Miller | KF300000 | Owner Manual | Miller PS-100 User manual

Miller PS-100 User manual
~4MiUerThermaI ,Inc.
A Ham
Group Ltd. Company
555 Communication Dr., P.O. Box 1081
Appleton,
WI 54912 USA
Tel. 414-731-6884
FAX 414-734-2160
~
~
PS 100
~
OPERATORS
Model P9-100
MANUAL
Part Number 5001765
lMPORTANT~ Read and understand the entire contents of this manual, with special
on the safety material throughout this manual, before Installing, operating, or
.
emphasis
maintaining this equipment This unit and these Instructions are for use only by persons
andexperlencedIn ttwaafe.operatlon of thermaispray. equipment-Do not allow
untrained persons to instaII,.Qpe~ata,-. or~mainaIn-thIg~un~L...Contect a-Factory~REpre~
sentaflve ifyou do not fully understand these Inetructiona
trained
LIMITED WARRANTY
This warranty supersedes all MILLER Thermal
warranties and is exclusive with no other guaran
tees or warranties expressed or implied.
LIMITED WARRANTY Subject to the terms and
conditions here of, Miller Thermal, Inc., Appleton,
Wisconsin warrants to the original user that all
new and unused equipment furnished by Miller
Thermal is free from defect in workmanship and
material as of the time and place of delivery by
Miller Thermal. No warranty is made by Miller
Thermal with respect to engines, trade acces
sories or other items manufactured by others.
Such engines, trade accessories and other items
are sold subject to the warranties of their respec
tive manufacturers, if any.
All engines are
warranted by their manufacturer for one year
from date of original purchase.
-
Except as specified below, Miller Thermals war
ranty does not apply to components having
normal useful life less than one (1) year, such as
wire nozzles, air caps, anodes and cathodes,
wire guides, or other items considered to be
consumable items.
Miller Thermal shall be
required to
honor warran
ty 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. All Power Sources, Robots,
and
1 year
main power rectifiers
OrigInal
in power source
(labor
4. All
-
1 year
Spray
3 years
only)
Guns and
Wire Feeders
5. All Feed
6.
1 year
and
Hoppers
Cooling Systems
Replacement or repair parts,
1 year
exclusive of labor
60
7. Batteries
days
6 months
provided that Miller Thermal is notified in writing
thirty (30) days of the date of such failure.
within
As
a
matter of
case
reasonable
depreciation based upon actual use)
goods at Customers risk and
Thermals
Miller
option of repair or
expense.
replacement will be F.O.B., Factory, at Appleton,
upon return of the
or F.O.B., Factory, at a Miller Ther
mal authorized service facility, therefore, no
compensation for transportation costs of any
kind will be allowed. Upon receipt of notice of
apparent defect or failure, Miller Thermal shall
instruct the claimant on the warranty claim pro
cedures to be followed.
Wisconsin,
ANY EXPRESS WARRANTY NOT PROVIDED
HEREIN AND ANY IMPLIED WARRANTY,
GUARANTY OR REPRESENTATION AS TO
PERFORMANCE, AND ANY REMEDY FOR
BRGACH OF CONTRACT WHICH, BUT FOR
THIS PROVISION, MIGHT ARISE BY IMPLICA
TION, OPERATION OF LAW, CUSTOM OF
TRADE OR COURSE OF DEALING, INCLUD
ING
ANY
IMPLIED
WARRANTY OF
MERCHANTABILITY OR OF FITNESS FOR
PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY
MILLER THERMAL IS EXCLUDED AND DIS
CLAIMED BY MILLER THERMAL.
1 year
Components
2. All Control Consoles
3.
of Miller Thermals breach of warranty
other
duty with respect to the quality of
any
any goods, the exclusive remedies therefore
shall be, at Miller Thermals option (1) repair or
(2) replacement or, where authorized in writing
by Miller Thermal in appropriate cases, (3) the
reasonable cost of repair or replacement at an
authorized Miller Thermal service station or (4)
payment of or credit for the purchase price (less
In the
or
Miller Thermal
the original user
9eneral policy only,
may honor claims submitted
within the foregoing periods.
by
EXCEPT AS EXPRESSLY PROVIDED BY
MILLER THERMAL IN WRITING, MILLER
THERMAL PRODUCTS ARE INTENDED FOR
ULTIMATE PURCHASE BY COMMERCIALJIN
DUSTRIAL USERS AND FOR OPERATION BY
PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF SPRAY
EQUIPMENT AND NOT FOR CONSUMERS
OR CONSUMER USE. MILLER THERMALS
WARRANTIES DO NOT EXTEND TO, AND NO
RESELLER IS AUTHORIZED TO EXTEND
MILLER THERMALS WARRANTIES TO, ANY
CONSUMER.
TABLE OF CONTENTS
Section No.
SECTION 1
Page
SAFETY RULES FOR OPERATION OF
-
1-1.
Introduction
1-2.
General Precautions
1-3.
Arc
1-4.
Standards Booklet Index
ARC
WELDING POWER SOURCE
1
.---.~
1
4
Welding
5
SECTION 2INTRODUCTION
2-2.
Volt-Ampere Curves
Duty Cycle
2-3.
General Information And
2-4.
Receiving-Handling
Description
2-1.
2-5.
SECTION 3
3-1.
Location
Weld
3-3.
3-4.
SECTION 4
7
7
7
Safety
8
8
INSTALLATION
3-2.
8
Output Connections
Control Module Receptacle Information
Electrical Input Connections
8
And Connection
9
10
OPERATOR CONTROLS
4-1.
PilotLight
11
4-2.
Circuit Breaker
11
4-3.
Control Module
SECTION 5
5-1.
5-2.
Receptacle
11
SEQUENCE OF OPERATION
Operation
Shutting Down
11
11
SECTION 6- MAINTENANCE & TROUBLESHOOTING
6-1.
Routine Maintenance
12
6-2.
Fan Motor
12
6-3.
Overload Protection
6-4.
Troubleshooting
Chart
No.
12
13
SECTION 1
SAFETY RULES FOR OPERATION OF-ARC WELDING POWER SOURCE
INTRODUCTION
We learn
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
sonal
Avoid
others teach you.
Hot metal such as electrode stubs and
shOFd never be handled without gloves.
1-1.
-
-
by experience. Learning safety through perexperience, like a child touching a hot stove is
harmful, wasteful, and unwise. Let the experience of
Safe practices developed from experience in the use of
welding and cutting are described in this manual. Re
search, development, and field experience have
evolved reliable equipment and safe installation, opera
tion, and servicing practices. Accidents occur when
improperly used or maintained. The rea
practices may not always be given.
based on common sense, others may require
equipment
son
are
technical volumes to
greasy clothing. A spark may ignite them.
workpieces
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 im
mediate treatment of flash burns of the eyes and skin
burns.
explain. It is wiser
to follow the
Ear
in
a
should be worn when working on overhead or
confined space. A hard hat should be worn when
plugs
others work overhead.
rules.
Flammable hair preparations should not be used
Read and understand these safe
sons
practices before at
tempting to install, operate, or service the equipment.
Comply with these procedures as applicable to the par
ticular equipment used and their instruction manuals, for
personal safety and for the safety of others.
B.
intending
Severe discomfort, illness or death can result from
fumes, vapors, heat, or oxygen enrichment or depletion
that
welding (or cutting) may produce. Prevent them
adequate ventilation as described in ANSI Stan
with
injury or
equipment can be used with confidence.
wittroxygen.
practices may cause seri
death. When safety becomes a habit, the
These safe
practices
are
divided into two Sections:
1-General Precautions, common to arc welding and cut
ting; and 2-Arc Welding (and Cutting) (only).
Reference standards: Published Standards on safety
are also available for additional and more complete pro
cedures than those given in this manual. They are listed
in the Standards Index in this manual. ANSI Z49.1 is the
most
complete.
Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements also provide a basis for equip
The National Electrical
ment
installation,
1-2.
GENERAL PRECAUTIONS
use, and service.
by per
to weld or cut.
Toxic Fume Prevention
Failure to observe these safe
ous
-
or
is
for the safe
Some
oily
dard Z49.1 listed in Standards Index. NEVER ventilate
Lead -,cadmium-, zinc -, mercury-, and beryllium-bear
ing and similar materials, when welded (or cut) may pro
duce harmful concentrations of toxic fumes.
Adequate
local exhaust ventilation must be used, or each person
in the area as well as the operator must wear an air-sup
plied respirator.
For
Metals coated with
beryllium, both
or
containing
must be used.
materials that emit
toxic fumes should not be heated unless coating is re
moved from the work surface, the area is well ventilated
and, if necessary, while wearing
an
air-supplied respira
tor.
Work in
a
confined space
only while
and, if necessary, while wearing
an
it is being ventilated
air-supplied respira
tor.
Different arc
and
welding processes, electrode alloys,
fluxes can produce different fumes, gases, and
radiation levels. In addition to the information in
this manual, be sure to consult flux and electrode
manufacturers
Material
Safety Data Sheets
(MSDSs) for specific technical data and precautIon
ary measures concerning their material.
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 cuffless trousers
to avoid entry of sparks and slag.
Wear helmet with
safety goggles
and
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
Gas leaks in
a confined space should be avoided.
Leaked gas in large quantities can change oxygen con
centration dangerously. Do not bring gas cylinders into a
confined space.
Leaving confined space, shut OFF gas supply at source
prevent possible accumulation of gases in the space if
downstream valves have been accidentally opened or
to
left open. Check to be
re-entering it.
sure
that the space is safe before
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 prod
ucts. The ultraviolet (radiant) energy of the arc can also
decompose trichioroethylene and perchioroethylene
vapors to form phosgene. DO NOT WELD or cut where
solvent vapors can be drawn into the welding or cutting
124 645
Page
1
atmosphere or where the radiant energy can penetrate
atmospheres containing even minute amounts of
trtchloroethylene or perchloroethylene.
to
C.
Fire and
Explosion
Prevention
ment as recommended in A6.O.
level may substitute for
working
Waterfilling just
inerting.
below
A container with unknown contents should be cleaned
(see preceding paragraph). Do NOT depend on sense
or sight to determine if it is safe to weld or cut.
of smell
Causes of fire and explosion are: combustibles reached
by the arc, flame, flying sparks, hot slag or heated mate
rial; misuse of compressed gases and cylinders; and
short circuits.
BE AWARE THAT
flying sparks or falling slag can pass
through cracks, along pipes, through windows or doors,
and through wall or floor openings, out of sight of the
goggled operator. Sparks and slag can fly 35 feet.
To prevent fires and
explosion:
Keep equipment clean and operable, free of oil, grease,
(in electrical parts) of metallic particles that can
Hollow
welding
castings or containers must be vented before
or cutting. They can explode.
Explosive atmospheres. Never weld or cut where the air
may-contain flammable dust, gas, or liquid vapors (such
as gasoline).
D.
Compressed
Gas
Equipment
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-i, SAFE
HANDLING OF COMPRESSED GASES IN CYLIN
DERS, listed ii in Standards Index.
and
short circuits.
cause
Pressure
1.
Regulators
relief valve is
If combustibles
in area, do NOT weld or cut. Move
the work if practicable, to an area free of combustibles.
are
Avoid
paint spray rooms, dip tanks, storage areas, venti
lators. If the work cannot be moved, move combustibles
at least 35 feet away out of reach of
protect against ignition
sparks
with suitable and
and heat;
or
snug-fitting,
fire-resistant
covers or
Walls
on opposite sides should
(or cut). Walls, ceilings, and floor near
be protected by heat-resistant covers or
touching
not be welded
work should
shields.
combustibles
on
Fire watcher must be
standing by with suitable fire extin
guishing equipment during and for some time afterweld
ing or cutting if:
appreciable
construction)
b.
combustibles
are
(including building
within 35 feet
appreciable
combustibles
feet but
be
can
are
further than 35
Never connect
a
relief devices.
regulator
cylinder containing gas
regulator was designed.
to a
other than that for which the
faulty regulator from service immediately for
repair (first close cylinder valve). The following symp
toms indicate a faulty regulator:
Leaks-if gas leaks externally.
Excessive Creep-if delivery pressure continues to rise
with downstream valve closed.
Faulty Gauge-if gauge pointer does not move off stop
pin when pressurized, nor returns to stop pin after pres
release.
sure
Repair.
Do NOT attempt to repair. Send faulty regula
repair to manufacturers designated repair cen
ter, where special techniques and tools are used by
trained personnel.
ignited by sparks
within 35 feet may expose combustibles to
sparks
d.
one or more
tors for
openings (concealed orvisible) infloorsorwalls
c.
with
Remove
shields.
a.
Regulator
designed to protect only the
from
regulator
overpressure; it is not intended to protect
downstream
equipment. Provide such protection
any
combustibles adjacent to wails, ceilings, roofs,
metal partitions can be ignited by radiant or
conducted heat.
or
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
third rails, electrical wires, or welding circuits.
produce short circuit
(See i-3C.)
arcs
including
They can
that may lead to a serious ac
cident.
Hot work
ensure
permit should be obtained before operation to
supervisors approval that adequate precautions
ICC
or
DOT
assurance
have been taken.
marking must be on each cylinder. It is an
safety when the cylinder is properly han
of
dled.
After work is done, check that
glowing embers, and flames.
An
area
is free of
sparks,
empty container that held combustibles, or that can
flammable or toxic vapors when heated, must
produce
never be welded on or cut, unless container has first
been cleaned as described in AWS Standard A6.O,
listed 7 in Standards Index.
This includes:
a thorough steam or caustic cleaning (or
orwaterwashing, depending on the combusti
bles solubility) followed by purging and inerting with ni
trogen or carbon dioxide, and using protective equipa
solvent
124 645
Page
2
Identifying gas content. Use only cylinders with name of
gas marked on them; do not rely on color to identify gas
content. Notify supplier it 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;
keep them separate from FULLS and return
promptly.
mark MT;
Prohibited
use.
Never
use a
cylinder
or
its contents for
other than its intended use, NEVER as a support
roller.
or
Locate
or secure
cylinders
they
so
cannot be knocked
outlet away from people and
a c1e~n lintless cloth.
Passageways and work areas. Keep cylinders
where they may be struck.
clear of
of
ignition. Wipe
Transporting cylinders.
port such
With
a
Match
regulator to cylinder. Before connecting, check
regulator label and cylinder marking area, 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.
that the
areas
crane, use a secure sup
platform or cradle. Do NOT lift cylinders
off the ground by their valves or caps, or by chains,
slings, or magnets.
as a
Tighten connections. When assembling threaded
nections, clean and smooth
Do NOT expose cylinders to excessive heat, sparks,
and flame, etc. that may cause rupture. Do not al
slag,
low contents to exceed 130F.
where such exposure exists.
Cool with water spray
Protect cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when moving cylinders.
Stuck valve. Do NOT
hammer or wrench to open a
valve that can not be opened by hand. Notify
use a
cylinder
your supplier.
Mixing
gases. Never try to mix any gases in
a
cylinder.
Adapters. Use a CGA adapter (available from your sup
plier) between cylinder and regulator, if one is required.
use two wrenches to tighten adapter marked RIGHT
and LEFT HAND threads.
Regulatoroutlet (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.
Pressurizing Steps:
regulator of residual gas through suitable vent be
opening cylinder (or manifold valve) by turning ad
justing screw in (clockwise). Draining prevents exces
sive compression heat at high pressure seat by allowing
seat to open on pressurization. Leave adjusting screw
engaged slightly on single-stage regulators.
Drain
fore
cylinder.
Cylinder fittings should
changed.
con
seats where necessary.
Tighten. If connection leaks, disassemble, clean, and
retighten using properly fitting wrench.
5.
Never refill any
3.
sources
with
over.
never
be
modified
or
ex
Hose
Stand to side of
Prohibited
signed
use.
for the
Never
use
specified gas.
regulator while opening cylinder
valve.
hose other than that de
A
general hose identifica
tion rule is: red for fuel gas, green for oxygen, and black
for inert gases.
Use ferrules or clamps designed for the hose (not ordi
nary wire or other substitute) as a binding to connect
hoses to fittings.
Open cylinder valve slowly so that regulator pressure in
slowly. When gauge is pressurized (gauge
reaches regulator maximum) leave cylinder valve in fol
lowing 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.
creases
No copper
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on
tings
regulators.
to
tubing splices. Use only standard brass f it
splice hose.
Avoid long runs to prevent kinks and abuse. Suspend
hose off ground to keep it from being run over, stepped
on, or otherwise damaged.
Check for leaks on first pressurization and regularly
there-after. Brush with soap solution (capfull of Ivory
Liquid or equivalent per gallon of water). Bubbles indi
cate leak. Clean off soapy water after test; dried soap is
Coil
combustible.
excess
hose to prevent kinks and
Protect hose from damage by
sparks, slag, and open flame.
tangles.
sharp edges,
and
by
Examine hose regularly for leaks, wear, and loose con
nections. Immerse pressured hose in water; bubbles in
dicate leaks.
E.
Repair leaky
by cutting
ing (1-2D3). Do NOT tape.
hose
area out
and
splic
Proper Connections
Clean
cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing
Leaving Equipment
Close gas
G.
4.
ResponsibIlitIes
Remove leaky or defective equipment from service im
mediately for repair. See User Responsibility statement
in equipment manual.
F.
or worn
User
supply
Unattended
at source and drain gas.
Rope StagIng-Support
Rope staging-support should not be
cutting operation; rope may bum.
used for welding
or
*Trademark of Proctor & Gamble.
124 645
Page
3
ARC WELDING
1-3.
Viewing
Comply with precautions in 1-1, 1-2, and this section.
Welding, properly done, is a safe process, but a
Arc
Others working in
careless operator invites trouble. The
flash
equipment carries
high currents at significant voltages. The arc is very
bright and hot. Sparks fly, fumes rise, ultraviolet and in
frared energy radiates, weidments are hot, and com
pressed gases may be used. The wise operator avoids
area.
See that all persons
are
wearing
goggles.
Before starting to weld, make
doors are closed.
sure
that
screen
flaps
or
bay
B.
Toxic Fume Prevention
unnecessary risks and protects himself and others from
accidents. Precautions are descnbed here and in stan
Comply
dards referenced in index.
Generator engine exhaust must be vented to the outside
air. Carbon monoxide can kill.
A.
with
in 1 -2B.
precautions
Burn Protection
C.
Comply
with
Fire and
visibly bright. its radiation
can damage eyes, penetrate lightweight clothing, reflect
from
arc
and burn the skin and eyes.
Skin burns resemble acute sunburn, those from gasarcs are more severe
and
painful. DONT GET
BURNED; COMPLY WITH PRECAUTIONS.
Protective
1.
Clothing
Wear
long-sleeve clothing (particularly for gas-shielded
gloves, hat, and shoes (1 -2A). As nec
essary, use additional protective clothing such as
leather jacket or sleeves, flame-proof apron, and fire-re
sistant leggings. Avoid outer garments of untreated cotin addition to
arc)
ton.
Bare skin protection. Wear dark, substantial clothing.
Button collar to protect chest and neck and button pock
ets to
2.
prevent entry of sparks.
Eye
PreventIon
with
precautions
in 1 -2C.
is intense and
light-colored surfaces,
shielded
Explosion
in 1-2.
precautions
Comply
The welding
-
the weld. Provide face shields for all persons
looking directly at the weld.
who will be
and Head Protection
Protect eyes from exposure to arc. NEVER look at
arc without protection.
an
Equipments rated capacity. Do not overload arc
ing equipment. It may overheat cables and cause
Loose cable connections may overheat
fire.
or
weld
a
fire.
flash and
cause a
Never strike an arc on a cylinder or other pressure ves
sel. It creates a brittle area that can cause a violent rup
ture or lead to such a rupture under rough handling.
D.
Compressed
Comply
E.
with
Gas Equipment
precautions
in 1 -2D.
Shock PreventIon
Exposed hot conductors or other bare metal in the weld
ing circuit, or in ungrounded, electrically-HOT equip
ment can fatally shock a person whose body becomes a
conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR
TOUCH a wet surface when welding, without suitable
protection.
To protect
electric
against
shock:
Wear
Welding
helmet
shield containing a filter plate shade
no. 12 or denser must be used when welding. Place over
face before striking arc.
Protect filter
or
plate
with
a
clear
cover
dry insulating gloves and body protection. 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 dampness or sweat
can not
plate.
tween
Cracked
broken helmet
or
worn; radiation can pass
Cracked, broken,
or
loose filter
IMMEDIATELY.
ken, pitted,
Flash
or
or
Replace
spattered.
shield should NOT be
through
to cause burns.
plates
clear cover
must be
plate
replaced
when bro
goggles with side shields MUST be worn under
give some protection to the eyes should
the helmet to
the helmet not be lowered over the face before an arc is
struck. Looking at an arc momentarily with unprotected
eyes
(particularly a high intensity gas-shielded arc)
can
retinal bum that may leave a permanent dark
in the field of vision.
be avoided. Sweat, sea water, or moisture be
and an electrically HOT part or grounded
body
metal reduces the electrical resistance, and could en
able dangerous and possibly lethal currents to flow
through
the
body.
A voltage will exist between the electrode and any con
ducting object in the work circuit. Examples of conduct
ing objects include, but are not limited to, buildings, elec
trical tools, work benches, welding power source cases,
workpieces, etc. Never touch the electrode and any
metal object unless the weldIng power source Is off.
1.
Grounding
the
Equipment
cause a
area
3.
Protection of
Enclosed
welding
Nearby
area.
rate room or enclosed
Personnel
For
production welding,
a
sepa
bay is best. In open areas, sur
operation with low-reflective, non-combusti
ble screens or panels. Allow for free air circulation, par
ticularly at floor level.
round the
124645
Page
4
Arc
welding equipment-must be grounded according to
the National Electrical Code, and the work must be
grounded according to ANSI Z49.1 Safety In Welding
And
Cutting.
When
installing, connect the frames of each unit such as
welding power source, control, worktable, and water cir
culatorto the building ground. Conductors must be ade
quate to carry ground currents safely. Equipment made
electrically HOT by stray current may shock, possibly fa
tally. Do NOT GROUND to electrical conduit, orto a pipe
carrying ANY gas or flammable liquid such as oil or fuel.
b.
can
without output on/off control (no
Welding power
metal
sources
used with shielded
and similar proc
may not be equipped with welding power
output on-oft control devices. With such equip
ment the electrode is electrically HOT when the
power switch is turned ON. Never touch the
Three-phase connection. Check phase requirements of
equipment before installing. If only 3-phase power is
available, connect single-phase equipment to only two
Wires of the 3-phase line. Do NOT connect the equip
ment ground lead to the third (live) wire, or the equip
ment will become electrically HOT-a dangerous condi
tion that
Equipment
co.ntactor)
arc
welding (SMAW)
esses
.~electrode unless the welding power
Before
welding, check ground for continuity. Be sure
conductors are touching bare metal of equipment
7.
frames at connections.
should not be disconnected or shunted out.
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 re
ceptacle, the ground lead must be connected to the
ground prong only. If the line cord comes with a threeprong 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.
2.
is
Safety
Safety
Devices
devices such
as
interlocks and circuit breakers
Before installation, inspection, or service, of equipment,
shut OFF all power and remove line fuses (or lock or
red-tag switches)
power.
to prevent accidental turning ON of
all cables from welding power
all 115 volts line-cord plugs.
Disconnect
source, and
pull
Do not open power circuit or change polarity while weld
ing. 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.
Electrode Holders
Fully insulated electrode holders should
use holders with protruding screws.
be used. Do
NOT
3.
source
off.
shock, possibly fatally.
Power disconnect switch must be available
welding power
F.
Connectors
near
the
source.
ProtectIon For Wearers of ElectronIc LIfe
Sup
port DevIces (Pacemakers)
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
from hot metal and
5.
protected
Magnetic fields from high currents can affect pacemaker
operation. Persons wearing electronic life support
equipment (pacemaker) should consult with their doctor
before going near arc welding, gouging, or spot welding
operations.
1-4.
For more information, refer to the
their latest revisions and comply
1.
sparks.
Terminals And Other
Exposed Parts
Terminals and other exposed parts of electrical units
should have insulating covers secured before opera
tion.
STANDARDS BOOKLET INDEX
2.
ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126.
NIOSH, SAFETY AND HEALTH
Electrode
a.
IN ARC WELDING
AND GAS WELDING AND CUTTING obtainable
from the Superintendent of Documents, U.S. Gov
ernment
6.
following standards or
as applicable:
3.
Printing Office, Washington, D.C.
OSHA, SAFETY AND HEALTh STANDARDS,
29CFR 1910, obtainable from the
Equipment with output on/off control (contactor)
of Documents, U.S. Government
Welding
metal
power sources for
arc
use
with the gas
welding (GMAW), gas tungsten
arc
welding (GTAW) and similar processes nor
mally are equipped with devices that permit on
off control of the welding power output. When
so equipped the electrode wire becomes elec
trically HOT when the power source switch is
ON and the welding gun switch is closed. Never
touch the electrode wire or any conducting ob
ject in contact with the electrode circuit unless
the welding power source is off.
20402.
Washington,
Superintendent
Printing Office,
D.C. 20402.
4.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainable from the Ameri
can National Standards Institute, 1430 Broadway,
New York, NY 10018.
5.
ANSI Standard Z41.1, STANDARD FOR MENS
SAFETY-TOE FOOTWEAR obtainable from the
American
Broadway,
National Standards
New York, NY 10018.
Institute,
124 645
1430
Page
5
6.
7.
ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES
obtainable from the American National Standards
Institute, 1430 Broadway, New York, NY 10018.
AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUS
TIBLES obtainable from the American Welding So
ciety, 550
8.
N.W. LeJeune Rd, Miami, FL 33126.
NFPA Standard 51, OXYGEN-FUEL GAS SYS
TEMS FOR WELDING, CUTTING, AND ALLIED
PROCESSES obtainable from the National Fire
Protection Association,
Batterymarch Park, Quincy,
from the
Compressed
Gas Association, 1235 Jef
ferson Davis Highway, Suite 501, Arlington, VA
22202.
12. CSA Standard Wii7.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the Ca
nadian Standards Association, Standards
Sales,
178 Rexdale Boulevard, Rexdale, Ontario, Canada
M9W iR3.
13~NWSA booklet, WELDING SAFETY BIBLIOGRA
PHY obtainable from the National Welding Supply
Association, 1900 Arch Street, Philadelphia, PA
19103.
MA 02269.
Welding Society Standard AWSF4.1,
RECOMMENDED SAFE PRACTICES FOR THE
PREPARATION FOR WELDING AND CUTTING
OF CONTAINERS AND PIPING THAT HAVE
HELD HAZARDOUS SUBSTANCES, obtainable
14. American
9.
Standard 70, NATIONAL ELECTRICAL
CODE obtainable from the National Fire Protection
NFPA
Association,
Batterymarch
Park,
Quincy,
MA
02269.
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association,
Batterymarch Park, Quincy,
MA 02269.
11. CGA
Pamphlet P-i, SAFE HANDLING OF COM
PRESSED GASES
124 645
Page
6
IN
CYLINDERS obtainable
from the American
Welding Society,
550 N.W.
LeJeune Rd, Miami, FL 33126.
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA
TORY PROTECTION, obtainable from the Ameri
can
National Standards Institute, 1430
New York, NY 10018.
Broadway,
SECTION 2- INTRODUCTION
Rated
Welding
Amperes 100%
Duty Cycle
Range
Amperes Input At
Rated Load Output
Max. OpenCircuit
Weight
Dimensions
60 Hz Three-Phase
Voltage
-
200V
230V
460V
575V
KW
KVA
Net
Ship
Width: 27 in.
1155 lbs.
1370 lbs.
(686 mm)
Length: 27in
(686mm)
(524 kg)
(621 kg)
37 in.
Height:
(940 mm)
1200A@
20-1500
80V
Amperes
100 VDC
368
320
Figure
160
2-1.
128
104
128
SpecIfications
~-
.....
90
80
70
~r~o
60
50
30
20
0
50
0
300
450
600
750
DC
Figure
2-1.
The
VOLT-AMPERE CURVES
volt-ampere
curves
2-2.
The
DUTY CYCLE
duty cycle
of
and amper
voltage
welding power
source.
(Figure 2-3)
welding power source is the percent
of
ten
minute
a
period that a welding power source
age
can be operated at a given output without causing over
heating
and
a
damage
to the unit. This
welding power
source is rated at 100 percent duty cycle. This means
that the welding power source can be operated at rated
load continuously without causing overheating and
damage to the unit. Figure 2-3 enables the operator to
determine the output of the welding power source at
various duty cycles.
a
CAUTION: EXCEEDING DUTY CYCLE RAT
ING will damage the welding power source.
Do not exceed indicated
2-3.
A.
duty cycles.
GENERAL INFORMATION AND SAFETY
General
Information
presented
in this manual and
on
various la
bels, tags, and plates on the 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
1000
equipment.
200
350
1500
650
B-i 18 834
Curves
Volt-Ampere
(Figure 2-2)
show the
age output capabilities of the
2-2.
900
AOPODCS
B.
Safety
The
and
installation,
maintenance,
operation,
troubleshooting of arc welding equipment requires prac
tices 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 annual and all applica
ble codes such as, but not limited to, those listed at the
Operation Of Arc
end of Section 1, Safety Rules For
Welding Power Source.
Safety instructions specifically pertaining to this unit ap
pear throughout this manual highlighted by the signal
words WARNING and CAUTION which identify differ
ent levels of hazard.
WARN ING statements include
installation, operation,
and maintenance procedures or practices which if not
carefully followed could result in serious personal injury
or loss of life.
CAUTION statements include installation, operation,
and maintenance procedures or practices which if not
carefully followed could result in minor personal injury or
damage
A third
to this
signal
equipment.
word. IMPORTANT
highlights instruc
emphasis to obtain the most ef
equipment.
tions which need special
ficient
operation
of this
124 645
Page
7
RECEIVING-HANDLING
2-4.
When
requesting
information
concerning
this
equip
ment, it ii essential that Model Description and Serial
Number of the equipment be supplied.
Before
installing this equipment, clean all packing mate
carefully inspect for any
damage that may have occurred during shipment. Any
claim for loss or damage that may have occurred in tran
sit must be filed by the purchaser with the carrIer. A
copy of the bill of lading will be furnished by the manu
rial from around the unit and
facturer
request if occasion
on
DESCRIPTION
2-5.
This unit is
power
designed
to file claim arises.
three-phase,
constant current dc welding
with solid-state control. The dc output is
for use with spray arc equipment. A separate
a
source
ontt:omodule is
required for setting output parameters.
3000
2500
2000
U
Li
a
I
Li
a
1500
200 A
IOOX
000
I0
20
25
FIgure
2-3.
DUTY
60
50
40
30
%
70
80
90
00
CYCLE
B-116 833
Duty Cycle Chart
SECTION 3-INSTALLATION
3-1.
LOCATION
a
WARNING:
cause serious
This
welding power source has a lifting device for mov
ing the unit and holes in the base for mounting purposes.
FALLING
EQUIPMENT
can
personal Injury and equip
ment
damage.
lifting eye to lift unit only, NOT running
gear, gas cylinders, trailer, or any other heavy
options, accessories, or devices.
The location should allow sufficient room to remove the
cover and side panels for installation, maintenance,
top
and repair
procedures.
Use
Use
equipment of adequate capacity to lift the
unit.
If using lift forks to handle this unit, be sure the
lift forks are long enough to extend out of the op
posite side of the base.
lift forks too short will expose internal
components to damage should the tips of the lift
forks penetrate the bottom of the unit.
Using
RESTRICTED AIR FLOW
Ing
and
possible damage
overheat
to Internal parts.
Do not place any filtering device over the in
take air passages of this welding power source.
used.
The welding power source must be lo
that the Control Module cord can reach the
welding power source. The control module may be in
stalled into a control console.
cated
so
The service life and
is void if any type of
filtering device is
dirt, moisture, corrosive vapors, and extreme heat.
3-2.
WELD OUTPUT CONNECTIONS
(33
Page
8
OUTPUT
To obtain the full rated output from this unit, it is neces
sary to select, install, and maintain proper welding ca
bles. Failure to comply in any of these areas may result
in less than satisfactory welding performance.
A.
If
Welding Cables
cables were not ordered with this unit, the
listed
should be followed to ensure the best weld
steps
welding
ing performance:
124 645
operating efficiency of this unit are
subjected to high levels of dust,
reduced when the unit is
causes
Maintain at least 18 inches (457 mm) of unre
stricted space on a!! sides of unit, and keep un
derside free of obstructions.
Warranty
IMPORTANT:
1.
Keep
close
cables
possible, and place cables
iogether. Excessive cable length adds resis
as
short
as
tance which may reduce
ing of
2.
output
or cause
4A
Shut down unit and disconnect input power
employing lockout/tagging procedures before
making welding cable connections.
Select adequate size welding cable for the antici
pated maximum weld current. Use total length of
welding cable in the circuit to determine cable size.
For example: If the cable to spray gun is 25 feet (7.5
mm) long and work cable is 25 feet (7.5 mm) long,
consist
of
procedures
Lockout/tagging
padlocking line disconnect switch in open posi
tion, removing fuses from fuse box, or shutting
off and red-tagging circuit breaker or other dis
connecting device.
select the size cable recommended in Table 3-1 for
(15 m).
1.
Table 3-1.
WeldIng
Cable Size
2.
250
350
50
100
150
200
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
2/0
3/0
4/0
4/0
AMPERES
1/0
300
1
Connect end of spray gun cable to POSITIVE
weld output terminal.
(+)
Connect
()
end of work cable to NEGATIVE
one
terminal
weld
output
workpiece.
TOTA LLEN GTH OF CABLE (COPPER) IN WELD CI RCLJIT
WELDING
Do not touch live electrical parts.
overload
the unit.
50 feet
WARNING: ELECTRIC SHOCK can kill.
400
and
IMPORTANT: For Electrode
1/0
1/0
1/0
3/0
4/0
4/0
2.2/0
2/0
2/0
2/0
3/0
4/0
4/0
2-2/0
2-3/0
3/0
3/0
3/0
4/0
4/0
2-2/0
2-3/0
2-3/0
400
3/0
3/0
4/0
2-2/0
23/0
3-2/0
2-4/0
3-3.
500
4/0
4/0
2-2/0
23/0
23/0
2-4/0
3-3/0
MAT1ON AND CONNECTION
600
2-2/0
2-2/0
3/0
4/0
2-2/0
2-3/0
3-2/0
2-4/0
3-3/0
3-4/0
700
2-3/0
2-3/0
2-3/0
2-4/0
3-3/0
3-4/0
4-4/0
4-4/0
800
2-3/0
2-3/0
2-3/0
2-4/0
3-3/0
3-4/0
4-4/0
4-4/0
900
3-2/0
3-2/0
2-4/0
3-3/0
3-4/0
4-4/0
1000
2-4/0
2-4/0
43/0
4-4/0
3-3/0
3-3/0
4-3/0
4-4/0
1500
3-4/0
2-4/0
3-3/0
3-4/0
2-4/0
1250
3-4/0
4-4/0
A.
B.
C.
CONTROL
MODULE
RECEPTACLE
INFOR
(Figure 3-1)
17-pin Amphenol receptacle RC2 provides a con
point for the Control Module. To make connec
tions, align keyway, insert Control Module plug fully into
receptacle, and rotate threaded collar fully clockwise. A
properly connected Control Module is necessary for unit
operation.
The
nection
4-4/0
A-002 623
NOTE:
to
Negative/Straight Polarity
350
2/0
end
connections, reverse cable connections to weld output
terminals; electrode becomes negative.
300
250
remaining
5OFEETOR LESS.
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
The command
signals required and the output signals
receptacle RC2 are as fol
CIRCULAR MILS PER AMP.
available at the sockets of
WELD CABLE INSULATION WITH A VOLTAGE
RATING TO WITHSTAND THE OPEN-CIRCUIT VOLT
AGE )OCVI OF THE WELDING POWER SOURCE MUST
BE USED. WHILE MOST WELDING POWER SOURCES
HAVE AN OPEN-CIRCUIT VOLTAGE OF LESS THAN
lows:
100 VOLTS, SOME WELDING POWER SOURCES OF
SPECIAL DESIGN MAY HAVE HIGHER OPEN~CIRCUIT
VOLTAGE.
A-0026Z1
Pin A:
Reference
voltage
for output command;
+10 vdc
Pin B:
Output
Pin C:
Not used.
Pin Dr
Output
Pin E:
Output
command
signal.
contactor control.
signal;
current
volt
1
per
150
amperes.
Pin F:
3.
4.
Do not
use
damaged
or
frayed
Control circuit
Install correct size lugs of adequate amperage ca
pacity onto ends of both cables for connecting to
work clamp, spray gun, and weld output terminals.
Pin G:
Not used.
Pin H:
+24
volts
PinJ:
Install spray gun onto cable following manufactur
ers instructions. An insulated spray gun must be
used to
6.
ensure
Install work
operator safety.
clamp
dc
fused
unregulated;
at
1
ampere.
115 volts
applied
from external circuit for
contactor conti~l.
input
5.
common.
cables.
Designed for use
normally-open, momentary contact
with a
switch.
Pin K:
onto cable.
115 volts
applied
from external circuit for
Designed for use
input
contactor contivl.
with
normally-closed, momentary contact
a
switch.
B.
InstallatIon
Pin L:
24
volts
dc
fused
unregulated;
at
1
ampere.
POSITIVE
+
NEGATIVE
Pin M:
Pin N:
Output voltage signal;
1 volt per 10 volts.
+15 volts dc rectifier caution
signal. Present
when rectifier is overheated
or
there is
unbalanced output.
124 645
Page
9
Pin P:
Transformer caution signal. Normally-open
relay activates to potential of pin F (control
circuit common) when the transformer is
-
a
Fan
signal. Normally-open relay
potential of pin F (control circuit
common) when the fan motor is operating.
motor
Chassis
Pin T:
115 vac return for
Do not touch live electrical parts.
provides a safe and convenient means to
completely remove all electrical power from the
welding power source whenever it is necessary
to inspect or service the unit.
common.
input
kill.
This
activates to
Pin S:
can
Install a fusible line disconnect switch in the
input circuit to the welding power source.
overheating.
Pin R:
WARNING: ELECTRIC SHOCK
Employ lockout/tagging procedures
contactor control.
on
in
put line before making input connections to the
welding power source.
consist
of
procedures
Lockout/tagging
disconnect
line
switch
in
padlocking
open posi
tion, removing fuses from fuse box, or shutting
off and red-tagging circuit breaker or other dis
connecting device.
When making input power connections, work
from the welding power source to deenergized
line disconnect switch. Always work on deener
gized circuits when making input power connec
tions.
9
Figure
3-1.
TA-ill 059
Front View Of 17-Pin
Amphenol Re
ceptacle With Socket Locations
3-4.
Remove the top cover and reposition or install, if appli
cable, the umper links onto the terminal board to match
the available line
voltage
ELECTRICAL INPUT CONNECTIONS
shown
voltage positions
the
on
input
label.
C. Input Conductor Connections
INPUT
A.
Electrical
This
welding power
a
source
is
designed
provides guidelines
size
conductors and line fuses. The
to be
to be made.
Matching The Welding
Available input Voltage
a
Power Source To The
WARNING: ELECTRIC SHOCK
can
an
selecting the proper
input conduc
insulating material that
operated
the type of electrical system available at the installation
site or how proper connections to the welding power
B.
for
compiles with national, state, and local electrical codes.
kill.
Do not touch live electrical parts.
Shut down unit and disconnect input power
employing lockout/tagging procedures before
inspecting or servicing.
consist
of
Lockout/tagging
procedures
padlocking line disconnect switch in open posi
tion, removing fuses from fuse box, or shutting
off and red-tagging circuit breaker or other dis
connecting device.
Input Conductor
Table 3-2.
three-phase 60 Hertz, ac power supply which has
a line voltage rating that corresponds with one of the
electrical input voltages shown on the nameplate. Consuit the local electric utility if there is any question about
source are
input
tor should be covered with
Input Requirements
from
Table 3-2
Input
200V
Conductor Size
I
AWG
I4eov
230V
5OMCM400MCM~
(1)
-
575V
1/0
1
(4)
(6)
Fuse Size In
20OV~
600
(2)
And Fuse Size
Amperes
230V
I460V I
575V
500
300
200
input conductor sizes are based on r4adonal Electncal Codespocifi
ampacttiesof insulated copper conductors, hav
ing a temperature rating of 75 degrees C, with not more than three
conductors in a racoway or cable. Numbers in ( ) are equipment
cations for allowable
around conductor sizes.
rnstall terminal
lugs of adequate amperage capacity and
input and ground conductors.
correct stud size onto the
a
WARNING: ELECTRIC SHOCK
can kill.
Do not connect an input conductor to the
ground terminal in the unit.
Do not connect the ground conductor to an in
put line terminal.
Install and connect
input
and
ground conductors
as
fol
lows:
This unit is
equipped with input voltage jumper links
either installed or in a bag on the input terminal board to
allow operation from different line voltages. If installed,
the jumper links are positioned for the highest voltage
stated on the nameplate or input data label. If in a bag,
proper installation is necessary before operation.
~24
645
Page
10
1.
Obtain and install a proper strain relief connector
into rear panel access hole ( hole accepts standard
conduit fittings).
2.
Insert input conductors and ground conductor
through rear panel access hole and route conduc
tors to contactor.
3.
Connect
input conductors
to line terminals on con-
5.
4.
end of ground conductor to a
Use a grounding method that is ac
to the local electrical inspection authority.
remaining
Connect
propeTground.
tactor.
Connect
ground
conductor to
ground
ceptable
terminal next
6.
to contactor.
Reinstall and
top
secure
cover onto
unit.
SECTION 4-OPERATOR CONTROLS
4-1.
PILOT LIGHT
pilot light, when illuminated, indicates that the welding power source primary contactor is energized.
The
4-2.
CIRCUIT BREAKER
Circuit breaker CB1 functions as the unit ON/OFF
switch. CB1 also protects the primary contactor circuitry
from overload. If CB1 opens, correct the
manually reset CB1.
4~3.
problem
and
CONTROL MODULE RECEPTACLE
The Control Module receptacle RC2 provides a connec
tionpointfortheremotecontrolmodule.SeeSection3-3
for connection information.
SECTION 5-SEQUENCE OF OPERATION
51.
OPERATION
4A
Allow work and equipment to cool before han
dung.
WARNING:
ELECTRIC SHOCK can kill;
MOVING PARTS can cause serious Injury;
IMPROPER AIR FLOW AND EXPOSURE TO
ENVIRONMENT can damage Internal parts.
MAGNETIC FIELDS FROM HIGH CURRENTS
can
in
pacemaker operatIon.
Wearers should consult with their doctors before going near arc welding, gouging, or spot
Do not touch live electrical parts.
Keep all covers and panels
erating.
affect
place
welding operations.
while op-
See Section 1
Arc
Safety Rules For Operation Of
Power Source for basic welding
Welding
safety information.
Warranty is void if the welding power source is
operated with any portion of the outer enclosure
removed.
ARC RAYS, SPARKS, AND HOT SURFACES
burn eyes and skIn; NOISE can damage
1.
Install and connect unit
hearIng.
2.
Install and connect Control Module as instructed in
Section 3 of this manual and control console Own
can
Wear correct eye, ear, and
FUMES AND GASES
your health.
Ventilate to
keep
can
from
body protection.
serIously
ers
harm
3.
breathing
fumes and
to Section 3.
according
Manual.
Prepare any remaining equipment
for the
applica
tion.
gases.
If ventilation is
breathing device,
HOT
cause
inadequate,
use
approved
METAL, SPATTER AND SLAG
can
5.
and
52.
on power to welding power
begin operation.
Turn
source contactor
SHUTTING DOWN
fire and burns.
1.
Stop operation.
2.
Turn off power to
3.
Turn off all
Watch for fie.
Have a fire
how to use it.
extinguisher nearby,
and know
welding power
source contactor.
auxiliary equipment.
124 645
Page
11
SECTION 6- MAINTENANCE & TROUBLESHOOTING
ROUTINE MAINTENANCE
6-1.
FAN MOTOR
6-2.
IMPORTANT:
This unit is
this unit for
forced draft for
Every six months inspect the labels on
legibility. All precautionary labels must be
in a clearly readable state and replaced
maintained
when necessary. See Parts List for part number of pre
mæfictu
quires
no
equipped with an exhaust fan and
adequate cooling. The fan
red with lifetime sealed bearings
relies
on
motor is
and
re
maintenance.
labels.
cautionary
OVERLOAD PROTECTION
6-3.
WARNING:
ELECTRIC SHOCK
can
kill.
WARNING: ELECTRIC SHOCK
Do not touch live electrical parts.
Shut down unit and disconnect input power
employing lockout/tagging procedures before
inspecting, maintaining, or servicing.
Allow
can cause severe
cooling period
before
kIll.
Shut down unit and disconnect input power
employing lockout/tagging procedures before
inspecting, maintaining, or servicing.
of
consist
procedures
Lockout/tagging
padlocking line disconnect switch in open posi
tion, removing fuses from fuse box, or shutting
off and red-tagging circuit breaker or other dis
connecting device.
HOT SURFACES
can
Do not touch live electrical parts.
consist
of
procedures
Lockout/tagging
padlocking line disconnect switch in open posi
tion, removing fuses from fuse box, or shutting
off and red-tagging circuit breaker or other dis
connecting device.
burns.
servicing.
Troubleshooting
formed only by qualified person.
of internal parts to be per
CAUTION:
a
IMPROPER FUSES
can
damage
unit
Be
sure
replacement fuses
are same
size,
type, and rating (see Parts List).
Table 6-1. MaIntenance Schedule
A.
FREQUENCY
Transformer And RectIfier ProtectIon
MAINTENANCE
The main transformer and rectifier
Every
Every
Month
3 Months
Units in heavy service environment
Check weld cables, check labels,
clean internal parts.
Check weld cables (see Section
6-lA).
Every
6 Months Check all labels
(see IMPORTANT
block, Section 6-1).
Clean internal parts (see Section
Yearly
assembly are pro
three normally-closed thermo
stats TP1, TP2, and TP3. TP1 and TP2 are located in
the main transformer, and TP3 is located in the rectifier
assembly. If overheating of the transformer and/or recti
tected from overload
by
fier occurs, the associated thermostat(s) will open
deenergizing the output contactor. The welding power
signals the control
source
ceases.
before
console and weld output
If this condition occurs, allow a cooling period
resuming operation.
6-1B).
B.
A.
Weld Cables
three months
Every
Repair
cables for breaks in insula
inspect
replace cables if insulation breaks are
present. Clean and tighten connections at each inspec
tion.
or
Fuses Fl and F2 protect both the + and 24 volts cir
cuits. If Fl opens, 24 volts dc is not available from PCi
to receptacle RC2. If F2 open, +24 volts dc is not avail
able from PCi to receptacle RC2. The fuses are located
the rear of the circuit board mounting bracket inside
on
tion.
B.
CIrcuit Board Protection (FIgure 6-1)
Internal
CleanIng
Blow out
or vacuum dust and dirt from around the inter
nal components. Do this annually depending on the lo
cation of the unit and the amount of dust and dirt in the
atmosphere. If dirty or dusty conditions are present,
clean unit monthly. The power source outer enclosure
should be removed, and a clean dry airstream or vac
uum suction should be used for this cleaning operation.
124 645
Page
12
the unit. It is necessary to
gain access to the fuses.
C.
remove
the unit
top
cover
to
Fan Protection
Fuse F4 open when fan motor FM stalls or draws exces
sive current from the main transformer. F4 is located on
the rear panel under the windtu nnel by the input conduc
tor strain relief. It is necessary to remove the tight side
panel
to
gain
access
to this fuse.
-,~
Fl
ise
Block
Printed Circuit
Board PCi
(~) Circuit
Board PC3
Strip And
Control Rectifier
Mount Inside (See Parts List)
PC2
Ref.: TA-OgO 925-A
6-1.
FIgure
6-4.
Component
TROUBLESHOOTING CHART
4A
It is assumed that the unit
WARNING: ELECTRIC SHOCK
can kill.
employing lockout/tagging procedures
inspecting, maintaining, or servicing.
device.
Keep
serious
Injury.
moving parts.
HOT SURFACES
Allow
can cause
can cause severe
cooling period
before
controls, the weld
and the trouble
is not process related.
before
consist
of
Lockout/tagging
procedures
padlocking line disconnect switch in open posi
tion, removing fuses from fuse box, or shutting
off and red-tagging circuit breaker or other dis
clear of
was properly installed and
according to Section 3 of this manual, the op
ing power source was working properly,
Shut down unit and disconnect input power
MOVING PARTS
connected
erator is familiar with the function of
Do not touch live electrical parts.
connecting
Locations
burns.
The
following chart is designed to diagnose
remedies for
this
some
welding power
and
of the troubles that may
provide
develop in
source.
Use this chart in
conjunction with the circuit diagram
pertorming troubleshooting procedures. If the
trouble is not remedied after performing these proce
dures, contact the nearest Factory Authorized Service
Station. In all cases of equipment malfunction, the
manufacturers recommendations should be strictly fol
while
lowed.
servicing.
Troubleshooting of internal parts
formed only by qualified persons.
to be per
124 645
Page
13
Table 6-2.
TroubleshootIng
REMEDY
PROBABLE CAUSE
TROUBLE
No weld output; unit
Line disconnect switch in the OFF
completely inoperative
position.
Place line disconnect switch in the
ON position.
Line
Replace
fuse(s) open.
Improper electrical input connectt~ns~
Input voltage jumper
position.
-
links not in proper
fuse(s).
See Section 3-4 for proper
connections.
input
See Section 3-4 B for proper
link
Main transformer Ti and/or main
rectifier SRi and SR2 assembly
line
jumper
position.
Allow the unit to cool down
(see Section 6-3).
overheating (thermal shutdown).
Erratic weld output
Poor and/or improper
connections.
No 24 volts control circuits.
Fuse(s)
Fan does not
Fuse F4
124 645
Page
14
run.
Fl and/or F2.
input
and/or output
See Sections 3-2 and 3-4 for proper
input and output connections.
Replace Fuse(s) (see Section 6-3).
Replace
fuse
(see Section 6-3).
296-A
30
SD-i
No.
Diagram
Circuit
Diagram
Circuit
6-2.
Figure
01
RC~2(7)
(7)
WCbO)6
PC~3
295-A
C-130
(7)
PC~O
No.
ISV.
Diagram
-
Circuit
57.
I
-
I~V~
PCi
Board
Control
For
Diagram
Circuit
2
30295-A
6-3.
C-I
Figure
~
49C52
4~
6C53
642
I
6~ ~
~_J
I
-
-24V.
24V.
(
6C52)3 RC~3(
(2)
C~O(
(3)
RC5I
<
(9)
RC5I(O) RC~I
(B)
I
RC~
Rc~I )
Circuit Diagram No. B-099 583
Figure
6-4. Circuit
Diagram
For
Firing Boards PC2
And PC3
124 645
Page
17
Dia.
Mkgs.
Part
No.
Quantity
Description
Complete Assembly
CB1
034 945
CIRCUIT BREAKER, manual reset 2 pole 5 amp 240VAC
129 746
CAPACITOR, (consisting of)
CAPACITOR, cer .1 uf 500VDC
CAPACITOR, 1000 uf 5OVDC
RESISTOR, carbon 2 watt 10K~hm
CAPACITOR, ceramic 0.003 uf 3000 volts
RELAY, enclosed 120 volts ac DPDT
MOTOR, 1/4 hp 230 volts ac 1625 rpm (consisting of)
SWITCH, motor
BLADE, fan 50 hz 20 inch 3 wing 24 deg
WINDTUNNEL, 20 inch
FUSE, miniature glass sb bbo 1 amp
HOLDER, fuse
FUSE, cartridge 30 amp 600 volts
HOLDER, fuse
SENSOR, current
CIRCUIT CARD, control
CIRCUIT CARD, SCR firing
ENCLOSURE, circuit cards
013,14
C16,17
028 291
R25
601 394
C18,19
083 332
CR1 ,2,4
FM
059 266
113 525
032 633
011 850
032 617
059 585
Fl ,2
012 643
098 376
F4
012 639
070 404
HAl ,2
093 342
PCi
130 293
P02,3
106 585
115 149
110 375
PL1
027 645
PLG 50
081 379
PLG51 ,56,57
090 469
PLG52,53
POS,NEG
072 566
STAND-OFF, support
LIGHT, indicator red lens 125 volts
HOUSING, terminal header 12 pin
HOUSING, terminal header 10 pin
TERMINAL
115148
~TERMlNALBOARD
053 605
TERMINAL
R5
605 787
124 035
039 210
SR1,2
115429
RC2/C21-24
SCR1-1 2
109 091
01-12
048420
1P3
601 066
086 354
025 248
028 516
048 373
048 777
.
.
.
1
1
1
2
1
2
1
2
1
8
4
4
4
4
ASSEMBLY, pri 3 ph 2V (consisting of)
1
1
1
12
12
1
4
8
24
4
4
1
1
TERMINAL BOARD
1
038 652
LINK, jumper
6
168830
~iNSULATION
010 915
602 209
18
1
2
038 846
601 836
Page
1
-
038 890
124 645
1
1
TEl
602 247
1
2
035 704
038 900
3
1
SR3
601 839
I
2
3
NUT, brass-hex jam 1/2-13
NUT, brass-hex jam 1/2-13
STUD, brass 1/2-13 x 2-1/4
WASHER, flat-SAE 1/2
WASHER, lock-internal tooth 1/2
RECEPTACLE, w/Ieads
RESISTOR, WW fixed 375 watt 12 ohm
RECTIFIER, SCR main (consisting of)
THYRISTOR, SCR 865 amp 300 volts
CAPACITOR, ceramic 0.01 uf500voltsdc
THERMOSTAT, NC
CLAMP, diode/rectifier
STAND-OFF, 1/4-20 x 1-1/4
PIN, spring 1/8 x 1/4
HEAT SINK, rectifier snowflake 1.500
HEAT SINK, rectifier snowflake 2
RECTIFIER, integrated 30 amp 400 volts
601 840
2
1
ac
BUS BAR
038 847
1
2
12
HOUSING, terminal header 8 pin
ASSEMBLY, power output (consisting of)
115 397
1
.
STUD, 1/4-20 x 2-1/8
NUT, brass-hex jam 1/4-20
WASHER, fIat-brass 1/4 ID x 5/8 OD
WASHER, lock-internal tooth 1/4
12
12
24
...
12
12
Dia.
Mkgs.
Part
No.
Quantity
Description
Complete Assembly (Contd)
Ti
TRANSFORMER, power main (230/460) (consisting of)
COIL, pri/sec LH
1
2
120 337
COIL, pn/sec center & RH
-THERMOSTAT, NC
TRANSFORMER, power main (460/575) (consisting of)
COIL, pn/sec LH
COIL, pri/sec center & RH
-THERMOSTAT, NC
TRANSFORMER, power main (575) (consisting of)
COIL, pri/sec LH
120338
-COIL,pri/seccenter&RH
2
120 441
120 333
120 334
TP1,2
026181
Ti
123 478
123 494
123 495
TP1,2
026 181
Ti
120 443
TP1,2
026 181
T2
W
115 ~
004 104
WI
004259
034 821
Zi
3T
1
.
2
1
1
2
2
1
1
-
THERMOSTAT. NC
2
TRANSFORMER, interphase
1
CONTACTOR, def prp 2iOA 3P 120/24OVAC (consisting of)
1
.
COIL
1
INTERLOCK, NO
1
115338
STABILIZER
1
072 253
STUD, connection
106 699
BLOCK, terminal 15 amp
038618
LINK,jumper
CATCH, spring
605 583
010855
010 853
010357
026 627
080 509
015 722
010 494
1
ii
pole
1
2
loaded
2
RETAINER,screwNo.2
FASTENER, screw hd No. 2
2
NUT,speedNo.2
GASKET, lifting eye
2
GROMMET, scr No. 8/10 panel hole
GROMMET, 1-1/4 ID x 1-1/2 mtg hole
BUSHING, snap-in 1-3/8 ID
1
NAMEPLATE
2
1
1
1
115 189
(order by model
BRACKET, mtg-terminal
098 639
BASE
i
098 519
FRAME, mtg-transformer
FRAME, center base
FRAME, center base
PANEL, rear
PANEL, front
PANEL, side
PLATE, ident control rating
COVER, top
LABEL, warning electric shock can kill, etc
LABEL, warning general precautionary
LABEL, danger high voltage
BUSHING, snap-on 15/1610 x 1-1/8
PANEL, control module
GUARD, circuit breaker
1
098 634
098 523
149535
122206
098 428
122 191
+098 429
109 035
134 327
602 498
057357
115 167
018 104
& serial
number)
1
1
1
1
1
1
2
1
i
1
1
1
1
i
1
+When
ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
124645
Page
19
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