Miller MP-65E Owner's Manual

 OWNER'S
MANUAL
May 1979 FORM: OM-228C
Effective With Serial No, HK243390
MODEL
MP-65E
MILLER ELECTRIC MFG. CO.
718 5. BOUNDS S7. P.O. Box 1079
APPLETON, WI 54912 USA
NWSA CODE NO. 4579
PRINTED IN U.S A.
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"LIMITED WARRANTY
Le A A
EFFECTIVE: JANUARY 1,1979
This warranty supersedes all previous MILLER warranties and is ex-
clusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY Subject to the terms and conditions
hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants to
its Distributor/Dedler that all new and unused Equipment furnished
by Miller is free from defect in workmanship and material as of the
time and place of delivery by Miller. No warranty is made by Miller
with respect to engines, trade accessories or other items manu-
factured by others. Such engines, trade accessories and other
items are sold subject to the warranties of their respective manu-
facturers, if any. At the present time, the manufacturer's warranty on
the Mag-Diesel engine on DEL-200 is limited to six months and on
all other engines to one year.
Except as specified below, Miller's warranty does not apply to
components having normal useful life of less than one (1) year, such
as spot welder tips, relay and contactor points, MILLERMATIC parts
that come in contact with the welding wire including nozzles and
nozzie 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 resulting from a defect within the
following periods from the date of delivery of Equipment to the
original user:
1. Arc welders, power sources and components . . . 1 year
2. Original main power rectifiers. . . . . . . . . . .. 3 years
(labor - 1 year only)
3. All welding guns and feeder/guns . . . . . . . . . . 90 days
4. Ali other Millermatic Feeders . . . . . . . . . . .. | year
5. Replacement or repair parts, exclusive of labor . +, 60 days
6. Batteries . . . .. ere, a . . 6 months
provided that Miller is notified in writing within thirty (30) days of
the date of such failure.
As a matter of general policy only, Miller may honor claims
submitted by the original user within the foregoing periods.
In the case of Miller's breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedies
therefor shall be, at Miller’s option, (1) repair or (2) replacement or,
where authorized in writing by Miller in appropriate cases, (3) the
reasonable cost of repair or replacement at an authorized Miller ser-
vice station or (4) payment of or credit for the purchase price (less
reasonable depreciation based upon actual use) upon return of the
goods at Customer’s risk and expense. Upon receipt of notice of
apparent defect or failure, Miller shail instruct the claimant on the
warranty claim procedures to be followed.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA-
TION AS TO PERFORMANCE, AND ANY REMEDY FOR
BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUS-
TOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY
IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND
ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDE
AND DISCLAIMED BY MILLER.
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN WRIT-
ING, MILLER PRODUCTS ARE INTENDED FOR ULTIMATE
PURCHASE BY COMMERCIAL/INDUSTRIAL USERS AND FOR
OPERATION BY PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT AND
NOT FOR CONSUMERS OR CONSUMER USE. MILLER’ WAR-
RANTIES DO NOT EXTEND TO, AND NO RESELLER IS
AUTHORIZED TO EXTEND MILLER’S WARRANTIES TO,
ANY CONSUMER.
AAA,
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ERRATA SHEET
After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to data appearing later in
this manual.
Item Dia. Part Replaced
No. Mkgs. No. With Description - Quantity
23 SR1 023264 079 696 RECTIFIER, silicon diode .............erree»reasserearcocacanr. 1
23 SR1 027391 047 384 RECTIFIER, silicon diode ..............re..erceconsreaoceconrer 1
102 031 688 +031688 CAPACITORI(qtychg) «cocina 1
103 Di-6 037 510 +037 157 DIODE, Mmatched .............. eee ean 12
103 D1-6 037 156 +037 155 DIODE, Kmatched ............. reread RER EEK KEG 12
132 012617 046432 HOLDER, fuse [Effw/JA453270)............e.e.—eecevreveccacas 2
+ Change in second & fourth columns only.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
1, 13/81 OM-228C Page A
E TABLE OF CONTENTS mmm msn
Section No. Page No.
SECTION 1 — SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1. Introduction .......220442 0 022 4 4 4 40 8 4 1 0 4 4 0 0 0 a 4 4 0e 0 0 ue a 0 81 1000 6
1-2. General Precautions. ...... OP
1-3. ArcWelding . «ov ove i i i tie a aaa ee
1-4. Standards Booklet Index .. ... RR nears
BG) mm
SECTION 2 — INTRODUCTION
-1. General ...........— AA ванне ова роже вововаениненее
- 2. Receiving-Handling ...........—.—_—eom_eerarereceareanaea ra crorec.
- 3. Description ........e..eav0ameaverervvrererrarecreacarareodo J
-4. Safety Lo... Ce ee ee ee ee ee eee
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SECTION 3 — INSTALLATION
[Melo of ToT. MP Re
. Electrical Input Connections ..... iit ee eee
. Secondary Connections «oo... tite ee ees
. 115 Volts AC Receptacles .... 111112100441 4 4 0 0 4 44 aa 4 aa a 4 a aa aa A
WW WW Ww
SEWN =
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SECTION 4 — FUNCTION OF CONTROLS
- 1. Power SWiteH . oe ee ee 4 4 4 42 4 4 4e a a 2 4 0 504»
- 2. Load Voltage Range Switch ....... ——.—erererecorrecereorarorerne
- 3. Voltage Adjustment Control ............ ee 4 ea A a ea ee a ea era 000 0
Remote Voltage Control Receptacle & Switch ......................
. Contactor Control Receptacle & Switch ....... oo...
. Meter LLL ie ee ee eet eee eet eet ta eae 10 a
DULY CY CIE oii ee ee ie ie a eee
. Volt-Ampere Curve .......o _—eeeaereroovcorerevverearecarereorene
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SECTION 5 — SEQUENCE OF OPERATION
5-1, Gas Metal-Arc Welding ..........__eosoororareaarrorerarareerao 10
5-2. Shutting Down .........eeeeerersecorecareererearerereraara. 10
SECTION 6 — MAINTENANCE
-1. Rectifier .............. e s0ddaiarerdocarareroversaravaroranea 11
-2. Fan Motor ......._..-eererdevenoaonaracrervaaoroererdereorevere, 11
- 3. Transformer ....... ee o_o asrdadadderndoarervererneararcerneorarmo 11
- 4. Contral Circuit Protection . ..crrerormea. ere aaa 11
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SECTION 7 — TROUBLESHOOTING
PARTS LIST
wa SECTION 1-SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE =m
1-1.
INTRODUCTION
We learn by experience. Learning safety through personai
experience, like a child touching a hot stove is harmfui,
wasteful, and unwise. Let the experience of others teach you.
Safe practices developed from experience in the use of weld-
ing and cutting are described in this manual. Research, devel-
opment, and fieid experience have evolved reliable equipment
and safe instaliation, operation, and servicing practices. Acci-
dents occur when equipment is improperly used or main-
tained. The reason for the safe practices may not always be
given. Some are based on common sense, others may require
technical volumes to explain. It is wiser to follow the rules.
Read and understand these safe practices before attempting
to install, operate, or service the equipment. Comply with
these procedures as applicable to the particular equipment
used and their instruction manuals, for personal safety and
for the safety of others.
Failure to observe these safe practices may cause serious in-
jury or death. When safety becomes a habit, the equipment
can de useg 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) Z49.1 is the most complete,
The National Electrical Code, Occupational Safety and
Health Administration, local industrial codes, and tocal in-
spection requirements also provide a basis for equipment in-
stallation, use, and service,
GENERAL PRECAUTIONS
Burn Prevention
Wear protective clothing - leather (or asbestos) gauntlet
gloves, hat, and high safety-toe shoes. Button shirt collar and
pocket flaps, and wear cuffless trousers to avoid entry of
sparks and slag.
Wear heimet with safety goggles or glasses with side shields
underneath, appropriate fitter lenses ar plates (protected by
clear cover glass). This is a MUST for welding or cutting, (and
chipping) to protect the eyes from radiant energy and flying
metal. Replace cover glass when broken, pitted, or spattered.
See 1-3A.2.
Avoid oily or greasy clothing. A spark may ignite them.
Hot metal such as electrode stubs and workpieces should
never be handled without gloves.
Medical first aid and eye treatment. First aid facilities and a
qualified first aid person should be available for each shift
unless medical facilities are close by for immediate treatment
of flash burns of the eyes and skin burns.
Ear plugs should be warm when working an overhead or in a
confined space. A hard hat should be wom when others work
overhead.
Flammable hair preparations should not be used by persons
intending to weld or cut.
Toxic Fume Prevention
Adequate ventilation. Severe discomfort, itiness or death can
result from fumes, vapors, heat, ôr oxygen enrichment or
depletion that welding {or cutting) may produce. Prevent
them with adequate ventilation as described in ANSE Stan-
dard Z49.1 listed 1 in Standards index. NEVER ventilate
with oxygen.
Lead -, cadmium -, zinc -, mercury -, and beryllium - bearing
and similar materials, when welded (or cut) may produce
harmful concentrations of toxic fumes. Adequate local
exhaust ventitation 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 used.
Metals coated with or containing materials that emit toxic
fumes should not be heated unless coating 1s removed from
the work surface, the area is well ventilated, or the operator
wears an air-supplied respirator.
Work in a confined space only while it is being ventilated
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 danger-
ously. 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 down-
stream valves have been accidently opened or left open.
Check to be sure that the space 1s safe before re-entering 11.
Vapors from chlorinated scivents can be decomposed by the
heat of the arc {or flame} to form PHOSGENE, a highly toxic
gas, and other lung and eye irritating products. The ultra
violet (radiant) energy of the arc can also decompose tri-
chioroethylene and perchioroethylene vapors to form phos-
gene. DO NOT WELD or cut where solvent vapors can be
drawn into the weiding or cutting atmosphere or where the
radiant energy can penetrate to atmospheres containing even
minute amounts of trichloroethylene or perchloroethylene.
Fire and Explosion Prevention
Causes of fire and explosion are: combustibies reached by the
arc, flame, flying sparks, hot slag or heated material; misuse
of compressed gases and cylinders; and short circuits.
BE AWARE THAT flying sparks or faliing stag can pass
through cracks, along pipes, through windows or doors, and
through wall or floor openings, out of sight of the goggled
operator. Sparks and slag can fly 35 feet.
To prevent fires and explosion:
Keep equipment clean and operable, free of oil, grease, and
(in electrical parts) of metallic particles that can cause short
Circuits.
If combustibles are in area, do NOT weld or cut. Move the
work if practicable, to an area free of combustibles, Avoid
paint spray rooms, dip tanks, storage areas, ventilators. 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
shields.
Walls touching combustibles on opposite sides should not be
welded on {or cut}. Walls, ceilings, and fioor 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 weld-
ing or cutting if:
a. appreciable combustibles
tion) are within 35 feet
b. appreciable combustibles are further than 35 feet but can
be ignited by sparks
c. openings (concealed or visible) in floors or walls within 35
feet may expose combustibles 10 sparks
d. combustibles adjacent to walls, ceilings, roofs, or metal
partitions can be ignited by radiant or conducted heat.
(including building construc-
Hot work permit should be obtained before operation to
ensure supervisor's approval that adequate precautions have
been taken.
After work is done, check that area is free of sparks, glowing
embers, and flames.
An empty container that held combustibles, or that can pro-
duce flammable or toxic vapors when heated, must never be
welded on or cut, unless container has first been cleaned as
described in AWS Standard AB.0, listed 3 in Standards index.
OM-228 Page 1
Page 2
This includes: a thorough steam or caustic cleaning (or a
solvent or water washing, depending on the combustible’s
solubility) foliowed by purging and inerting with nitrogen or
carbon dioxide, and using protective equipment as recom-
mended in AG.0. Waterfilling 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
todetermine if itis safe to weld or cut.
Hollow castings or containers must be vented before welding
Qr cutting. They can explode.
Explosive atmospheres. Never weld or cut where the air may
contain flammable dust, gas, or liquid vapors {such as gaso-
line).
Compressed Gas Equipment
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-1, PRECAU-
TIONS FOR SAFE HANDLING OF COMPRESSED GASES
IN CYLINDERS, listed 6 in Standards index.
1. Pressure Regulators
Regulator relief valve is designed to protect only the regula-
tor from cverpressure: it 15 not intended to protect any
downstream equipment. Provide such protéction with one or
more relief devices,
Never connect a regulator to a cylinder containing gas other
than that for which the regulator was designed.
Remove faulty regulator from service immediately for repair
(first close cylinder valve). The following symptoms indicate
a faulty reguiator:
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 reguiators 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
raiis, 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. [t is an
assurance of safety when the cylinder is properly handled.
Identifying gas content. Use only cylinders with name of gas
marked on them; do not rely on color 10 identify gas con-
tent. Notify supplier if unmarked. NEVER DEFACE or alter
name, number, or other markings on a cylinder. It is illegal
and hazardous.
Empties: Keep valves closed, replace caps securely; mark MT;
keep them separate from FULLS and return promptly.
Prohibited use. Never use a cylinder or its contents for other
than its intended use, NEVER as a support or roller.
Locate or secure cylinders so they cannot be knocked over.
Passageways and work areas, Keep cylinders clear of areas
where they may be struck.
Transporting cylinders. With a crane, use a secure support
such as a platform ог стае. Ос МОТ lift cylinders off the
ground by their valves or caps, or by chains, slings, or mag-
nets.
Do NOT expose cylinders to excessive heat, sparks, slag, and
flame, etc. that may cause rupture. Do not allow contents to
exceed 130°F. Cool with water spray where such exposure
exists.
Protect cylinders particularly valves from bumps, falls, falling
objects, and weather. Replace caps securely when moving
cylinders.
Stuck valve. Do NOT use a hammer or wrench to open a
cylinder valve that can not be opened by hand. Notify your
supplier.
Mixing gases. Never try to mix any gases in a cylinder,
Never refill any cylinder.
Cylinder fittings should never be modified or exchanged.
3. Hose
Prohibited use. Never use hose other than that designed for
the specified gas. À general hose identification rute IS: red for
fuel gas, green for oxygen, and biack for inert gases,
Use ferrules or clamps designed for the hose {not ordinary
wire or other substitute} as a binding to connect hoses ta
fittings.
No copper tubing splices. Use only standard brass fittings to
splice hose,
Avoid tong runs to prevent kinks and abuse. Suspend hose off
ground to keep It from being run over, stepped on, or other
wise damaged.
Coil excess hose to prevent kinks and tangles.
Protect hose from damage by sharp edges, and by sparks,
siag, and open flame.
Examine hose requiarly for leaks, wear, and loose connec-
tions, Immerse pressured hose in water; bubbles indicate
leaks.
Repair leaky or worn hose by cutting area out and splicing
(1-2D3). Do NOT use tape.
4, Proper Connections
Clean cylinder valve outiet of impurities that may clog
orifices and damage seats before connecting regulator. Except
for hydrogen, crack valve momentarily, pointing outlet away
from people and sources of ignition. Wipe with a clean lint-
less cloth.
Match regulator to cylinder. Before connecting, check that
the regulator isabel and cylinder marking agree, and that the
regulator inlet and cylinder outlet match. NEVER CON-
NECT a regulator designed for a particular gas or gases to a
cylinder containing any other gas.
Tighten connections. When assembling threaded connections,
clean and smooth seats where necessary. Tighten. If connec-
tion 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 identified by
right hand threads for oxygen and left hand threads (with
grooved hex on nut or shank) for fuel gas.
5. Pressurizing Steps:
Drain regulator of residual gas through suitable vent before
opening cylinder (ог manifold valve) by turning adjusting
screw in (clockwise). Draining prevents excessive compression
heat at high pressure seat by allowing seat to open on pressur-
ization. Leave adjusting screw engaged slightiy on single-stage
reguiators.
Stand to side of regulator while opening cylinder valve.
Open cylinder valve slowly so that regulator pressure in-
creases slowly. When gauge is pressurized {gauge reaches regu-
lator maximum) leave cylinder valve in following position:
For oxygen, and inert gases, open fully to seal stem against
possible leak. For fuel gas, open to less than one turn to
permit quick emergency shutoff.
1-3.
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 gation of water}. Bubbles indicate leak. Clean
off soapy water after test; dried soap is combustible,
User Responsibilities
Remove leaky or defective equipment from service immed-
iately for repair. See User Responsibility statement in equip-
ment manual,
Leaving Equipment Unattended
Close gas supply at source and drain gas.
Rope Staging-Support
Rope staging-support should not be used for welding or cut-
ting operation; rope may burn.
ARC WELDING
Comply with precautions in 1-1, 1-2, and this section. Arc
Welding, properly done, is a safe process, but a careless opera-
tor invites trouble. The equipment carries nigh currents at
significant voltages. The arc is very bright and hot. Sparks fly,
fumes rise, ultraviolet and infrared energy radiates, weld-
ments are hot, and compressed gases may be used. The wise
operator avoids unnecessary risks and protects himself and
others from accidents. Precautions are described here and in
standards referenced in index.
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
VWHTH PRECAUTIONS.
1. Protective Clothing
Wear longsleeve clothing (particularly for gæ-shielded arch in
addition to gloves, hat, and shoes {1-2A). As necessary, use
additional protective clothing such a 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 pre-
vent entry of sparks.
2. Eye and Head Protection
Protect eyes from exposure to arc. NEVER look at an elec-
tric arc without protection,
Weiding 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 heimet or shield should NOT be worn;
radiation can pass through to cause burns,
Cracked, broken, or loose filter plates must be replaced IM-
MEDIATELY. Replace clear cover plate when broken, pitted,
Or spattered.
Flash goggles with side shields MUST be worn under the
helmet to give some protection to the eyes should the helmet
not be lowered over the face before an arc is struck. Looking
at an arc momentarily with unprotected eyes (particulary 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
*Trademark of Proctor 8: Gamble,
operation with tow-reflective, noncombustible screens or
panels, Allow for free air circulation, particularly at floor
level.
Viewing the weld. Provide face shields for all persons who
will be looking directiy 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.
Toxic Fume Prevention
Comply with precautions in 1-2B,
Generator engine exhaust must be vented to the outside air.
Carbon monoxide can kill.
Fire and Explosion Prevention
Comply with precautions in 1-2C.
Equipment’s rated capacity. Do not overload arc welding
equipment. {1 may overheat cables and cause a fire,
Loose cable connections may overheat or flash and cause a
fire.
Never sirike 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.
Compressed Gas Equipment
Compiy with precautions in 1-20.
Shock Prevention
Exposed hot conductors or other bare metat in the welding
circuit, or in ungrounded, electrically-HOT equipment can
fatally shock a person whose body becomes a conductor. DO
NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wet sur-
face when welding, without suitable protection.
To protect against shock:
Keep body and clothing dry. Never work in damp area with-
out adequate insulation agatnst electrical shock. Stay on a
dry duckboard, or rubber mat when dampness or sweat can
not be avoided. Sweat, sea water, or moisture between body
and an electrically HOT part - 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 circula-
tor to the building ground. Conductors must be adequate to
carry ground currents safely. Equipment made electrically
HOT by stray current may shock, possibly fatally, Do NOT
GROUND to electrical conduit, or to a pipe carrying ANY
gas or a flammable liquid such as oil or fuel,
Three-phase connection. Check phase requirement of equip-
ment before installing. If only 3-phase power is available,
connect single-phase equipment to only two wires of the
3-phase line. Do NOT connect the equipment ground lead to
the third (live) wire, or the equipment will become electri-
cally HOT - a dangerous condition that can shock, possibly
atally.
Before welding, check ground for continuity. Be sure conduc-
tors are touching bare metal of equipment frames at connec-
tions.
If a line cord with a ground lead is provided with the equip-
ment for connection to aswitchbox, connect the ground lead
to the grounded switchbox. If a three-prong plug is added for
connection to a grounded mating receptacle, the ground lead
must be connected to the ground prong only. 1f the line cord
comes with a three-prong plug, connect to a grounded mating
receptacle. Never remove the ground prong from a plug, or
use a plug with a broken off ground prong.
OM-228 Page 3
Page 4
2. Electrode Hoiders
Fully insulated electrode holders should be used. Do NOT
use holders with protruding screws.
3. Connectors
Fully insulated lock-type connectors should be used to join
welding cable lengths.
4. Cables
Frequently inspect cables for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn or
damaged insulation to avoid possibly - lethal shock from
bared cable, Cables with damaged areas may be taped to give
resistance equivalent to original cable.
Keep cable dry, free of oil and grease, and protected from
hot metat and sparks.
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 electrically HOT when the power
switch of gas metal-arc welding equipment is ON and welding
gun trigger is pressed. Keep hands and body clear of wire and
other HOT parts. :
7. Safety Devices
Safety devices such as interlocks and circuit breakers shouid
not be disconnected or shunted out.
Before installation, inspection, or service, of equipment, shut
OFF all power and remove ling fuses {or lock or red-tag
switches) to prevent accidental turning ON of power. Discon-
nect all cables from welding power source, and pull all 115
volts line-cord plugs.
1-4.
Do not open power circuit or change polarity while welding.
If, in an emergency, it must be disconnected, guard against
shock burns, or flash from switch arcing.
Leaving equipment unattended. Always shut OFF and dis-
connect all power to equipment.
Power disconnect switch must be available near the welding
power source,
STANDARDS BOOKLET INDEX
For more information, refer to the following standards or
their latest revisions and comply as applicable:
1. ANS! Standard Z49.1, SAFETY IN WELDING AND
CUTTING obtainable from the American Welding
Society, 2501 NW 7th St, Miami, Fla, 33126.
2. ANS! Standard Z87.1, SAFE PRACTICE FOR OCCUPA.
TION AND EDUCATIONAL EYE AND FACE PROTEC-
TION, obtainable from American National Standards
Institute, 1430 Broadway, New York, N.Y. 10018.
3. American Welding Society Standard AB6.0, WELDING
AND CUTTING CONTAINERS WHICH HAVE HELD
COMBUSTIBLES, obtainable same as item 1.
4. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING AND CUTTING, obtainable from the
National Fire Protection Association, 470 Atlantic
Avenue, Boston, Mass. 02210.
5. NFPA Standard 518, CUTTING AND WELDING PRO-
CESSES, obtainable same as item 4.
6. CGA Pamphlet P-1. SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 500 Fifth Avenue, New
York, N. Y. 10036.
7. OSHA Standard 29 CFR, Part 1910, Subpart Q, WELD-
ING, CUTTING AND BRAZING.
2-1.
2-3.
SECTION 2 - INTRODUCTION 2
Input At Rated
Load Output
Rated Max. 60 Hz. Three-Phase
Welding Open- Amperes At Overall Weight
Current Voltage | Circuit 230 460 Dimensions (Pounds)
Amperes Ranges | Voltage | Volts | Volts | kva | kw (Inches) Net | Ship
650 @ 5329 Height - 30
44 Volts 37.44 58 190 50 40 | 35 | Width - 22-1/4 | 640 | 650
100% Duty Cycie 19-44 Depth - 40
Figure 2-1. Specifications
P/O
Power
Switch $1
Input Voltage
Jumper Links
TEZ
1
Input Contactor НА ово Main
Power W Contacts umper Links Transformer
TET т;
Standard
Fan Motor Control Voltage
FM Transformer Adjustment
T2 Control 81
h
Control
Fuse F3 Fuse FA Rectifier
SR2
Contactor
115 МАС Contactor Control
Duplex Receptacle W Coil Receptacle
RC2 RC4
115 VAC Contactor P/O
Twistiock Control Power
Receptacle RC3 Switch Switch $1
54
Stabilizer
2
Magnetic
Amplifier
Main
Rectifier
SR1
Remote Voltage
Control Receptacle
RC]
as 5 6 „+ 6
Remote
Voltage
Control
Switch $2
Load Voltage
Range Switch
53
P/O Part Of
| Positive 300 Amps
Output
Terminal
Positive 650 Amps
Qutput
Terminal
Negative
Output
Terminal
TB-080 691
Figure 2-2. Functional Diagram
GENERAL
This manual has been prepared especially for use in familiar-
IZzing personnel with the design, installation, operation, main-
tenance, and troubleshooting of this equipment. All informa-
tion presented herein should be given careful consideration to
assure optimum performance of this equipment.
RECEIVING-HANDLING
Prior to installing this equipment, clean all packing material
from around the unit and carefully inspect for any damage
that may have occurred during shipment. Any claims for loss
or damage that may have occurred in transit must be filed by
the purchaser with the carrier. A copy of the bill of lading
and freight bill will be furnished by the carrier on request if
occasion to file claim arises.
When requesting information concerning this equiprnent, it is
essential that Model Description and/or Stock Number and
Serial for Style) Numbers of the equipment be supplied.
DESCRIPTION
This unit is a three-phase welding power source which pro-
2-4.
duces dc welding current. This welding power source is
designed specifically for use with the Gas Metal-Arc Welding
(GMAW) process.
SAFETY
Before the equipment is put into operation, the safety sec-
tion at the front of this manual should be read completely.
This will help avoid possible injury due to misuse or improper
welding applications.
The following definitions apply to CAUTION, IMPORTANT,
and NOTE blocks found throughout this manuat:
Under this heading, installation, operating, and main-
tenance procedures or practices will be found that if
not carefully followed may create a hazard to
personnei.
Kr |
OM-228 Page 5
IMPORTANT
Under this heading, instailation, operating, and main-
tenance procedures or practices will be found that if
not carefully followed may result in damage to equip-
L ment. |
3-1.
Page 6
LOCATION (Figure 3-1)
A proper installation site should be selected for the welding
power source if the unit is to provide dependable service, and
remain relatively maintenance free.
A proper installation site permits freedom of air movement
into and out of the welding power source, and also least
subjects the unit to dust, dirt, moisture, and corrosive vapors.
A minimum of 18 inches of unrestricted space must be main-
tained between the welding power source front and rear
paneis and the nearest obstruction. Also, the underside of the
welding power source must be kept completely free of
obstructions. The instaliation site should also permit easy
removal of the welding power source outer enclosure for
maintenance functions.
IMPORTANT
Do not place any filtering device over the intake air
passages of the welding power source as this would
restrict the volume of intake air and thereby subject
the welding power source internal components to an
overheating condition and subsequent failure, War-
| ranty is void if any type of fiitering device is used. I
Holes are provided in the welding power source base for
mounting purposes. Figure 3-1 gives overall dimensions and
the base mounting hale layout.
TC-900 505-3
aE
Figure 3-1. Dimensional Drawing and Base Mounting Hole
Layout
On most welding power sources a lifting device is provided
for moving the unit. However, if a fork lift vehicle is used for
lifting the unit, be sure that the lift forks are long enough to
extend completely under the base.
IMPORTANT
The use of lift forks too short to extend out of the
opposite side of the base will expose internal com-
ponents to damage should the tips of the lift forks
I penetrate the bottom of the unit. I
Under this heading, explanatory statements will be
found that need special emphasis to obtain the most
fficient operation of the equipment.
Ea— —]:<e—:[[———]
ELECTRICAL INPUT CONNECTIONS
Electrical Input Requirements
This welding power source is designed to be operated from a
three-phase, 60 Hertz, ac power supply which has a line voit-
age rating that corresponds with one of the electrical input
voltages shown on the nameplate. Consult the local electric
utility if there is any question about the type of electrical
system available at the installation site or how proper connec-
tions to the welding power source are to be made.
Input Conductor Connections
ft is recommended that a line disconnect switch be
installed in the input circuit to the welding power
source. This would provide a safe and convenient
means to compietely remove all electrical power from
the welding power source whenever it is necessary to
I perform any internal function on the unit. 1
Before making electrical input connections to the
welding power source, “machinery lockout
procedures’ should be employed. If the connection is
to be made from a line disconnect switch, the switch
should be padlocked in the open position. If the
connection is made from a fuse box, remove the fuses
from the box and padlock the cover in the closed
position. If the unit is connected to a circuit breaker,
or other disconnecting device without locking
facilities, attach a red tag to the device to warn others
i that the circuit is being worked on. I
Connect the input conductors to the welding power
source before making connections to the three-phase
I power supply. |
The input conductors should be covered with ап insulating
material which conforms to local electrical standards. Table
3-1 is provided only as a guide for selecting the proper size
input conductors and fuses,
Table 3-1. Input Conductor and Fuse Size
Input Conductor Size - AWG” Fuse Size In Amperes
200(208)V | 230V | 460V [| 575Vv | 200(208)V | 230V | 460V | 575V
2 3 6 8
175 150 80 0
{8} (3) (8) (8) 6
*Input conductor sizes are based on allowable ampacities of
insulated copper conductors, having a temperature rating of
759€, with not more than three conductors in a raceway or
cable. Numbers in ( ) are equipment ground conductor sizes.
Insert the three input conductors plus one ground conductor
through the access hole on the rear panel. This hole will
accept standard conduit fittings. See Figure 3-2 for hole loca-
tion and size.
230 VOLTS
ene Era
OL, CL, ©; lio
460 VOLTS
olde oo
O YE
О]
Figure 3-3. input Voltage Jumper Link Arrangement
It is recommended that a terminai lug of adequate
amperage capacity be attached to the ends of the in-
put and ground conductors. The hole diameter in the
terminal lug must be of proper size to accommodate
1 the line and ground terminal studs. |
O
GRD.
Connect the three input conductors to the line terminals on
the primary terminal board and connect the ground conduc:
tor to the ground terminal. (Refer to the input voltage label
for identification of these terminals. See Figure 3-2 for loca-
tion of this label.) The remaining end of the ground conduc-
tor should be connected to a proper ground. Use a grounding
method that is acceptable to the local electrical inspection
authority.
MS ADL в
The ground terminal is connected to the welding
power source chassis and is for grounding purposes
only. Do not connect a conductor from the ground 3-3
terminal to any one of the line terminals as this will *
SECONDARY CONNECTIONS (Figure 4-1)
result in an electrically enargized welding power
source chassis. To obtain the full rated output from this unit, 1115 necessary
TS to select, install, and maintain proper welding cables. Failure
to comply in any of these areas may result in less than
satisfactory welding performance.
Welding
Power Source
Ensure that the unit is completely shut down before
making any weid output connections.
Line Disconnect et
Switch —
Input Voltage Label EE = Location
The POSITIVE and NEGATIVE weid output terminals are
Ground
located on the front panel.
! Terminal
1-3/4" ACCESS muir
| Hole
e
The secondary terminals consist of a POSITIVE and NEG-
ATIVE terminal and a single positive terminal labeled,
POSITIVE 300 AMPS, MAX, Connections are to be made to
the tandem positive and negative terminals whenever the fuil
Input range that the welding power source was designed to be
Line Terminals Voltage Jumper operated on is desired.
Links
TA-900 732-38
Figure 3-2. Input Conductor Connections
Matching The Welding Power Source To The Avail-
able Input Voltage
The input voltage jumper links provided on the primary ter-
minal board permit the welding power source to be operated
from various line voltages. The various voltages from which
this unit may be operated are stated on the nameplate and on
the input voltage label. See Figure 3-2 for location of this
label. The input voltage jumper links are positioned for the
highest of the voltages stated on the namepiate. If the weld-
ing power source is to be operated from a line voltage which
is lower than the highest voltage for which the unit was
designed, the jumper links will have to be moved to the
proper positions before operating the unit, Figure 3-3 shows
the various positions of the jumper links on the standard
welding power source. If the input voltages on the name-
plate differ from those shown in Figure 3-3, the input voltage
jumper links must be positioned as shown on the input voltage
label.
H only one jumper link is required on each of the
grouped terminals, it is recommended that the unused
jumper links be placed across the terminals which are
to be used. This will prevent losing the jumper links
| which are not required for this connection. 1
The POSITIVE 300 AMPS MAX, terminal is to be used only
when the required amperage is below 300 amperes.
IMPORTANT
it is imperative that the output does not exceed 300
amperes when connected to the POSITIVE 300 AMPS
MAX. terminal. It is also recommended that the LOW
position on the LOAD VOLTAGE RANGE switch be
| used when utilizing this terminal. I
Also, when secondary connections are made to this terminal,
a load voltage range of 17 to 23 volts will be obtainable. The
minimum recommended output that can be obtained from
this terminal is 100 amperes at 17 volts.
Welding Cables
If welding cables were not ordered with this unit, the steps
listed
should be followed to ensure the best welding
performance:
1.
It is recommended that the welding cables pe kept as
short as possible, be placed close together, and be of
adequate current carrying capacity. The resistance of the
welding cables and connections causes a voltage drop
which is added to the voitage of the arc. Excessive cable
resistance may result in overloading as well as reducing
the maximum current output capability of this unit,
Proper operation Is to a great extent dependent on the use
of welding cables and connections that are mn good
condition and of adequate size. An insulated electrode
holder must be used to ensure the Operator's safety.
OM-228 Page 7
2. Use Table 3-2 as a guide for selecting correct cable size for
the anticipated maximum weld current which will be
used. Table 3-2 shows total cable length, which inciudes
the electrode and work cable. Example: If the electrode
holder cable is 75 feet long and the work cable is 25 feet
long, select the size cable that is recommended for 100
feet at the maximum weld current that is to be used.
3. Do not use damaged or frayed cables.
4. Follow the electrode holder manufacturer's instructions
for installing the electrode holder onto the electrode
cable.
5. Use correct lugs on the weld cables to connect the
work clamp and to connect the cables to the weld
output terminals.
6. Ensure that all connections are clean and tight.
Table 3-2. Welding Cable Size
WELDING [TOTAL LENGTH QF CABLE (COPPER) IN WELD CIRCUIT
AMPERES| "50 | 100 150 | 200 250 | 300 | 350 | 400
100 4 4 2 2 2 ! 1/0 1/0
150 2 2 2 1 1/0 2/0 3/0 3/0
200 1 1 1 1/0 2/0 3/0 4/0 4:0
250 1/0 1/0 1/0 2/0 3/0 4/0 | 4/0 2.2/0
300 |2/0 {2/0 2/0 13/0 4/0 4/0 2-2/0 | 2-3/0
350 |3/0 12/0 3/0 {4/0 4/0 2-2/0 | 2-3/0 | 2-3/0
400 |3/0 (3/0 3/0 4/0 2-2/0 | 2-3/0 1 3-2/0 | 2-4/0
500 [4/0 |4/0 4/0 2-2/0 | 2-3/0 | 2-3/0 1 2-4/0 | 3-3/0
600 {2-2/0 |2-2/0 1 2-2/0 | 2-3/0 | 3-2/0 | 24/0 | 3-3/0 1 3-4/0
700 {23/0 |2.3/0 1 2.3/0 | 2-4/0 | 3-3/0 | 3-4/0 1 4-4/0 | d-4/0
800 2-3/0 {2-3/0 | 2-3/0 § 24/0 | 3-3/0 { 3-4/0 | 4-4/0 | 4-4/0
A-002 623
NOTE: ‘A. S50FEETOR LESS.
3-4.
Page 8
"8. CABLE SIZE IS BASED ON DIRECT CURRENT (DC),
100% DUTY CYCLE AND EITHER A 4 VOLTS OR LESS
DROP OR A CURRENT DENSITY OF NOT OVER 300
CIRCULAR MILS PER AMP.
°C. WELD CABLE INSULATION WITH A VOLTAGE
RATING TO WITHSTAND THE OPEN-CIRCUIT VOLT-
AGE (OCV) OF THE WELDING POWER SOURCE MUST
BE USED. WHILE MOST WELDING POWER SOURCES
HAVE AN OPEN-CIRCUIT VOLTAGE QF LESS THAN
100 VOLTS, SOME WELDING POWER SOURCES OF
SPECIAL DESIGN MAY HAVE HIGHER OPEN-CIRCUIT
VOLTAGE.
115 VOLTS AC RECEPTACLES (Figure 4-1)
Two receptacles, both labeled 115 VOLTS AC, are provided
on the front panel. The duplex 115 VOLTS AC receptacle is
DC DC
Ammeter
Contactor Control Voltmeter
Switch
10 Ampere
Fuses
Contactor Control
3-6.
SECTION 4 - FUNCTION
intended to be used for operating accessory equipment. The
three-pole, twistlock, 115 VOLTS AC receptacle is intended
to be used for supplying operating power to the control/
feeder. To secure the corresponding three-pole plug into the
twistiock receptacle, rotate the plug as far as it will turn in a
clockwise direction.
IMPORTANT
Both 115 VOLTS AC Receptacles and CONTACTOR
CONTROL Circuitry are protected by a 10 ampere
fuse F3 which is located on the front panel. If it
should become necessary to replace the fuse, ensure
that a fuse of the same rating is used for a replace-
ment. À fuse of a larger rating will permit overloading
of the 115 volts circuitry and thereby cause damage to
| the machine. a
CONTACTOR CONTROL CONNECTIONS (Figure
4-1
The CONTACTOR CONTROL Receptacle provides a junc-
tion point for connecting a Remote Contactor Control device
to the contactor control circuitry in the welding power
source,
To connect the Remote Contactor Control to the CON-
TACTOR CONTROL Receptacle, insert the two-pole plug
from the Remote Contactor Control device into the CON-
TACTOR CONTROL Receptacle and rotate the plug as far as
it will turn in a clockwise direction. The plug will now be
locked in the receptacle and will not pull out under stress.
REMOTE VOLTAGE CONTROL CONNECTIONS
The Remote VOLTAGE CONTROL Receptacie RC1, lo-
cated on the front contro! panel, is a three-pole, twistlock
receptacte. The VOLTAGE CONTROL Receptacle provides a
connection point between the Remote Voitage Control and
the welding power source voltage adjustment circuitry. When
utilizing a Remote Voltage Control insert the plug from the
Remote Voltage Control fully into the VOLTAGE CON-
TROL Receptacle and then rotate the piug as far as it will
turn in a clockwise direction. This rotating action will secure
the plug in the receptacle and prevent it from coring out if
tension should be applied to the Remote Voltage Control
cord,
OF CONTROLS === Ús
Power
Switch
qd ve tage Control
Switch
0
Voltage
© Control
Receptacie
o
E
115 Volts AC
Duplex Receptacie
Receptacle
Negative КК
Secondary | №
Terminal
Load
115 Volts AC Voltage
Twistlock Range
Receptacle Switch
o
o
Voltage
Adjustment Secondary
Terminal
Control
Positive 300
Amp. Max,
Secondary
Terminal
Positive
A-900 505-4
Figure 4-1. Control Location
4-1.
4-2.
POWER SWITCH (Figure 4-1)
Placing the POWER Switch in the ON position will energize
the welding power source fan and control circuitry and place
the welding power source in a ready-to-weld status. Placing
the POWER Switch in the OFF position will shut the welding
power source down.
Even though the POWER Switch is in the OFF posi-
tion and the weiding power source is apparently elec-
trically shut down, electrical input power is stili
present on all circuitry up to the POWER Switch and
contactor contacts. To completely cut-off ati electrical
power to the welding power source, it wiil be nec-
essary to place the line disconnect switch in the OFF
position or remove the input circuit fuses, |
LOAD VOLTAGE RANGE SWITCH (Figure 4-1)
A four-position LOAD VOLTAGE RANGE Switch is pro-
vided on the front pane! for selecting any cone of four coarse
toad voltage ranges available. Fine voltage adjustment within
the selected range, is made by the VOLTAGE ADJUST-
MENT Control the function of which will be further
explained in Section 4-3. The minimum to maximum load
voltage range of the four positions and the corresponding
iabeling of the positions are as follows:
Switch Position Load Voltage Range
Low 19-29
Medium 27-38
High 37-44
Single Wide 19-44
When in the SINGLE WIDE position the VOLTAGE
ADJUSTMENT Control will be capable of load voltage
adjustment over the entire range of the welding power
source; that is, from the minimum of the LOW posi-
tion (19) to the maximum of the HIGH position (44). 3
4-3. VOLTAGE ADJUSTMENT CONTROL (Figure 4-1)
The VOLTAGE ADJUSTMENT Control, located on the
front panel, provides a means of selecting the exact voltage
desired within the range being used. Rotating the control in a
clockwise direction increases the load voltage.
NOTE
The contacts of the VOLTAGE ADJUSTMENT con-
trol are of the continuous type, thereby making it
1 possible to adjust this control while welding.
The scale surrounding the VOLTAGE ADJUSTMENT con-
trol is calibrated in percentage and should not be miscon-
strued as an amperage or voltage reading. lt is recommended
that the meters be read whenever it is necessary to know the
amperage and vottage output,
REMOTE VOLTAGE CONTROL RECEPTACLE &
SWITCH (Figure 4-1)
M a Remote Voltage Control is to be used, make Connections
from the Remote Voltage Control to the VOLTAGE CON-
TROL Receptacle as instructed in Section 3-6.
When remote control of the voltage is desired, itis essential
that the VOLTAGE CONTROL Switch be placed in the RE-
MOTE position. Likewise, if a Remote Voltage Control is not
to be utilized, the switch must be in the STANDARD posi-
tion, When in the STANDARD position only the VOLTAGE
4-6.
4-7,
contactor coil
ADJUSTMENT Control on the front panel will control the
voltage.
The 30 volts control circuitry in the welding power source is
protected by a 10 ampere fuse F1 which is located on the
front panel. If this fuse should open, the weld output will go
to the middle of the welding power source overall range and
remain there, regardless of the position of any of the welding
power source controls. When this occurs, neither the LOAD
VOLTAGE Range Switch, VOLTAGE ADJUSTMENT Con-
trol, or Remote Voltage Control will have any effect on the
weld output.
IMPORTANT
When replacing fuse F1, ensure that a fuse of equal
size and rating is used as a replacement. Failure to
comply may result in damage to the welding power
I source. |
CONTACTOR CONTROL RECEPTACLE &
SWITCH (Figure 4-1)
Whenever the CONTACTOR CONTROL Switch is in
the STANDARD position, open<ircuit voltage is
present at the secondary terminals as long as the
POWER Switch is positioned to ON.
Whenever a Remote Contactor Control is to be used, make
connections to the CONTACTOR CONTROL Receptacle
RC4 on the welding power source as instructed in Section
3-5. In order for a Remote Contactor Control Station to
operate the contactor in the welding power source, the
Remote Contactor Control Station must be able to supoly
115 volts ac to the CONTACTOR CONTROL Receptacle
whenever weld output is desired. Also, whenever suspension
of weld output is desired, the Remote Station must be able
to cut-off the 115 volts ac supply to the receptacle RCA.
Another prerequisite for remote control of the contactor is
to have the CONTACTOR CONTROL Switch on the welding
power source in the REMOTE position. If this switch is left
in the STANDARD position, the contactor will energize as
soon as the POWER Switch is positioned to ON.
The CONTACTOR CONTROL Circuitry {and 115 VOLTS
AC Receptacles) is protected by a 10 ampere fuse F3 which
is located on the front panel. if this fuse should open, the
would de-energize (if the CONTACTOR
CONTROL switch were in the STANDARD position} and all
weld output would be suspended. if this fuse should open,
115 volts ac would not be available at the 115 VOLTS AC
Receptacles.
IMPORTANT
When replacing fuse F3, ensure that the fuse being
used as a replacement is one of proper size and rating.
A fuse of larger rating will permit overioading of the
115 volts circuitry and thereby cause damage to the
welding power source.
a
METERS (Figure 4-1)
The meters are provided to monitor the welding operation.
They are not intended for exact current or voltage measure-
ments. These meters are internally connected to the output
terminals. The voitmeter will indicate the voltage at the
output terminals, but not necessarily the actual voltage at the
welding arc {due to cable resistance, poor connections, etc.).
The ammeter will indicate the current output of the unit.
DUTY CYCLE {Figure 4-2)
The duty cycle of a welding power source is the percentage
OM-228 Page 9
— SECTION 5 - SEQUENCE OF OPERATION
5-1.
Page 10
of a ten minute period that a welding power source can
safely be operated at a given output. This welding power
source 15 rated at 100 percent duty cycle. This means that
the welding power source can be safely operated at rated
load continuously. Figure 4-2 enables the operator to
determine the safe output of the welding power source at
various duty cycles.
IMPORTANT
Exceeding the indicated duty cycle will cause the
welding power source to overheat and thereby cause
I damage to the welding power source. 1
700
Ww
uid
x ^^
=
* во >
o SN
=
=
= 700 =
600
40 50 60 70 80 90 100
% DUTY CYCLE
5-001 888
Figure 4-2. Duty Cycle Chart
Never, under any circumstances, operate the welding
power source with any portion of the outer enclosure
removed. In addition to a hazard, improper cool-
ing may result in damage to the weiding trans-
former and the welding power source components.
Warranty is void if the welding power source is opera-
ted with any portion of the outer enclosure removed.
GAS METAL-ARC WELDING (GMAW)
1. Make electrical input connections as outlined in
Section 3-2.
2. Make secondary connections as outlined in Section
3-3.
3. If desired, make Contactor Control connections as
instructed in Section 3-5.
4. Place the CONTACTOR CONTROL Switch in the
desired position.
5. IF a Remote Voitage Control is to be used, make
connections to the VOLTAGE CONTROL Receptacle
as instructed in Section 3-5 and place the VOLTAGE
CONTROL Switch in the REMOTE position. If a
Remote Voltage Control is not to be used place the
VOLTAGE CONTROL Switch in the STANDARD
position,
6. If 115 volts ac is required to operate a controi/feeder,
make connections to the three-prong twistlock 115
VOLTS AC Receptacle as instructed in Section 34.
7. Place the LOAD VOLTAGE RANGE Switch in the
desired position.
8. Rotate the VOLTAGE ADJUSTMENT Control to the
approximate desired setting.
4-8.
VOLT-AMPERE CURVE (Figure 4-3)
The volt-ampere curve shows the output voltage available at
any given output current within the limits of the minimum
and maximum values of the VOLTAGE CONTROL setting.
Load voltage is predetermined to a large degree by arc char-
acteristics. With the use of the volt-ampere curve, it is pos-
sible to détermine the amperage required for a specific load
voltage. With reference to the volt-ampere curve {Figure 4-3},
the curve shows the maximum and minimum settings of the
VOLTAGE CONTROL only. Curves of other settings will fall
between the maximum and minimum curves shown.
50
50
E
©
DC YOLTS
a
o
70
POSITIVE 1500 AMPERÍ TERMINAL
nk RANGE SWITCH IN LOW POSITION
1 1 | 1 | al J
© 100 200 300 400 500 590 FDO
DE AMPERES
B-022 356
Figure 4-3. Volt-Ampere Curves
9, Ensure the Line Disconnect Switch is in the ON posi-
tion.
Prior to welding, it is imperative that proper protective
clothing {welding coat and gloves) and eye protection
(glasses and/or welding helmet} be put on. Failure to
comply may result in serious and even permanent
bodily damage.
10. Turn on the shielding gas supply.
11. Place the POWER Switch to the ON position and com
mence welding,
12. The VOLTAGE ADJUSTMENT Control or Remote
Voltage Control may be adjusted while welding.
SHUTTING DOWN
1. Break the arc.
2. Allow the welding power source to idle for 3 minutes
with no load applied.
3. Place the POWER Switch in the OFF position.
4. Turn off the shielding gas at the shielding gas source.
If welding is performed in a confined area, failure to
turn off the shielding gas supply could result in a build
up of gas fumes, thereby endangering personnel re-
entering the welding area.
— SECTION 6 - MAINTENANCE = —————
6-2,
Ensure that the branch circuit or main disconnect
switch Is open or electrical input circuit fuses are
removed before attempting any inspection or work on
the inside of the welding power source. Placing the
welding power source POWER Switch in the OFF
position does not remove voltage from the power ter-
| - minals inside the welding power source. 3
RECTIFIER
[lt is recommended that the rectifler be cleaned occasionally
by blowing it out with compressed air. This cleaning opera-
tion Is necessary so that maximum cooling will be accom-
plished by the air stream. This should be done periodically,
depending upon the location of the unit and the amount of
dust and dirt in the atmosphere.
FAN MOTOR
All modeis are equipped with an exhaust fan and rely on
forced draft for adequate cooling for high duty cycles and
overloads. The fan motor is manufactured with lifetime lubri-
cated sealed ball bearings and no attention should be
required,
6-3.
6-4.
TRANSFORMER
Occasional blowing out the dust and dirt from around the
transformer is recommended. This should be done periodi-
cally depending upon the location of the unit and the
amount of dust and dirt in the atmosphere. The welding
power source case cover should be removed and a clean dry
air stream should be used for this cleaning operation.
CONTROL CIRCUIT PROTECTION
The entire control circuit of the welding power source 1$
protected by a 600 volts, 6 ampere, cartridge type fuse F2.
This fuse is located behind the rear access panel, immediately
to the upper right. Should this fuse open, the welding power
source would completely shut down.
IMPORTANT
if it should become necessary to replace this fuse or
any other fuse in the welding power source, ensure
that the proper size fuse is used as a replacement.
hee —————
_—ooo:::: ws SECTION 7 - TROUBLESHOOTING ==
are present on the internal
voitages
circuitry of the welding power source as {ong as power
Is connected to the unit. Disconnect power before
attempting any inspection or work on the inside of the
unit, Troubleshooting of internal circuitry should be
| performed by qualified personnel only.
Mazardous
The following chart is designed to diagnose and provide
remedies for some af the troubles that may develop in this
welding power source.
It is assumed that proper installation has been made,
according to Section 3 of this manual, and that the welding
power source has been functioning properly until this trouble
developed,
Use this chart in conjunction with the circuit diagram while
performing troubleshooting procedures. If the trouble 15 not
remedied after performing these procedures, the nearest
Factory Authorized Service Station should be contacted. In
ali cases of equipment maifunction, the manufacturer's
recommendations should be strictly followed.
TROUBLE PROBABLE CAUSE
REMEDY
Limited output and iow
open-circuit voltage.
Operation on single-phase. Open
line fuse on one phase.
Check incoming three-phase power for correct voltage.
Replace fuse if open.
Input voltage jumper links | See Figure 3-3 or input voltage label.
connected to wrong terminals.
Fan runs slow, input voltage jumper links on | See Figure 3-3 or input voltage label. Connect jumper links
primary connection board
connected for incorrect input
voltage,
for correct input voltage,
Fan does not run.
Fan motor (FM) defective.
Check fan motor (FM) leads. if O.K. and fan turns free the
motor could be burned out.
*Fuse (F2) open.
Replace fuse {F2}.
Line disconnect fuses open.
Repiace defective fuses.
Erratic weld current.
Incorrect welding cable size.
Use proper size & type of cable, See Section 3-3.
Loose welding cable connection,
Tighten all welding connections.
Incorrect drive gear for wire size
on the feeder.
See wire feeder instruction manual troubleshooting guide.
Contactor will not energize when
CONTACTOR CONTROL switch
is in STANDARD position and
there i5 no 115 volts ac at the 115
VOLTS AC receptacle.
*Fuse (F3) open.
Replace fuse (F3).
VOLTAGE ADJUSTMENT
control (R11) inoperative.
*Fuse (F1) open.
Replace fuse (F1),
“If it becomes necessary to replace any fuse in the welding power source, ensure that a fuse of the proper size is used.
OM-228 Page 11
POSITIVE
AD0 AMPS MAX,
FOSITIVE
ESO AMPS
Y
NEGATIVE
t O4 aa Hs +47 Сна 29 za |
O hOC E DO kh CO 9
11 a Эт ов 527 4 25 23 at
— —— "<= — === me mm — =
KRALIS L'NAIMER
ALTERNATE SWITCH 53 Circuit Diagram No. CB-900 505-1A2
GR-LROUND CWwHT]
B-BRASS(Y)
C-COPPERIN)
REMOTE CONTROL
OPTICAL -EXTRA?
Figure 7-1. Circuit Diagram
Page 12
May 1979 FORM: OM-228C
Effective With Serial No. HK243390
Fig F
TD-900 505-C
Fig D
ASS TI
a)
JS
== TORES
= WS /
AE
\
E
A ANY;
10 11 12 13
19
20
21
22
Fig H
OM-228 Page 1
Figure A — Main Assembly
item Dia. Factory
No. Mkgs. Part No. Description Quantity
Figure A Main Assembly
1 005 195 PANEL, side... i siete ta tae ees 2
2 005 194 COVER, top ..........eeamoovrarareroreannamércvwrerermnaarea 1
3 Figure B AMPLIFIER ASSEMBLY, magnetic (See Page 3) ................. 1
4 R6 028 839 RESISTOR, WW adj 100 watt 10 ohm ..........eeceecesreavendere, 1
5 R7 028 840 RESISTOR, WW adi 300 watt Bohm...........eorm-rerearonanarm 1
6 R25 6030582 RESISTOR, WW fixed 25 watt 5 ohm .........o—eeeeacerraneaeen, 2
7 026 627 GASKET, lifting eye... oie ee ee ee ee eee iia 1
8 Z 004 536 STABILIZER . i ee a 4 a 4 a ea 6 1
9 SR2 035 914 RECTIFIER, integrated 30 amp 400 volts .....2.2222020 0000 0000000 1
10 012638 HOLDER, fuse - cartridge... 122101000044 4 4 4 a 0 4 aa 1 LL LL 20 1
11 F2 *012 639 FUSE, cartridge 6 amp 600 volts .. 1... 1144211 11122 14 4 4 4 4 4 40 1
12 T2 024 013 TRANSFORMER, kva 1 30-115 or
12 T2 003 062 TRANSFORMER, kva 2 30-115 120211040114 ieee 1
13 R9 026 520 RESISTOR, grid oe 1
14 Figure D PANEL, rear - with components (See Page 4) .................. ... 1
15 TE1 038 125 TERMINAL ASSEMBLY, primary {See Fig. CPage 3) ............. 1
16 W 034 652 CONTACTOR, 3 pole 115 volts (Allen Bradley) or
15 149, +003 708 CONTACTOR, 75 amp 3 pole 600 volts (Furnas) (See Fig. E Page 4) .. 1
17 023378 CHANNEL, core clamping ........ o o ._.se2e0macarodoaronena 1
18 1TT1 024 011 TRANSFORMER, power - main (See Fig. F Page 5) ..............o. 1
19 059712 CLIP, plastic cable ............. 2... esecrirenmereoarananmen 1
20 R8 030 603 RESISTOR, WW fixed 10 watt 10K ohm ............... . em. 1
21 004 538 BASE . uu nrereneonaeeneonenorecanereroaanoo 1
22 023 502 BUS BAR, rectifier to output stud ........ ——.—...—........erecxro. 1
23 SR1 079 697 RECTIFIER, silicon diode or
23 SR1 023264 RECTIFIER, silicon diode (See Fig. G Page 5) ................... i
23 SRI1 079699 RECTIFIER, silicon diode or
23 SRT 027391 RECTIFIER, silicon diode {See Fig. GPage5).................... 1
24 Figure H PANEL, front - with components (See Page 6). ................... 1
*Recommended Spare Parts.
+When ordering replacement contactor the Furnas is preferred.
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-228 Page 2
Item Factory
No. Part No, Description Quantity
Figure B Amplifier Assembiy, Magnetic (See Page 2 Item 3)
36 023487 BUSBAR LL... 11211112 4e 4 44 4 a a A4 4 A 4 48 a 4 8 ee tt eerste aaa, 3
37 031085 CHANNEL, clamping core - rear a 14200 1
38 023379 BAR, ,spacing .. 1.220020 444 40 4 8 44 8 0 4 4 4e 4 eee reese ane 5
39 031 204 AMPLIFIER 1111100044 44 2844 14 A4 a 4 0 24 a 4 a aa a a a a aa a a aan» 6
40 031084 CHANNEL, clamping core -front......11122200 4004 44114 a ea aa Lee 1
36 37 38
39 тв-024 012
Figure B — Amplifier Assembly, Magnetic
TC-038 125
Figure C — Terminal Assembly, Primary
[tem Factory
No. Part No. Description Quantity
Figure C 038 125 Terminal Assembly, Primary (See Fig. À Page 2 item 15)
51 601 835 NUT, brass - hex 10-32 ......... .....60 m0. mearraraenare nero. 30
52 038618 LINK, jumper .........ee.m.reacdorerare arena rave ra aarrenene. 7
53 010913 WASHER, flat - brass 3/16 1D x 1/2 0D... coi, 15
54 038 887 STUD, brass with hex collar 10-32 x 1-3/8 .......... ol. 16
55 038 058 TERMINAL BOARD ...........—.—..eoeerveeerercería rre. 1
56 601 836 NUT, brass - hex 1/4-20 ........... 92.222. 0x xxx racer. o 6
57 ‚038 888 STUD, brass with hex collar 1/4-20 x 1-1/2 ..... ............ Do 3
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 3
item Dia. Factory
No. Mkgs. Part No. Description Quantity
Figure D Panel, Rear - With Components {See Fig. A Page 2 Item 14)
66 FM 032605 MOTOR, SP 1/4 HP 230 voltsac ..........—.oeeserroecoocorerroo, 1
67 027 160 CHAMBER, plenum 12104404 La 242411 2e a 14 1 a 0 a a a a 1 0 0 00 sa 0 0 1
68 605 799 BLADE, fan 14inch5wing30deg60Hz ........................ 1
69 018 144 PANEL, rear ...... ii iii ett tiara seit eee 1
3 FL их хо
dj a Pa . x E og
PRE A r ES У ERA
ae gr 6 a a A .
, $ AER FE ñ a
- CU E
: ; . ET .
; Pak ИЯ e ; A F
LA - . XT LAA ri a y {A
E
FA
7
De ¿EE
Fy
| TD-024 590
Figure D — Panel, Rear - With Components
TC-034 652
77
(Furnas) TC-004 927 {Allen Bradley}
Figure E — Contactor
Item Factory
No. Part No. Description Quantity
Se
Figure E Contactor (See Fig. A Page 2 ltem 16) = 2
tr)
= <
76 033675 COIL, contactor 115 volts ac (Allen Bradley) . ......... ... cen ...e. 1
76 003 710 COIL, contactor 120 volts ac 75 amp (Furnas) ......... e e... 1
77 *034 661 KIT, point-contact{AllenBradiey} . . . ....... i... 1
77 *003 709 KIT, point - contact (Furnas). . .. .. eee terre eee 3
*Recommended Spare Parts
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-228 Page 4
item Factory
No. Part No. Description Quantity
Figure F 024011 Transformer, Power - Main (See Fig. A Page 2 Item 18)
86 *¥023400 TRANSFORMER SUBASSEMBLY (consisting of) ............. 1
87 023596 .STRIP, glastic 1/8 x 3-7/16x 4 .............. 2... кк... с... 4
83 024 001 .WEDGE, phenolic - single bevet 3/8 x 1 x 9-1/2 ............... 3
89 024 002 .WEDGE, phenolic - single bevel 5/16 x 1x 9-1/2 .............. 3
90 023595 STRIP, glastic 1/8 x 4 x 11 ooo eee eee es 2
91 **024 014 COIL, primary/secondary 3
ii
o
D
NN
<
il
=
A
I
я и к аа жк ит ее на тж ч вен нии ни г Yan ax"
86
ee
37 88 89 90
101 102 103
TB-024 001
Figure F — Transformer, Power - Main
|
TA-023 264
Figure G — Rectifier, Silicon
[tem Dia. Factory
No. Mkgs. Part No. Description Quantity
ге <= 3 =
. e: cdi 3 8 ES 68
Figure G Rectifier, Silicon (See Fig. A Page 2 item 23) o.
58565 8
101 C7 031683 CAPACITOR, paper-oil 0.58 ufb00voltsde .................... T 1 1 1
102 031688 CAPACITOR, ceramic 0,1 uf 500 volts de ..............oéoem.. 1 2 1 2
102 031689 CAPACITOR, ceramic 0.01 uf 500 volts de ............. 2... 510 510
103 1h01-6 037510 DIODE, N matched . 2.2... a asereaore nao à 12 12
103 D1-6 037156 DIODE, L matched ............ 2.2. 0 ee 2 ae 12 12
** Replace at Factory or Factory Authorized Service Station.
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 5
Item Dia. Factory
No. Mkgs. Part No. Description Quantity
Figure H Panel, Front - With Components (See Fig. À Page 2 [tem 24)
116 V 025604 METER, voltage 0-100 de... a He 1
117 A 025 610 METER, amperage 0-800dc ............ cirrus 1
118 023443 PANEL, front ...........oe0ec00ormoarecoresoocrooaranoroo 1
119 RC3 039686 RECEPTACLE, ground -twistlock 2P3W._................... 1
120 S524 011611 SWITCH, toggle DPDT 15 amp 125 volts. . . . . . ov vs si ieee. 2
121 R34 030098 RESISTOR, WW fixedbwatt ohm. . ........ cu... u... 2
122 $3 027 400 SWITCH, rotary 4 position 3P or
122 53 605 781 SWITCH, rotary 4 position 4P (Kraus & Naimer) ................. 1
123 1=RI1 *030 653 RHEOSTAT, WW 150 watt 15 0hm ..............2. 00 0ex0 ii... 1
124 51 011 813 SWITCH, toggle 3PST 20 ampere 250 volts ............eresredeo 1
125 НС 039 607 RECEPTACLE, twistlock 3P3W 11101104 4044444 4 4 14 a a 4 a 4 ae 1
126 RC2 604176 RECEPTACLE, duplex - ground straight 2P3W .................. 1
127 Neg 039 046 TERMINAL, power output - black (See Fig. H1 Page 7) ........... 1
128 Pos 039 047 TERMINAL, power output - red (See Fig. H1 Page 7) ............. 2
129 019 627 KNOB, pointer .......... 2... ee ee ee ee A 1
130 039 687 CAP, electrical - ground twistlock 2P3W . . ...... ................ 1
131 F1,3 *012655 FUSE, miniature - glass TO ampere .......... .... 0000 0000a0a0o 2
132 012617 HOLDER, fuse - miniature ............ e s2r00merenraoaoanoao 2
133 039 63% BODY, connector - electrical twistlock 2P2W ear. 1
134 RC4 039634 RECEPTACLE, twistlock - male flange 2P2W ..... .............. 1
135 NAMEPLATE (order by stock, model, and serial numbers) .......... 1
132
“Recommended Spare Parts
121
Figure H — Panel, Front - With Components
TD-002 496-A
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-228 Page 6
item Factory
No. Part No. Description Quantity
ST
Figure H1 Terminal, Power Output (See Fig. H Page 6 [tem 127 8: 128) 5 8
ся 3
o_o
146 601 879 NUT, steel - hex full 1/2-13 .........e..e._.enacaracomoraorranaooe. 1 1
147 039 044 BUS BAR ........ 01 444 04 40 a 4 8 4 0 0 4 0 a 4 a ea a a a a a 4 au eu a ae nee ea 000 1 1
148 601 880 NUT, steel - hex jam 1/2-13 1.111222 0022 0 4 214 4 a ee a ee 1 a 0 ee неее 1 1
149 039 045 TERMINAL BOARD, black ......1120200 00404 2 44 4 00 4 ea 4 a 4 ea sa aa a ne 1
149 039 049 TERMINAL BOARD, red .............—..eserecxvorecovanmvcenmenrenmoo 1
150 053 032 CLIP, spring - bus bar ........—.om.eerevreraoeoraverereroarananonoa 1 1
151 601 976 SCREW, cap - steel hex hd 1/2-13 x 1-1/2 ...... e... aras ram. 1 1
151
T8-005 763
Figure H1 — Terminal, Power Output
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 7