENCE OF OPERATION SUN KNIE ELECTRIC SHOCK can kill; MOVING PARTS can cause serious injury; IMPROPER AIR FLOW AND EXPOSURE TO ENVIRONMENT can damage internal parts. e Maintain at least 18 inches (457 mm) of unrestricted space on all sides of unit and keep underside free of obstructions. | © Do not place any filtering device over the intake air passages of this welding power source. ® Keep all covers and panels in place while operating. Warranty is void if any type of filtering device is used or if the welding power source is operated with any portion of the outer enclosure removed. ARC RAYS, SPARKS, AND HOT SURFACES can burn eyes and skin; NOISE can damage hearing. ® Wear correct eye, ear, and body protection. FUMES AND GASES can seriously harm your health. e Use enough ventilation to keep fumes and gases from the breathing zone. See Section 1 - Safety Rules For Operation Of Arc Welding Power Source for basic welding safety information. 5 - 1. WELDING WIRE THREADING КОДОВ ELECTRIC SHOCK can kill. e Do not energize welding power source until instructed to do so. ® Do not touch live electrical parts. The welding wire is electrically energized whenever the gun trigger is depressed. 8 WELDING WIRE can cause puncture wounds; HOT SURFACES can burn skin. e Do not activate gun trigger until instructed to do so. e Do not point gun toward any part of the body or other personnel when threading welding wire. e Allow gun to cool before touching. 1. Install the wire spool as instructed in Section 3-8. Bde WAR Spooled wire has a tendency to unravel when foosened from the spool. Maintain a firm grip on the wire during the threading operation. 2. Cut off any portion of the free end of the wire which is not straight. Ensure that the cut end is free from rough surfaces to permit proper feeding. 3. Loosen the wing nut on the drive roll pressure adjustment, pivot the pressure adjustment free of the cover, and pivot the pressure gear assembly away until it is in an open position. 4. Feed the wire through the inlet wire guide, past the drive rolls, and on into the outlet wire guide. Feed approximately 4 inches of wire into the outlet wire guide. Page 22 5. Close the gear cover making sure the teeth on | the pressure gear mesh with the teeth on the drive gear. The welding wire must also be in the grooves of the drive rolis. 6. Pivot the pressure adjustment wing nut until the washer on the pressure adjustment is seated on top of the gear cover. 7. Turn the pressure adjustment wing nut in a clockwise direction until the drive rolls are tight against the welding wire. Do not overtighten. Further adjustment to attain desired clamping pressure can be made after the welding power source and wire feeder are put into operation. 8. Draw the gun cable out straight. 9. Turn the Line Disconnect Switch and the welding power source POWER switch to the ON position. If the welding power source has spot welding capabilities, place the Selector switch located on the welding power source front panel, in the CONTINUOUS position. 10. Press gun trigger and hoid in until the wire extends about 1/4 in. (6 mm) out of the contact tube, If excess wire feeds out, cut off to 1/4 in. (6 mm) length with side cutters, © 5-2. GAS METAL ARC CONTINUOUS WELDING - 1. Thoroughly clean the joint area of the base metal with sandpaper or wire brush. 2. Slowly open the gas cylinder valve. Adjust the regulator for desired flow rate. 3. Place the Line Disconnect Switch in the On position, 4, Place the POWER switch in the ON position. 5. If the welding power source has been idle for any length of time, air will begin to displace the shielding gas in the gas hose between the gas valve and the gun. To avoid contaminating the weld, release drive roll pressure and depress the gun trigger for approximately fifteen seconds to purge the gas hose. Retighten drive rolls. EZ GNIDIE ELECTRIC SHOCK can kill; ARC RAYS can burn eyes. e Do not touch live electrical parts. e Keep the welding wire isolated from the work clamp or any conductive surface when not welding. The welding wire is electrically energized whenever the gun trigger is depressed. The difference in potential between the welding wire and the work clamp (or workpiece or table if the work clamp is connected to either) will cause current to flow if contact is made. Select the desired weld current polarity by inserting the Polarity selector plug in the POSITIVE or NEGATIVE output receptacle. Electrode positive (Reverse Polarity) produces deeper penetration and a flatter bead crown. Electrode negative (Straight Polarity) produces shallower penetration and a higher bead crown. Insert the work cable in the remaining output . receptacle. Connect the work clamp to the Set a voltage condition with the VOLTAGE RANGE selector plug and VOLTAGE ADJUST- MENT control appropriate for the base metal thickness and type of shielding gas (see Table 6. 7. workpiece. 8. 5-1). 9, Set a wire speed condition with the WIRE SPEED ADJUSTMENT contro! appropriate for the wire diameter size and base metal thickness (see Table 5-1). The wire speed setting can be adjusted while welding to fine tune the arc. DE Electrode extension approximately 1/4 in. {6 mm} beyond gun nozzle with a sharp end en- sures a smoother start. 10. 11. 12. Position wire over joint. Lower welding helmet; depress gun trigger, and begin welding, maintaining a distance of approximately 3/8 in, (9 mm) from end of nozzle to workpiece, At the end of the joint, release the gun trigger, and then pull the gun away from the joint. 5 - 3. GAS METAL ARC SPOT WELDING (Models With SKP-35 Panel Only) 1. Thoroughly clean the surface area of the base metal with sandpaper or wire brush. | 2. Slowly open the gas cylinder valve. Adjust the reguiator for desired flow rate. | 3. Remove the standard nozzle and install the appropriate spot nozzle. 4. Place the Line Disconnect switch in the ON position, 5. Place the POWER switch in the ON position. 6. Hf the welding power source has been idle for any length of time, air will begin to displace the shielding gas in the gas hose between the gas valve and the gun. To avoid contaminating the weld, release drive roll pressure and depress the gun trigger for approximately fifteen seconds to purge the gas hose. Retighten drive rolls. RULE ELECTRIC SHOCK can kill: RAYS can burn eyes. ® Do not touch live electrical parts. e Keep the welding wire isolated from the work clamp or any conductive surface when not welding. The welding wire is electrically energized whenever the gun trigger is depressed. The difference in potential between the welding wire and the work clamp (or workpiece or table of the work clamp is connected to either) will cause current to flow if contact is made. ARC 7. Place the Selector switch in the SPOT position. Table b-1. Suggested Parameters For Continuous Welding RANGE LOW HIGH Voltage Adjustment 1 2 3 4 5 8 1 2 3 4 5 6 Metal Gages 24-22 20-18 19-16 18-16 18-14 14-12 12-10 10-174" 1/47 + t/4 + . inches 024. 032 036-.043 048-080 .048-.0680 .080-.075 .075-.105 105-.135 .135-.250 .280 + 250 + Thickness Milirmaters 81-81 ‚91-1.22 1,22-1,52 1.22.1.62 1.52-1,91 1.91.2.87 2.67-3.43 3.43-6.36 6.35 + 8.35 + Wira Speed Adjustment 1 _ _ 023-025 1.6 mm) wira 20% 5% 19% 30% 405 50% Wire Speed Adjustment 12% 10% 28% 35% 40% 45% 50% 80% 70% ‚030 [.8 mm} wire Wire Speed Adjustment 59% 15% 25% 30% 40% 45% 48% 57% 70% .036 {.9 mm} wire Wire Speed Adjustment 5% 10% 14% 25% 30% 36% 40% ‚045 (1.2 mmi wire Suggested Parameters For Aluminum Wire (4043) With Spoolmatic 1 Gun Using Argon At 25CFH RANGE LOW HIGH ‘Heat Control 1 2 3 4 5 6 1 2 3 4 5 8 Wire Speed Satting SC Spray | SC Spray | SC Spray) SC Spray | SC Spray} SC Spray| SC Spray SC SPray | SC Spray 030 1.8 mm} wire 5%. |5% -. 15% - 185% - [8% 55%[65% 5% |7.5% 6.5% E — Wire Speed Satting 5% 5% 5% 15.75% 6% 5% [6.5% 5% [7.5% 6% [8.5% 6% [3.5% 7% .036 [9 mm) wire Wire Speed Setting 4% 5% 5% 156% 4 15% 45%| 5% 4.5% 5% 5.5% 3/64 (1.2 mm) wire SC = Short Circuit OM-1303 Page 23 8. Select the desired weld current polarity by inserting the Polarity selector plug in the POSITIVE or NEGATIVE output receptacle. Electrode positive (Reverse Polarity) produces deeper penetration. Electrode negative (Straight Polarity) produces shallower penetration. 9. Insert the work cable in the remaining output receptacle. Connect the work clamp to the workpiece. Wis LYLE Weld voltage and wire speed are relatively high for spot welding compared to continuous welding. : 10. Set a voltage condition with the VOLTAGE RANGE selector plug and VOLTAGE ADJUST- MENT control appropriate for the base metal thickness and type of shielding gas. 11. Set a wire speed condition with the WIRE SPEED ADJUSTMENT control appropriate for the wire diameter size and base metal thickness. 12. Set a weld time with the SPOT TIME control appropriate for the base metal thickness and welding conditions. 13. Seta burn back time with the BURNBACK TIME control that will allow the wire to burn back just clear of the weld nugget. 14. Cut the welding wire off slightly back inside the spot nozzle. 15. Position the spot nozzle against the workpiece and depress the gun trigger. After the arc goes out, raise the gun. If the wire sticks in the weld puddle, release the work clamp and depress the gun trigger. Wire will feed out, raising the gun from the work. Cut the wire off close to the weld nugget, and slightly back inside spot nozzie, Ín- crease BURNBACK TIME adjustment. If the wire burns back into the contact tube, remove the nozzle. |f the wire has not burned back completely into the contact tube, it may be possible to pull the wire out of the tube with a pliers. If a complete burnback has occurred, remove the contact tube, cut the wire off behind the tube, and reinstall a new contact tube. Replace the nozzle and decrease BURNBACK TIME adjustment. Table 5-2. Suggested Parameters For Pulsed Con- — tinuous Welding RANGE “ LOW HIGH Voitage Adjustment 2 3 4 5 6 1 Metal Gages 24 22 20 18 16 14 Thickneas Inches .024 | .030 | .036 | .048 060 | .075 Milimatars | .61 78 31 1.22 1.52 | 1.91 Puise On Time % 10% | 10% | 10% 10% | 10% Puisa Off Time % 10% | 10% | 10% 10% | 10% Wire Speed Adjustment 25% | 36% | 59% 75% | 87% .923-.025 (.6 mm) wire Pulse Qn Time % 10% | 19% | 10% | 10% 10% | 10% Pulsa Off Tima % 10% | 10% | 10% | 10% 10% | 10% Wire Speed Adjustmant | 15% | 25% | 35% | 46% 55% | 66% 430 (8 mm) wire Pulsa Ón Time % 20% | 20% | 20% | 20% 20% | 20% Pulsa Off Time % 10% | 10% F 10% | 10% 10% | 10% Wire Speed Adjustment | 14% | 20% | 25% | 35% 40% | 45% 035 (.9 mm) wire MS A —— 5 - 4. GAS METAL ARC PULSED CONTINUOUS WELDING - Pulsed continuous welding requires the same set-up procedures as continuous welding with the following additions: Set pulse on and pulse off times, wire fead speed, and weld voltage appropriate for the base metal thickness and wire diameter size (see Table 5-2). la Za NE Move the gun across the joint at a slightly slower travel speed when pulsing. 5-5. SHUTDOWN 1. Close the gas cylinder vaive. 2. Depress gun trigger to release gas in regulator. The gas pressure indicator will return to 0. 3. Place the POWER switch in the OFF position. 4. Place the Line Disconnect Switch in the Off position. PULGOUNGE HIGH CONCENTRATION OF SHIELDING GASES can harm health or kill. e Shut off gas supply when not in use. — SECTION 6 - MAINTENANCE & TROUBLESHOOTING =manommnecemmenes MKDILISE ELECTRIC SHOCK can kill. ® Do not touch live electrical parts. ® Disconnect unit from input power before internally inspecting or servicing. MOVING PARTS can cause serious injury. e Keep clear of moving parts. HOT SURFACES can cause severe burns, e Allow cooling period before servicing. Troubleshooting of internal parts to be performed only by qualified persons. ide ENEE Periodically inspect the labels on the unit for legibility. All precautionary labels must be maintained in a clearly readable state and replaced when Page 24 necessary. See Parts List for part number of all precautionary labels. 6 - 1. FAN MOTOR - This unit is equipped with an exhaust fan and relies on forced draft for adequate cooling. The fan motor is manufactured with lifetime sealed - bearings and requires noc maintenance. 6 - 2. INTERNAL CLEANING - Occasional blowing out or vacuuming of the dust and dirt from around the internal components is recommended. This should be done periodically depending on the location of the unit and the amount of dust and dirt in the atmosphere, The welding power source outer enclosure should be remov- ad and a clean, dry airstream or vacuum suction should be used for this cleaning operation. 6 - 3. DRIVE HOUSING REALIGNMENT (Figure 3-3) - The wire drive housing is made with mounting holes of sufficient clearance to provide adjustment of the wire guides up or down in relation to the drive rolls. This adjustment has been factory set, but if readjust- ment becomes necessary, disconnect input power and remove the welding power source wrapper, Loosen the mounting bolts (8) and the weld terminal bolt (8) securing the wire drive housing to the mounting plate. Slide the drive housing upward or downward until the wire can be fed straight through the guides while seated in the drive roll groove. Tighten mounting bolts and weld terminal bolt. 6 - 4. TROUBLESHOOTING THE WIRE FEEDER SYSTEM | A. General It is assumed that the unit was properly installed accor- ding to Section 3 of this manual, the operator is familiar with the function of controls, the welding power source - was working properly, and that the trouble is not related to the welding process. B. Troubleshooting Chart EINEN ELECTRIC SHOCK can kill. ® Do not touch live electrical parts. e Disconnect unit from input power before internally inspecting or servicing. MOVING PARTS can cause severe injury. ® Keep clear of moving parts. HOT SURFACES can cause severe burns. e Allow cooling period before servicing. Troubleshooting of internal parts to be performed only by qualified persons. The following chart is designed to diagnose and provide remedies for some of the troubles that may develop in this welding power source. Use this chart in conjunction with the circuit diagram while performing troubleshooting procedures. If the trouble is not remedied after performing these procedures, the nearest Factory Authorized Service Sta- tion should be contacted. In ail cases of equipment malfunction, the manufacturer's recommendations should be strictly followed. TROUBLE PROBABLE CAUSE - REMEDY No weld output; wire does not feed. Primary Switch in Off position. Line Disconnect Place Line Disconnect Switch in On position. open. Line fuse or circuit breaker Replace line fuse or reset circuit breaker. Control fuse F1 open. Replace fuse F1. Gun switch defective, or gun switch leads open, Replace gun switch (if applicable} or repair switch leads. POWER switch S1 defective. Replace POWER switch $1. Switch control relay CRT (or CR2 when using a Spoolmatic 1) defective. Replace relay CR1 (or CR2)., No weld output; wire feeds. Thermostat TP3 open. Allow approximately fifteen minute cooling period. Check for blocked air passages, excessive overloading, or defective fan motor or fan control circuitry. VOLTAGE RANGE selector piug or Polarity selector plug not secure in receptacle. . Secure connection. Work clamp connection loose or incomplete due to rust, paint, etc. on surface of workpiecs. Remake work connection ensuring good metal to metal contact. Defective contact tube. Replace contact tube. VOLTAGE ADJUSTMENT switch between positions. Place VOLTAGE ADJUSTMENT switch in proper position. OM-1303 Page 25 TROUBLE PROBABLE CAUSE REMEDY Contactor points defective. Replace points. Contactor coil W defective. Replace contactor coil W. 1 tor ' Spoolmatic 1) defective. Switch control relay CR1 CR2 when using a Replace relay CR1 (or CR2). Low weld output, Low primary voltage. Connect unit to proper input voltage. Input voltage jumper in wrong position. Place jumper link in position matching primary input voltage. Electrode wire stops feeding while welding. Sharp or excessive bend in gun cables or liners. Straighten gun cables and/or replace liners. Drive roll pressure too great or two little. Apply correct drive roll pressure. Spindle friction too great. Loosen and re-adjust hub tension (see Section 3-9). Contact tip orifice restricted: burnback of electrode. Replace contact tube. Friction in gun. Check wire passage; clean, replace parts as required. Gun casing liner dirty, restricted. Remove liner, blow out with compressed air, Broken or damaged casing or liner, Replace faulty parts. Drive roils worn; slipping. Replace drive rolls. Drive motor burned out. Replace motor. Gun trigger switch defective or wire leads broken. Replace switch; check connections. Fuse blown in power source primary. Replace fuse. Circuit breaker CB1 tripped. Reset circuit breaker CB1. Excessive loading of drive motor. Clear restriction in drive assembly. Wire drive rolls misaligned. Re-align drive rolls. Spot weld timer does not time out (models with SKP-35 panel). Defective SKP-35 panel. Replace panel. Pulsed wire feed operation not available. Defective SKP-35 panel. Replace panel. Page 26 ——_— am TR Em НН он TE TE EET Em A AA ee A ЕЁ тв ee == A A тан = == =4) e | #7 HI | 44 el (Fr has + El D3 } dr] } <0 Al f SR <a } ——l | «di oR и ] CE | =} toa © | Lo, } | i = | PLGI ‚ MEE <—] | — + m C9 | я 1 3 | В | о $ | al << oF | 7 a | CANISTER | > | 1-1: В 14 I N | o 17069 | A a | | | | Ca Г e | RCsy _ SEMA LS 000 | Ga ЛК Bi FROM a - DRIVE ROLL WIRE DRIVE A “гг MOTOR SCA UHIJUNCTION NE LEAD END VIEW A ' = a * = = ————- a Circuit Diagram No. B-086 101-B Figure 6-1. Circuit Diagram For Welding Power Source ` 54 Circuit Diagram No, A-086 594 Figure 6-2. Circuit Diagram For SKP-35 Panel OM-1303 Page 27 10 + 7 la CR50 5 5 ] 057% (© ; 8 0 ig © 50 19 CASI > a ¿ie "> - но 050 R do 5 e Osa С 12 $22 #19 __ 020 8721 _ _ 7 _ 45. Circuit Diagram No, B-086 783-В Figure 6-3. Circuit Diagram For SKP-35 Panel Printed Circuit Board Page 28 6 - 5. TROUBLESHOOTING THE GAS METAL-ARC WELDING PROCESS A. Porosity | | Dormant RII ITR la NEC LAN Rc re Figure 6-4, Porosity | Possible Causes Corrective Actions 1. Inadequate shielding gas coverage. Remove spatter from the gun nozzle. Check gas hoses for leaks. Eliminate drafts {from fans open doors, etc.) blowing into the welding arc. Reduce nozzle-to-work distance. Increase gas flow to displace all air from the weld zone. Decrease excessive gas flow to avoid turbulence and the entrapment of air in the weld zones. Hold gun at end of weld until molten metal solidifies. Check for frozen CO2 regulator flow meter. 2. Gas contamination. Use welding grade shielding gas. 3. Electrode contamination, Use only clean and dry electrode. Eliminate pick up of ail or lubricant on electrode in electrode feeder or conduit. : 4, Workpiece contamination. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding. Use a more highly deoxidizing electrode wire. 5. Excess tip-to-work distance. Reduce stick-out. OM-1303 Page 29 Incomplete Fusion {Lack of fusion) ee à 1 Er rrr на a mets Figure 6-5. Incomplete Fusion - Possible Causes Corrective Actions 1. Weld zone surfaces not free of film or | Clean weld zone surfaces of impurities prior to welding. excessive oxide. 2. Insufficient heat input. Select higher voltage tap. 3. Improper weld technique. When using a weaving technique dwell momentarily on the side walls of the groove. Provide improved access at root of joints. Kesp electrode directed at the leading edge of the puddie. Provide proper gun angle. 4, Improper joint design (Heavy material | Provide included angle of groove joint large enough to allow access to | oniy: trailer hitches, etc.) bottom of the groove and sidewalls with proper electrode extension and arc characteristics, or use a “J” ог О” groove. C. Lack Of Fusion Figure 6-6. Lack Of Penetration Possible Causes Corrective Action 1. Improper joint preparation. Material too thick. Joint preparation and design must be adequate to provide access to the bottom of the groove while maintaining proper electrode extension and arc characteristics. Reduce excessively large root face. Provide or increase the root gap in butt joints and increase the depth of back gauge. 2. Improper weld technique. Maintain electrode angle norma! to work surface to achieve maximum penetration. Keep arc on leading edge of the puddle. 3. Inadequate heat input. Select higher voitage tap and wire speed. Reduce the travel speed. Maintain proper electrode extension. Page 30 Figure 6-7. Excessive Penetration Possible Causes Corrective Actions 1. Excessive heat input. Select lower voltage tap and reduce wire speed. increase travel speed. E. Cracks In Weld Metal Possible Causes Corrective Actions 1. Improper joint design (Heavy material). Maintain proper groove dimensions to allow deposition of adequate filler metal to weld area. | 2. Heat input too high causing excessive shrinkage and distortion. Select lower voltage tap and reduce wire speed. Increase travel speed. FF. Waviness of Bead Figure 6-8. Waviness Of Bead Possible Causes Corrective Actions 1. Excessive electrode extension. Reduce electrode extension. 2. Unsteady hand. Support hand on solid surface. G. Humping Possible Causes Corrective Actions 1. Too much heat input. Select lower voltage tap or increase travel speed. Weld in small segments and allow to cool between welds. H. Excessive Spatter Possible Causes Corrective Actions 1.Excessive spatter when using CO shielding gas. Select lower voltage tap or adjust WIRE SPEED FINE ADJUSTMENT. OM-1303 Page 31 January 1983 FORM: OM-130: — Effectiv e With Serial No. JC629243 cee _—— MODEL MILLERMATIC 200 OM-1303 Page 1 11 Я Л e Ks For Parts List Of Gun See OM-1025 FigC TD-049 812-D Figure À - Main Assembly Item Dia, Part | | | | No. Mkgs. No. Description Quantity Figure À Main Assembly 1 +007 778 WRAPPER ........ i ee ee ee da an à 1 047 497 LABEL, general precautionary Cee aa aa a aa a 06 ree. 1 2 - 057 506 PAÑEL, side, ..........oeoorcrecooeorere reroaioreraarer acera rao enero 1 3 Figure B_BAFFLE, air-with components (See Pg 4) ...................0.0..000080000.. 1 4 604 550 HOSE, neoprene No. 1 x 3/16 (order by ft) ................e2eées0r0recee, 3 ft 5 Figure E PANEL, rear-with components (See Pg 12)................0.e0ees0vaa 00 1 6 010 296 FITTING, hose-brass elbow male 1/4 NPT x5/8-18 righthand .............. 1 7 GS 003 538 VALVE, 2 way 1/4 IPS 1/8 orifice Controls Co (consisting of) or............. 1 003 539 . COIL, 116 voltsac........1020 214 4 Aa AA Aa da A 4 aa da a da a ea aa aa ane 1 7 080 841 VALVE, 2 way 1/4 IPS 1/8 orifice Eemco (consisting of) ................. .. 1 080 872 . COIL, 115 мой ас...аоее асе аовоуоннаувнуунаануооя Cee PT E - 8 010 678 FITTING, pipe-brass elbow st 1/4 NPT couture ieee, . 1 9 073 433 FITTING, brass-barbed male 3/16 TBG Xx 1/4NPT. .. corinne. 1 10 038 778 RECEPTACLE, straight 2P3W 80 amp 250 volts. ..........._..er.reerercooa 1 11 PLG1 047 721 CORD, power 250 volts3C B ft ..............—...e2exeexeexewccccoraa0oe 1 11 PLG? +071 906 CORD, power (230 volts and over) ........... e. exce e a o ea anooa o 1 11 PLGT +041 688 СОВО SET, power 10 ga 3C 25ft................0e. 000 000 00d0 az 1 12 044 426 CONNECTOR, clamp-cable 1 inch ................0c00000000000 000 e AA 1 13 TE 081 862 TERMINAL ASSEMBLY, primary (consisting of) ....................,..... 1 14 026 631 . INSULATION........... 000,000 e ecarreoaoecaranicaarecoTaracoro, ~~ b 15 038 6818 . LINK, jumper .........._.eoorerxedicareaae rear en eden ceaoacaiacoaea 1 16 081 671 , TERMINAL BOARD .............r.eemecccco,ecaareraaceaeonencaa av ` 17 038 887 . STUD, brass No, 10-32 x 1-3/8 w/hex collar ............._..... 00, 5 18 | 010 913 . WASHER, flat-brass 0.225 1D x 1/2 0D x 1/32 ovina, 5 19 601 835 . NUT, brass-hex 10-32 ........e._.....ece0esridireeaaaoarercaooaooaaa 10 20 TI 088 770 TRANSFORMER, power-main (See Fig C Pg 4) ....................00. 0... 1 TP1 084 680 THERMOSTAT, NO... LL 4 4e a a A ed aa a a aa a aa aa aa aa aa nana 1 21 Zz 081 7168 STABILIZER. oii ir es tee eee aa a aa a da a na a ana anna 1 22 A | 1 23 1T 038 855 BLOCK, terminal 20 amp 2 pole ................ ee. encarar edr ana 1 24 Figure D PANEL, front-with components (See Pg 10) ...................20.0s. 1 25 See Note GUN ..........eéeeecsdedece enero onone arce eardcataredeCeraraai 1 26 RW 008 073 HOUSING RECEPTACLE Er SOCKETS (consisting of) .................c_... 1 058 972 . TERMINAL, female................... eee renee ee 8 27 008 040 CONNECTOR, jumper .........e.....0000cd0arerederecareda ee 1 28 010 855 RETAINER, screw NO. 2... ii iii ii iii i eee, 2 29 072777 LABEL, instruction .............. .. 2.0 eee ii 1 30 605 217 FASTENER, screw-Wing ............_eeccrrcoreoearercecedewceonoorecor 2 057 745 SPRING, compression-wire spooal............ ...oeveveree.. Cees 1 041 233 NO. 10B RUNNING GEAR (See Fig GPg 15) ................ 0. coca 1 TOptional Parts. | + When ordering components originally displaying a precautionary label, the label should also be ordered. Note: For complete breakdown of gun зее ОМ-1025. BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACMENT PARTS. OM-1303 Page 2 See Chart on Page 4 For Available Drive Rolls TC-04%3 810-8 T8-049 926 Figure C - Transformer, Power - Main Page 3 item Dia. Part | No. Mkgs. No. Description Quantity Figure B Baffle, Air - With Components (See Fig À Pg 2 Item 3) 1 058 427 RING, retaining-spool.............. andrarececaredecorercare care nrrarena 1 2 085-980 NUT, steel-hex 5/8-11 ...............—e—eerereoaa0eo, teeter ea 1 3 605 941 WASHER, flat-steel 41/64 ID x 1 OD x 14 ‘© RAR куку валу овванеовее 1 4 057 543 SPRING, compression ............_eeonea enorenercororarroorreevara daa 1 5 057 971 WASHER, flat-steel keyed 1-1/2 dia ....... see RAS RIRE 1 6 058 424 WASHER, fiber-brake ......... eee rire terre eee 2 7 058 428 HUB, spaol vivitar a à 1 8 083 102 BAFFLE, air ................,. fee eee eae 1 9 083 147 GROMMET, screw-push in ..............ececeroocerede a Cera Cee 6 10 082 902 STRIP, mounting-center .......... ocurra aococricovacooraronvendra aa 1 11 082 307 ANGLE, mounting-righthand ................. eee [PP A 12 C18 084 087 CAPACITOR, electrolytic 15,000 uf 45 volts de ............_..-eoecere re ea. 8 13 082 875 ANGLE, mounting-lefthand ..................... RS 1 14 057 314 CIRCUIT CARD ASSEMBLY (See FigB1Pg8) ......o iii iin. 1 15 Figure B2 PANEL, control-with components (See Pg6)............... EHER ER 1 16 000 382 LINK, jumper-contactor .........—...eoocorceccoreccarorieceai crecen e» ‘en 2 17 W 032 786 CONTACTOR, 60 amp 3 pole 600 volts (consisting off ...... PAS 1 035 837 . COIL, 115 volts... 011144 a ee ea 04 A4 da 4e a 0 Aa na aa aa da aa anne 1 *071 043 KIT, points. ...121002 14404 4442 4 4 a 6 0 4 4 ee a 4 8 4 a 4 8 a 8 48 a KR KK RER 1 18 SR2 035 914 RECTIFIER, integrated 30 amp 400 volts. .........._.es_oeereseneoreoarevev. 1 VR2,3 082 722 VARISTOR, 0.6 watt 175 volts de ................ rea 2 19 010 143 CLAMP, nylon 3/8 clampdia ................ee00eediorooiio e arieredoaaao 1 20 R16 079 781 RESISTOR, WW fixed 25 watt 50 ohm ............eor.recesrecocerercercere 1 21 C13 000 339 CAPACITOR, electrolytic 200 uf 40 volts de ......0.000000 aan nana 1 22 R15 604 288 RESISTOR, WW fixed 10watt2ohm ................... ee 1 23 CBi *011002 CIRCUIT BREAKER, manual-reset 0.7 amp ...........e.eeee00ddc0aa0a 00 1 24 010 145 CLAMP, nylon 1/2 dia ..............e.eeesvesoso rare carr ear anoCooocoraa 2 010 357 RECEPTACLE, clipon ............ec_er.e.cesrereon rar aareacor coronada à 2 25 Figure B3 DRIVE ASSEMBLY, wire (See Pg8) ...... eet te ere 1 Kit, Drive Roll & Guide Tube Wire Diameter & Type *Roit, Drive Guide Fraction | Decimai | Metric | Kit No. Type Part No. Inlet 030” 030 | .8MM | 079 594 | V-Groove | 053 695 | 056 192 036” 035 | .9MM | 079 595 | V-Groove | 053 700 | 056 192 045” 045 11.2MM | 079 596 | V-Groove | 053 697 | 056 192 Drive Roil & Wire Guide Kits item Part No. — No. Description Quantity Figure C 088 770 Transformer, Power - Main (See Fig A Pg 2 Item 20) 1 081 702 TRANSFORMER SUBASSEMBLY (consisting of) ...........—..0.e.ee..eveca.o 1 2 — 028 967 . WEDGE, 5/16 X 1x7 oti ie ee 2 3 026 345 . STRIP, polyester-glass laminate 1/16 x2x3-3/8 .............. J 4 4 1 **088 538 Coil, primary/secondary e enarar rara reriorervanreraorararcaranororaere raven *Recommended Spare Parts. **Replace At Factory Or Factory Authorized Service Station. BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-1303 Page 4 Dia. Part Mkgs. No. Description Quantity Figure B1 057 314 Circuit Card Assembly (See Fig B Pg 4 [tem 14) C2,3 031 694 CAPACITOR, mylar 0.47 uf 200 volts de .......... erariarerierro recrea or cea a» 2 C4,8,9 031 643 CAPACITOR, ceramic 0.01 uf BOO VOIIS dC. . Lo. i ities ee tee teens 3 C7 031 693 CAPACITOR, mylar 0.33 uf 75 vols dC oii tte ie eet et ranean 1 C10 031 633 CAPACITOR, electrolytic 80 uf 25 voits dc... 00220 a a ae a aa a a aa ane a 1 C12 031 721 CAPACITOR, mylar 0.22 uf 200 voits dc........1101111 014 ae eee a a ae a nana 1 D1-4 026 202 DIODE, 1 amp 400 volts straight polarity ................_.ees0r00arecrede ea. 0 4 DS 037 250 DIODE, zener 24 volts 1 watt. .........ec_ooorerarcrecoreciroresararenovadercea 1 QT 037 824 THYRISTOR, 7.4 amp 200 volts... 1101040 4 44 44 4 0 8 4 a A4 A 4 a 4 a a 4 ad a ea a a ann à 1 010 915 WASHER, flat-brass 1/4 (mounting QT) 1.111004 4 04 414 da 4 sa a a ea ae ana nue» 1 602 208 WASHER, lock-steet externai tooth 1/4 (mounting Q1) ..........co ivi... 1 601 867 NUT, steel-hex jam 1/4-20 (mounting Q1) ..............2.0e00 00d AA 1 037 261 HEAT SINK ............... 0. rre icarederecaceonoerorereocacacerecñecvoaren 1 Q2 037 289 TRANSISTOR, unijunction 50MA 35 volts .............ee ee eerecdirere 0. e. 1 R3 030 937 RESISTOR, carbon 0,5 watt 10 ohm ..........e..0..0erecoarec0oacireracaarero 1 R4 030 864 RESISTOR, carbon 0.5 watt 18K Ohm. oti i roe ce ee eee eee, 1 R6 030 945 RESISTOR, carbon 2 watt 4700 ohm. RAR RR à 1 R7 028 276 RESISTOR, carbon 0.5 watt 2200 ohm... ovine ee eee eee eee ees 1 R8 030 944 POTENTIOMETER, WW 1 turn 2 watt 5000 ohm ...........w_eeocoereoccoacacoaa. 1 R9 030 936 RESISTOR, carbon 0.5 watt 33K ochm itt ie eee ee st ete ee 1 R10 030 853 RESISTOR, carbon 0.5 watt 2200 ochm citi ee ee ee eee aaa 1 R11 030 938 RESISTOR, carbon 0.5 watt 1200 ohm 1111111004 a da aa ea a a a ana aan 1 R12 030 934 RESISTOR, carbon 0.5 watt 6800 ohm .. 1.111111 LL an La da a a aan aa 1 R20 030 090 RESISTOR, carbon 0.5 watt 47 ohm ...........0.0e00esesarvcas0edareacieaaceca 1 T2 085 399 TRANSFORMER, DUISE . ott iii titi tt ee er ee i ee ces ci, 1 R8 — < О) ВВ ED CA cio — AMS © Of lx 18 C12 — © C3 Ce © a R6 nn — COMPONENTS TO BE REPLACED BY QUALIFIED PERSONNEL ONLY TA-057 314 Figure B1 - Circuit Card Assembly BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. Page 5 Item Dia. Part No. Mkgs. No. | Description | Quantity Figure B2 . Panel, Control-With Components (See Fig B Pg 4 Item 15) 1. 026 837 INSULATOR, terminal-nylon.................. nenveraariccorornrovredeaa 3 2 CR1 034 841 RELAY, 24voltsac DPDT ... iii iin. ee teen 1 010 026 202 DIODE, rectifier 1 amp 400 volts straight polarity ........ J 1 3 004 255 PÂNEL, mounting-component .....2202002 000044 aa 4 4 aa a 4 a ea aa a 4 A A 1 a aa a 4 0 1 4 010 301 BUSHING, brass 0.106 ID x 1/4 OD x5/16 ..............e ee... eran. 1 5 031 251 BRACKET, mounting-RC5........._eeooecerecrescio.aoarodeoorerarereceneo 2 6 RCH 039 756 CONNECTOR, edge 10 pin ..........e0e..eesdderedarorasó ao a nooo arov. 1 7 038 784 STRIP, terminal 1 pole ...........ee.eeceoororecdrroceroareoereraorendaene aa 1 8 R21 028 276 RESISTOR, carbon 0.5 watt 2200 ohm ARR eae 1 9 601 375 RING, mounting-capacitOr RR RR à asados 1 10 C1 031 698 CAPACITOR, electrolyte 250 uf 175 volts de ............ e... .. enana 1 11 CR2 052 964 RELAY, 24 voltsdc DPDT ..... er tt ee ee ee eae 1 12 Rt 030942 RESISTOR, WW fixed 12 watt 10 ohm ..........e....e. aaa 1 052 704 CLIP, spring-mtg resistor ............_—_eoeeeerececeosv der ddaderecóean a 2 13 SR1 035914 RECTIFIER, integrated 30 amp 400 volts ...........__.eeerreageodoroaedaoon 1 VR1 082722 VARSISTOR, 0.6 watt 175 volts de ,............e.eeeecuirer ri eea ri ececemo 1 14 =ÑR2 030 941 RESISTOR, WW fixed 100 watt 5 ohm .............—.e. Crete 1 11 TA-049 815 Figure B2 - Panel, Control - with Components BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. | | OM-1303 Page 6 Y -BLL E6PO-IL энд ‘Ajquessy Эли - ся e:n6 GL 91 L “< SIT y A I~. ноу MG КУ vI 3 EL SUrOY sopnjou| SIJOH 9AUG ajGejeAY 103 у эбед чо HEY 395 ‚ Раде 7 item Part - | | No. No. Description Quantity Figure B3 Drive Assembly, Wire (See Fig B Pg 4 item 25) 048 159 DRIVE ASSEMBLY, wire (Consisting Of) .............coe.r..e.0c08recicararrece ne 079 633 . FITTING, hose-brass barbed nipple 3/16 TBG LL. 4001204660 aa a a a ea 0e a aan a sa 006 081 709 . HOUSING, adapter-gun/feeder.......002 0004044 eee a a a aa 4 0 4 0 aa a aa a a sa dan a na 00 a 085 243 . KNOB, adjustment-tension ...........eweoéxrercocecosrererarererevenrere re vena 085 244 . WASHER, cupped-steel .........._.ee..crevondrorcrredcacrerreverarvecórereoveo 010 231 .SPRING, compression ............_ee0-rxveeorooreeceraracaracorararoecocaeeo, 085 242 FASTENER, pinned... oi i i i i tt it etter cea 010 224 . Р\№, зрипа-сотпргеззЮют 3/16 х 1 .................... a KR 601 925 . SCREW, cap-steel hex hd 1/4-20x1/2 ..... avecreoreria RAA AAA 10 604741 .PIN, cotter-hair 0,042 x 15/16.............-ese.eomrÑeciaereacdevrrerrereaneoecendoco. 11 079 669 . LEVER, mounting-pressure gear ........ Cee eee er ere 12 079 634 |, PIN, RINGO. otitis et ert et tame tte aia aaa 13 079 772 KNOB, Plastic. vot it it ete ret tt et te ter eee ee ete ce 14 604 538 . WASHER, flat-steei SAE 5/16 ...........e00.0ecor0oorrre dea ie, cena venarerdea, 15 605 518 SCREW, cap-steel hex hd 1/4-20 x1-1/4..........—.ew_w.eovecoveredrverareoetr eve 16 079626 SCREW, machine-steel fillister hd 10-32 x 7/8 ..........w..eesccoesvrae ere ee. 17 053 842 GEAR, spur-insulated w/bearing ...........__.._e—eerecrerecorrrsar ener iar e area, 18 605 308 RING, retaining ........._.e_eerereasrrrerecerredaearoeocedaren ares rerecer ena 19 079625 WASHER, spring-steel 9/16 .........._...resevececadarierecorieorvecraodererme. 20 053 841 GEAR, spur-insulated w/key ........_._.—c_.eeovecovceaarerereeavverevcoraecev rene 21 602 241 WASHER, flat-steel SAE 1/4 ............-esvccscorecrenvrvieenmerrearvorerecea ceo. 22 000 418 SCREW, cap-steel hex hd 1/2-20 x 1/2 self-locking ..............csrecdoe rare ee... 23 048449 BUSHING, flanged-nylon ............o_e.eeeso0rdrrore dae ea rec evade dercercere, 24 601 8338 NUT, brass-hex 3/8-16 ............cecs0vrciedivedadro decia dea reneo0aavdearenca, 25 602 213 WASHER, lock-steelsplit3/8 .................. ree ea a ea 26 010 910 WASHER, flat-stael SAE 3/8... iii i te 8 ee ee 8 4444 a 0 da a A ae ea 40 27 079 635 INSULATOR, MOO Lo. iii i iti te tetera tment iia raters 28 081 699 BRACKET, mounting-drive assemblywire .,.................. eee a 29 075 150 WASHER, fiber-shielded 0.622 x1 Xx 3/8... iii iii iit 4 ee sa ae een 6 30 038804 STUD, brass 3/8-168 x 2-1/2 iii i ree er eceararcar naa. Naveda 31 6046 948 MOTOR, gear 1/20 hp 115 volts de 3450 rpm (consisting:0f) .............e.eereevens *058 422 .BRUSH.........ecreccecrecarrovenoraraererecerarenraredrvvareroveooonra ae 058 423 . SPRING :........eesrercdrerearere acarrea rerrareanecorrereerecarecrereorea 057 432 . SCREW, cap-brush holder ..............__oereceereeesrrdrececaarameeocan ee en © 0 4 O E AUN FMM DMN = dl ed a PON) = BM) = = => №) Li OL Cd ==® ==® e ld ld ld del de ed — = *Recommended Spare Parts, BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-1303 Page 8 Includes TC-049 809-C Figure D - Panel, Front - With Components Page 9 Item Dia. Part No. Mkgs. No. Description Quantity Figure D Panel, Front - With Components (See Fig A Pg 2 Item 24) 1 067 608 RECEPTACLE, jack plug-yellow (consisting of). .............. FUE à 2 2 039 889 .NUT, terminal-yellow ........._.._eeccreccersrrr orinar. aaa 2 3 010 291 . WASHER, flat-nylafil 5/8 1D x 1-1/4 OD x 1/8 .........—-.ee... acorde. 2 4 604 668: . NUT, steel-self-locking hex 1/2-20...........o.ea.eewrevorererereroaaó = 2 5 086 296 . RECEPTACLE 0er 0 aan as ae nana 00 PR eas 2 605 787 , WASHER, lock-internal tooth 1/2 ....... i eter a ee 1 6 601 881 . NUT, steel-hex jam 1/2-20 ..........eeocreexcoocesererecer RR 2 7 046 432 HOLDER, fuse-miniature (Consisting Of) ..........c_serveexconsrodesereone. 1 8 059 139 .CAP,fusehoider ............. viii, eters e 1 9 NAMEPLATE (order by modet and serial numbers). ..............ceeeeeceven. A 10 082 951 PANEL, front ...........c_ee_eococdddcoarecóa von ea ena PS 1 11 087 274 PLATE, cover-module......1.1044400 004 4 04444 0 4 4 4 848 4 4 ea 44 a a 4 666 a a a a 00 1 12 REC 048 282 RECEPTACLE W/SOCKET (consisting of) ........ iii iii, 1 | 079 534 . TERMINAL, female 1 socket ............_.e_eceeorescsorere»oraerrar a e. 4 13 Rb 030 943 POTENTIOMETER, carbon 1 turn 2 watt 18K ohm. ........ cco iin. 1 14 51 011 629 SWITCH, toggle DPST 30 amp.........e._eerrrecadoocorgedareore ree ven 1 15 026 190 INSULATOR, switch. ........._eeeocoesvocreracer:: arre re eenee rr vaa e, Ce 1 16 $3 049 280 SWITCH, selector (See Fig D? Pg 11) oii ities 1 17 RC3 073 326 RECEPTACLE, 4 socket 97-3102-18-453 .........rrceesccccrcare rev reo. e 1 18 F1 *012618 FUSE, miniature-glassbamp.............. oii KEREG 1 19 019 609 KNOB, pointer .............c oe0.rríesvdrdeaor:arevcereareracecaaróerveco a 1 20 010 647 PIN, spring-compression ..........eorrrrresesverercorerecererer irene. 1 21 006 927 HANDLE, switch-range .............—-eerervearererenreriorreccarrerecrao 1 22 010 907 NUT, locking 1 inch............eé.0eveccari a veoareeraeoa radar aoravev 2 23 ° 039 628 RECEPTACLE, ewistiook-insulated e ene 2 24 .. 039630 PLUG, male-twistlock-insulated ...........eeec.eonverceozeaia, rra. 2 25 600 329 CABLE, weid No. 1 (order by ft) ........... o. eerezee er vecarieaooradra ca 3 ft 26 010 290 BUSHING, strain-relief 1.09 x 1.03 hole ..........ñ_e_eeee-esvesreesovodedo 2 27 049 347 CABLE Et PLUG, jack-yellow (consisting of) .............esoeeeoorrrcereseaa 1 28 082 067 .CABLE .........e.ssdcrrorerro ercerecarrere rororarrarcareredreovacarea 1 29 039 878 | PLUG, jack-yellow (consisting of) ............o..eee.e0vedoriarer,areo e. 1 30 010 521 .. WIRE, tie .........._..0s0oraca ria ren aaa e PUE 1 31 019 833 ..STRIP, copper 0.010 X 2-1/2 X 3/4 LL 1114 A 1444 a aa a a ea a aa a aa 0e aan 1 32 602 178 ..SCREW, set-steel socket hd 1/4-20 x3/8.............._reoreaorverev e. 1 33 101 219 ..PLUG, jackK....... res... r.eseciveresrericr e reasreroorervedrorerrerena 1 34 026 975 ..INSULATOR, jack piug-yellow ............_eeecesvnrdeccoceco.arercereenc. 1 35 602 160 .. SCREW, self-tapping fillister hd 8-32 x 174.111 1111212 04 4 4 4 4 aa a sa da ae 1 *Recommended Spare Parts. BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-1303 Page 10 item No. Part No. Figure D1 049 280 Description Switch, Selector (See Fig D Pg 10 item 16) Quantity O 00 0 EWN = 005 562 005 561 005 564 605 276 005 559 005 560 008 485 005 566 011 644 052 405 052 404 005 557 005 558 BRACKET, mounting-switch ............e.....00m 000000000 e ear enedie | SHAFT, rotor ........eeeeorecdeooeeocerooeoaaaooaoaaa a A4 ae a A4 aa ae aa a a 0 INSULATOR, screw-switch 0.101010 Lea aan WERNER KR SCREW, cap-steel hex hd 1/4-20 X 1-1/4 LL LL LL aa ana nana ana CONTACT BOARD, movable-switch ..... cuttin cence CONTACT, switch-movable...........—.eecce.ee.ceccoarerecaareraeonaci SPACER, contact-switch ............__.eé00eriiccacereararrdcodens0e cacao, CONTACT BOARD, stationary-switch ................eerescooorodoaraareo CONTACT, stationary-switch ...........ec._.eeeeoreorrecarecóreareroereo SPRING, pressure-contact switeh ..........._...o o..ecxcciaerreaacerorcerae0 CONTACT, movable-switch..........._ ee aa a aa aa aa BUS BAR, switch-range .......2020 000044 0e a a da as Aa ea da Va aa ad aa aa aa SPRING, selector-sWitCh i i 4 Ad A da A a a da чё red mt mk Wy] md ed ed ed nd А А о 13 Figure D1 - Switch, Selector BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. Page 11 TC-052 524 item Dia. Part No. Mkgs. No. Description a ) — Quantity Figure E Panel, Rear - With Components (See Fig A Pg 2 Нет 5) 1 FM 081373 MOTOR, 1/15 hp 115 volts ac 60 hz 3000 rpm. ...........eessraccaceerere. 1 2 081 372 BLADE, fan 60 hz 9 inch 20 degree. ...........eoeeee... a eee ieee 1 3 045 873 PANEL, rear... oii rea ea 1 4 SR3 087 660 RECTIFIER, silicon diode {consisting of} ......... ccc iii iii... 1 5 081 678 .BRACKET, mounting-fan motor ............eeoe_rercorriroorrererrra ae 1 —6 037 957 . DIODE, rectifier 275 amp 300 volts reverse polarity ..............eo__reese.. 2 7 TP2 086323 .THERMOSTAT, NO ..........ererecoocscrocerenavendmecrarorrenvarara ra 1 8 C14-17 031 689 . CAPACITOR, ceramic 0.01 uf 500 volts dc w/3/16 x 1/4 terminals .......... 4 9 037 956 . DIODE, rectifier 275 amps 300 volts straight polarity .......... terran 2 10 1 ТРЗ 006 334 THERMOSTAT, NC LL iii i i tiie eee inane, MS wr 8106 98765 в 4 TD-049 811-4 Figure E - Panel, Rear - With Components BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-1303 Page 12 - item Dia. Part No. Mkgs. No. Description Quantity Figure F 086 271 SKP-35 (Spot Panel) (Optional) 1 R50,52 028 769 POTENTIOMETER, carbon 1 turn 2 watt 750K ohm paarecari dire cian Cadera 2 2 R53,54 030 002 RESISTOR, carbon 0.5 watt 100K ohm.............ñcéeeoosrocerreacen.a 2 3 RB1 028770 POTENTIOMETER, carbon 1 turn 2 watt 1 megohm..........e_eeceeeceeccos 1 4 S50 1 086 895 SWITCH, rotary 3 position... e... 0000 i a. 1 5 073 914 WASHER, centering 7/18 dia ...............eee.0.00s0000 000 c00rooea 2 6 RBS 605890 RESISTOR, WW fixed 15 watt 0.25 ehm ............coeceeeerc0o. ar a 006 1 7 048 029 CLIP, retaining-socket ...............ewccexeéemoreoo AR 1 8 049 970 BRACKET, mtg-relay ............ee_.eeeorocorarevoreorenrcoraeroameroo 1 9 027 811 CONNECTOR, 14pin......... onerervocari recacaomenrenaoreroedrane redee, 1 10 079 844 SPRING, holddown-connector .................eeéreseevcsedeodccoooaa a 1 11 CRB €081 797 RELAY, enclosed 24 voltsac 4PDT ............... e... 02 0. an aa aa 1 12 PLGS1 084 198 HOUSING, connector-edge 6 pin .............._ eo e..0.0.000B200000 0 ena 1 13 PLG54 079 798 HOUSING, terminal 13 position .................0. 2002 eee ee 1 14 010 301 BUSHING, 9/64 1D x 1/4 OD x5/16 ..............e....00000000 00 0000decOs 1 15 031 251 BRACKET, mtg-connector................eeererrondeadi reo aan aan 2 16 RBZ 073730 CONNECTOR, edge 22 pin .................... 2. e erereccecec.a 1 17 PC50 086204 CIRCUIT CARD (Fig F1 Pg 14) ........... 2 ereredciecerercecar ere 1 19 086650 PANEL ............... PS are PS 1 20 010 146 CLAMP, 5/8 clamp dia.........02002002 2 ae Ada a aa aa a aa a aa a aa ana ana 2 21 NAMEPLATE (order by model and serial number) ................es-eeeevr0 1 22 . 024366 KNOBG, pointer ...............eeoorrc..er.eeadicenaceaarsereareroaaoioro 4 087 255 LABEL........... ceva. avacirocorereareadveraaaareraaorar. 1 046 468 NOZZLE, spot-outside corner 1 046 469 МО2ХЖЬЕ, ро! е согпег. ........ na aa ana ana nana ooo 1 046 470 NOZZLE, spot-flat ..............ee._..es0dcrecriaereniroaareae ia occ. 1 21 TC-086 924 Figure F - SKP-35 (Spot Panel) (Optional) BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. Page 13 Dia. Part Mkgs. No. Description Quantity Figure F1 086 204 Circuit Card (Fig F Pg 13 Item 17} A50,51 009 153 . AMPLIFIER, operational 358 type 32/16 volts de ..........c._.2_.._e. 2 C50 039 482 .CAPACITOR, electrolytic 100 uf 35 volts de ............_e ee... 1 C51,53,55 032 820 .CAPACITOR, tantalum 2.2 uf 35 volts de ..........e _..es_cenvca 3 C52,56 073 714 .CAPACITOR, tantalum 0,22 uf 35 volts ..........._eececoneccrooo 2 C54 072 113 .CAPACITOR, tantalum 4.7 uf 35 volts de ...........e._.eseecare. 1 C57 083 182 .CAPACITOR, ceramic 0.1 uf 50 volts de ............_eeeocseneano 1 CR50,51 027 810 .RELAY, enciosed 24 volts de APDT ............e_eeecoeoccsoonoa 2 079 843 . SOCKET, relay ...........e-oeceorcocorarre cr roo cre rere otr: avaa 2 | 079 844 . SPRING, holddown-relay ..........._e0c_eeceéoceeosrcsrerosao 2 D50-55,57-62 026 202 . DIODE, rectifier 1 amp 400 volts ............ez_..eosrsccrecrecena 12 D56 037 449 , DIODE, zener 15 volts 1 watt SP-55 ...........c.. eee 1 Q50,51 037 200 , TRANSISTOR, 200 MA 40 volts NPN TO-5 ............._eseeceoo 2 052 073 535 . TRANSISTOR, 100 MA 30 volts NPN GF ..........e.eeeerescrao 1 R80 030 712 , RESISTOR, carbon 1 watt 1000 ohm .............. oii 1 R51 605 918 .RESISTOR, carbon 0.25 watt 100 ohm ............. coin. 1 R52 078 433 . RESISTOR, carbon 0.26 watt 1 megohm ....................... 1 R53,57,61,68 - 605 912 . RESISTOR, carbon 0.25 watt 4700 ohm ...........ew_eceerexcoroo 4 R54,56,59,60,62,66,67 605 911 .RESISTOR, carbon 0.25 watt 10K ohm ............._._eeecxecccca 7 R55,58 605 909 .RESISTOR, carbon 0.25 watt 22K ohm ............._reccccscaoao 2 R63 039 333 . RESISTOR, CF 0.25 watt 18K ohm ............ee.0evrerscarecad 1 R64,69 039 327 .RESISTOR, CF 0.25 watt 220 ohm ..........._eeonccrarcecrervoo 2 RES 035 887 .RESISTOR, CFO.25 watt 3300 ohm............_eeeorevesaredreoa 1 RC50 079 793 . TERMINAL, header 4 pin :+..........e...000s0rredece reco o 00 1 RCS1 084 196 . CONNECTOR, edge 6 PIM. co E 1 RC54 079795 . TERMINAL, header 13 pin ...........eeoceceeeoceccarezazencen o 1 RC55 080 072 HOUSING, plug & pins (consisting Of) ..............c iii 1 058 971 ; TERMINAL, malelpin....................... PS 8 R54 = Lt + N Pa tg © R&S Q52 © 3 A © ASO_ £2 Drees 58 ? BL EN | e с © a 35 9 RIC 95 Q UAH LE R58 {1 | | ‘ D56 —Æ > ol T+ 26 SOC) = OU pa AS 3 > SN TH e) a {lo 0 0 0c 0 © RBS "5008 3 RCSi vou Ds9 —I NS | m OQ O go 9 9 0 o 2 Г = A ASSEMBLY = x 086204 UV 5 Ч un o: RSE ! BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. 0 0 0 OD god QO 0 9 0 6 59| 4 aa MATO RCS R53 COMPONENTS TO BE — REPLACED BY QUALIFIED PERSONNEL ONLY Figure F1 - Circuit Card OM-1303 Page 14 item Part No. No. Description Quantity Figure G No. 108 Running Gear 601 954 SCREW, cap-steel hex hd 1/4-20 x3/4 RES PA ee ee ea | 025 193 HANDLE, running gear ..........._r.ec_osrcsoonoreorrecr er ren eearerercorerereceno oa 604 423 GRIP, handle .............e—.es0r0000ri dere ae arararara ena tte ta 057 478 BRACKET, SUDPOM-taNK. «ott iit i rte ttt eee eter etter, 022 617 CHAIN, cylinder 180K . o.oo ere ee ee ee eee ee eee eee esa 602 389 . HOOK, S blunt 1-1/2 iii tet eee tet te tee ee ee teeta B02 387 .CHAIN, weldless .. o.oo iii RER ER ana ee 602 384 SNAP, Chain. oii ee a a à 052 693 RACK, CYlNder. . oor i ie tee ee tee ee ee a a a ea ana 10 602 250 WASHER, flat-steel SAE 3/4 IN. La 4 A ee terete eee a a a a aa 11 602 336 PIN, cotter 1/8 x 1-1/2 1111010020 ee AN Add Aa a a A a a a a da na 12 070 799 WHEEL, rubber, 3/4 bore 10 x 2-3/4 1111110 eee eee eee ce eco 13 052 692 AXLE, running gear ......110020 000 aa ea aa a aa aa a ea aa ea PARA к... 14 601 944 SCREW, cap-steel hex hd 5/16-18 Xx 3/4 .................00e.—r0ír.evesricerecac,c acer. 15 602211 WASHER, lock-steel split 5/16 ..............c0.ece0rriea::000ea aa anecooar ae 16 601 869 NUT, steel-hex jam 5/16-18............—..eeeeeerócorececiadicodooiacaneeova dedo 17 008 999 CASTER, swivel 4 indía 2.000000 tities eee et ete da a aa aa na nan 18 052 691 BAR, spreader cylinder rack .............o.eenvceriere ci ea aaoareoóacaavededva e, 19 002 213 WASHER, lock-steel split 3/8 ................eomeveuiricoa redee. envenenan 20 601 871 NUT, steel-hex jam 3/8-16 ...............0.000;00r0 recreo arecicacaieade crac iO © SO N PAWN — NNINARA INN ANA E CTT Tr ini 20 es 19—— a ER 17 TC-049 808-8 Figure G - No. 108 Running Gear BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. Page 15

Miller MILLERMATIC 200/MIGMATIC 200 User manual

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