Miller PS-100 Owner's Manual

FORM:F2544B
June 1988
Effective With Serial No. JJ393769
Millerfi
MODEL
ps-100
F~1LE COPY
RETURN TO FOLDER
OWNERS
MANUAL
iMPORTANT
Read and understand the entire contents of this manual.
with special emphasis on the safety material throughout the manual.
before installing, operating, or maintaining this equipment. This unit and
these instructions are for use only by persons trained and experienced In
the safe operation of welding equipment. Do not allow untrained persons
to install, operate, or maintain this unit. Contact your distributor if you
do not fully understand these instructions.
PRINTED IN U.S.A.
Miller Electilc Mfg. Co.
A~L~C~at~
P0. Box 1079
Appleton, WI 54912 USA
Tel. 414-734-9821
ACOITIONAL COPY PRCE 70 CENTS
EFFECTIVE: FEBRUARY 16. 1988
This warranty
supersedes
all
previous MILLER
warranties and is exclusive with
LIMITED WARRANTY
Subject to the terms and condidons hereof, Miller Electric Mfg. Co., Appleton, Wisconsin
warrants to its Distributor/Dealer that all new and unused
Equipment furnished by Miller is free from defect in workmanship and material as of the time and place of delivery by Miller.
No warranty is made by Miller with respect to engines, trade
-
accessories
or
other items manufactured
trade accessories and other items
engines,
by others. Such
sold subject to
are
the warranties of their respective manufacturers, if any
All
engines are warranted by their manufacturer for one year from
date of original purchase, except Tecurnseh engines which
.
have
a two
year warranty.
Except
as specified below, Millers warranty does not apply
components having normal useful life of lees then one (1)
year, such as spot welder tips, relay and contactor points,
MILLERMATIC parts that come in contact with the welding
no
other guarantees
or
warranties expressed
or
implied.
In the case at Millers breech of warranty or any other duty
with respect to the quality of any goods, the exclusive rwi~diemi
therefore shall be, at Millers option (1) repair or (2) replacement
or, where authorized in writing by Miller in appropriate cases, (3)
the reasonable coat of repair or replacement at an authorized
Miller service station or (4) pa~mant of or credit for the purchase
pnce (lees reasonable depreciation based upon actual use) upon
return of the goode at Customers
risk and expense. MILLERs
option of repair or replacement will be F.O.B., Factory, at
Appleton, Weconsin, or F.O.B., at a MILLER 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 shall insmact the claimant on the warranty
claim
procedures
to
be followed.
to
~
~
~
~
including
nozzles and nozzle insulators where failure dose
not result from defect in workmanship or material.
wire
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 Equipthe
merit to
~.f
original
user:
1. Arc weldais, p~re~irces, robots, and
,or~nts
c
2. Loadbanks
j
3.
Original
(labor
~
r1~
~
ij(
~
!~
.~
4. All
-
main power rectifiers
1 year only)
welding guns, feeder/gun,
that Miller i. notified in
of the date of such failure.
As
a
matter of
by
the
EXCEPT
and torches
writing
within
general policy only, Miller
original
user
1 yeer
1 year
BREACH OF CONTRACT WHICH, BUT FOR ThIS PROVISION,
MIGHT ARISE BY IMPUCA11ON, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEAUNG. INCLUDING
ANY IMPUED WARRANTY OF MERCHANTABIUTY OR OF
FITNESS FOR PARTICULAR PURPOSE, WITh RESPECT TO
ANY AND AU. EQUIPMENT FURNISHED BY MILLER IS EX
CLUDED AND DISCLAIMED BY MILLER.
3 years
90 days
5. All other Millermatic Feeders
6. Replacement or repair parts, exclusive of labor
7. Batteries
provided
.
ANY EXPRESS WARRANTY NOT PROViDED HEREIN AND
WARRANTY. GUARANTY OR REPRESENTA
liON AS TO PERFORMANCE, AND ANY REMEDY FOR
ANY IMPUED
within die
1 year
..
60 days
6 months
thirty (30) days
cay honor dims
foreyoing periods
AS EXPRESSLY PROVIDED BY MILLER IN
PRODUCTS ARE INTENDED FOR
MILLER
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. MILLERS WARRANTIES DO NOT EXTEND
TO, AND NO RESELLER IS AUTHORIZED TO EXTEND
MILLERS WARRANTIES TO, ANY CONSUMER.
WRITING,
TABLE OF CONTENTS
Section No.
SECTION 1
No.
Page
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
-
1-1.
Introduction
1-2.
General Precautions
1
1-3.
Arc
4
1-4.
Standards Booklet Index
1
Welding
6
SECTiON 2-INTRODUCTION
2-2.
Vott-Ampere Curves
Duty Cycle
2-3.
General Information And
2-4.
Receiving-Handling
Description
2-1.
2-5.
SECTION 3
Location
3-2.
Weld
3-4.
8
Safety
8
8
9
INSTALLATION
3-1.
3-3.
8
9
Output Connections
Control Module Receptacle Information
Electrical Input Connections
9
And Connection
10
11
SECTION 4- OPERATOR CONTROLS
4-1.
PilotLight
4-2.
Circuit Breaker
4-3.
Control Module
13
13
Receptacle
13
SECTION 5- SEQUENCE OF OPERATiON
5-1.
5-2.
Operation
Shutting Down
13
13
SECTION 6- MAINTENANCE & TROUBLESHOOTING
6-1.
Routine Maintenance
14
6-2.
Fan Motor
14
6-3.
Overload Protection
14
6-4.
Troubleshooting Chart
16
SECTION 1
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
INTRODUCTION
1-1.
We learn by experience. Learning safety through per
sonal experience, like a child touching a hot stove is
harmful, wasteful, and unwise. Let the experience of
others teach you.
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
equipment is improperly used or maintained. The rea
son 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
Safe
rules.
Read and understand these safe practices before at
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.
tempting
Failure to observe these sale practices may cause seri
injury or death. When safety becomes a habit, the
equipment can be used with confidence.
ous
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
also ava~able 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
are
most
complete.
The National Electrical Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements also provide a basis for equip
ment installation, use, and service.
GENERAL PRECAUTiONS
1-2.
Different arc
welding processes, electrode alloys,
produce different fumes, gases, and
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
should never be handled without gloves.
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.
Ear plugs should be worn when working on overhead or
in a confined space. A hard hat should be worn when
others work overhead.
Flammable hair preparations should not be used
intending to weld or cut.
by per
sons
B.
Toxic Fume Prevention
Severe discomfort, illness or death can result from
fumes, vapors, heat, or oxygen enrichment or depletion
that
with
welding (or cutting) may produce. Prevent them
adequate ventilation as described in ANSI Stan
dard Z49.1 listed in Standards Index. NEVER ventilate
with oxygen.
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 beryllium, both must be used.
Metals coated with or containing 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 it is being ventilated
and, if necessary, while wearing an air-supplied respira
tor.
and fluxes can
radIation levels. In addition to the informatIon In
thIs manual, be sure to consult flux and electrode
manufacturers
Material
Safety Data Sheets
technical
for
data and precautIon
(MSDSs)
specIfic
their
measures
material.
concerning
ary
A.
Burn Prevention
Wear
protective clothing-gauntlet gloves designed for
welding, hat, and high safety-toe shoes. Button
shirt collar and pocket flaps, and wear cuffless trousers
to avoid entry of sparks and slag.
Gas leaks in a confined space should be avoided.
Leaked gas in large quantities can change oxygen con
centration dangerously. Do not bring gas cylinders into a
confined space.
Leaving confined space, shut OFF gas supply at source
to prevent possible accumulation of gases in the space it
downstream valves have been accidentally opened or
use in
left open. Check to be sure that the space is safe before
re-entering it.
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
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 trichloroethylene and perchloroethylene
F2544
Page
1
vapors to form phosgene. DO NOT WELD or cut where
solvent vapors can be drawn into the welding or cutting
atmosphere or where the radiant energy can penetrate
to atmospheres containing, even minute amounts of
trichioroethylene
C.
Fire and
or
perchioroethylene.
Explosion Prevention
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.
This includes: a thorough steam or caustic cleaning (or
a solvent orwaterwashing, depending on the combusti
bles solubility) followed by purging and inerting with ni
trogen or carbon dioxide, and using protective equip
ment as recommended in A6.O. Waterfilling just below.
working level may substitute for inerting.
A container with unknown contents should be cleaned
(see preceding paragraph). Do NOT depend on sense
of smell
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, verdi
lators. if the work cannot be moved, move combustibles
sparks and heat; or
and snug-fitting,
with
suitable
protect against Ignition
fire-resistant covers or shields.
at least 35 feet away out of reach of
Walls
if it is safe to weld or cut.
castings or containers must be vented before
welding 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).
Compressed Gas Equipment
explosion:
Keep equipment clean and operable, free of oil, grease,
and (in electrical parts) of metallic particles that can
cause
sight to determine
Hollow
D.
To prevent fires and
or
touching combustibles on opposite sides should
(or cut). Walls, ceilings, and floor near
should be protected by heat-resistant covers or
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.
,
Pressure
i.
Regulators
Regulator relief valve is designed to protect only the
regulator from overpressure; it is not intended to protect
any downstream equipment. Provide such protection
with one or more relief devices.
Never connect a regulator to a cylinder containing gas
other than that for which the regulator was designed.
not be welded on
Remove
work
repair (first close cylinder valve). The following
faulty regulator
from service
immediately
for
symp
shields.
toms indicate a
standing by with suitable fire extin
equipment
guishing
during and for some time afterweld
Leaks-if gas leaks externally.
Excessive Creep-if delivery pressure continues to rise
with downstream valve closed.
Fire watcher must be
ing
or
cutting
a.
b.
if:
Faulty Gauge-if gauge pointer does
appreciable combustibles (including building
construction) are within 35 feet
appreciable combustibles are further than 35
can be ignited by sparks
feet but
c.
openings (concealed orvisible) In floors orwalls
within 35 feet may expose combustibles to
sparks
d.
combustibles adjacent to walls, ceilings, roofs,
or metal partitions can be ignited by radiant or
conducted heat.
permit should be obtained before operation to
supervisors approval that adequate precautions
Hot work
ensure
pin when pressurized,
area
is free of
sparks,
empty container that held corrtustibles, or that can
produce flammable or toxic vapors when heated, must
An
be welded on or cut, unless container has first
been cleaned as described in AWS Standard A6.O,
listed 7 in Standards Index.
never
F2544 Pace 2
nor returns to
not move off stop
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.
tors for
2.
Cylinders
Cylinders must be handled carefully to prevent leaks
and damage to their walls, valves, or safety devices:
Avoid electrical circuit contact with cylinders including
third rails, electrical wires, or welding circuits. They can
produce short circuit arcs that may lead to a serious ac
cident.
(See 1 -3C.)
ICC
DOT marking must be on each cylinder. It is an
of safety when the cylinder is properly han
have been taken.
After work is done, check that
glowing embers, and flames.
faulty regulator:
or
assurance
dled.
Identifying gas content. Use only cylinders with name of
gas marked on them; do not rely on color to identify gas
content. Notify supplier if unmarked. NEVER DEFACE
or
alter name, number, or other
illegal and hazardous.
It is
markings on
a
cylinder.
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
where they may be struck.
areas
Transporting cylinders. With a crane, use a secure sup
port such as a platform or cradle. Do NOT lift cylinders
off the ground by their valves or caps, or by chains,
stings, or magnets.
Do NOT expose cylinders to excessive heat, sparks,
slag, and flame, etc. that may cause rupture. Do not al
Cool with water spray
low contents to exceed 130F.
where such exposure exists.
cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when moving cylinders.
Protect
Stuck valve. Do NOT use a hammer or wrench to open
cylinder valve
your supplier.
that can not be
Mixing gases. Never try
Never refill any
opened by hand. Notify
to mix any gases in a
cylinder.
never
be
modified
or
ex
Prohibited use. Never use hose other than that de
signed for the specified gas. 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
fittings.
tubing splices. Use only standard
splice hose.
No copper
tings
to
brass f it
Avoid long runs to prevent kinks and abuse. Suspend
hose off ground to keep it from being run over, stepped
on, or otherwise
Coil
excess
Match regulator to cylinder. Before connecting, check
that the regulator label and cylinder marking area, and
that the regulator inlet and cylinder outlet match.
NEVER CONNECT a regulatordesigned for a particular
gas or gases to a cylinder containing any other gas.
Tighten connections. When assembling
threaded con
and
clean
smooth
where
seats
nections,
necessary.
Tighten. If connection leaks, disassemble, clean, and
retighten using properly fitting wrench.
Adapters. Use a CGA adapter (available from your sup
plier) between cylinder and regulator, if one is required.
use two wrenches to tighten adapter marked RIGHT
and LEFT HAND threads.
Regulator outlet (or hose) connections may be identified
by right hand threads for oxygen and left hand threads
(with grooved hex on nut or shank) for fue gas.
5.
Pressurizing Steps:
Drain regulator of residual gas through suitable vent be
fore opening cylinder (or manifold valve) by turning ad
justing screw in (clockwise). Draining prevents exces
sive compression heat at
high pressure seat by allowing
pressurization. Leave adjusting screw
engaged slightly on single-stage regulators.
Stand to side of regulator while opening cylinder valve.
Open cylinder valve slowly so that regulator pressure 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
Hose
hoses to
Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing
outlet away from people and soui~es of ignition. Wiper
with a clean lintiess cloth.
seat to open on
cylinder.
Cylinder fittings should
changed.
3.
a
Proper Connections
4.
damaged.
hose to prevent kinks and
tangles.
Protect hose from damage by sharp edges, and by
sparks, slag, and open flame.
Examine hose regularly for leaks, wear, and loose con
nections. Immerse pressured hose in water; bubbles in
dicate leaks.
Repair leaky or worn hose by cutting
ing (1-203). Do NOT tape.
area out
and
splic
Use pressure charts (available from your supplier) for
sale and efficient, recommended pressure settings on
regulators.
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
combustible.
E.
User
ResponsIbIlItIes
Remove leaky or defective equipment from service im
mediately for repair. See User Responsibility statement
in equipment manual.
F.
Leaving Equipment Unattended
Close gas supply at
G.
source
and drain gas.
Rope Stag lng~Support
Rope staging-support should not be used for welding or
cutting operation; rope may burn.
Trademark of Proctor & Gamble:
F2544
Page
3
ARC WELDING
1-3.
Comply with precautions in 1-1, 1-2, and this section.
Arc Welding, properly done, is a sale process, but a
careless operator invites trouble. The equipment cames
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
unnecessary risks and protects himself and others from
accidents. Precautions are described here and in stan
dards referenced in index.
Burn Protection
H.
Comply
with
in 1-2.
precautions
bright. its radiation
damage eyes, penetrate lightweight clothing, reflect
from light-colored surfaces, and burn the skin and eyes.
Skin bums resemble acute sunburn, those from gasshielded arcs are more severe and painful. DONT GET
BURNED; COMPLY WITH PRECAUTIONS.
Clothing
Wear long-sleeve clothing (particularly for gas-shielded
arc) in addition to 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 cot
ton.
protection. Wear dark, substantIal clothing.
Button collar to protect chest and neck and button pock
Bare skin
ets to
prevent entry of sparks.
Eye and Head Protection
2.
Protect eyes from exposure to
electric arc without protection.
arc.
NEVER look at
an
Welding helmet or shield containing a filter plate shade
no. 12 or denser must be used when welding. Place over
face before striking am.
Protect filter
plate with
Cracked
broken helmet
or
a
clear cover
worn; radiation can pass
or
plate.
shield should NOT be
cause bums.
through to
loose filter plates must be replaced
IMMEDIATELY. Replace clear cover plate when bro
Cracked, broken,
ken, pitted,
Flash
or
or
spattered.-
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
cause a
area
3.
in the field of vision.
Protection of
Enclosed welding
Nearby Personnel
area.
rate room or enclosed
round the
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.
F2544 Pace 4
area.
See that all persons are wearing
goggles.
Before starting to weld, make
bay doors are closed.
I.
sure
that
screen
flaps
or
Toxic Fume Prevention
Comply
with
precautions
in 1 -2B.
Generator engine exhaust must be vented to the outside
air. Carbon monoxide can kilt.
Fire and
Comply
can
Protective
Others working in
flash
J.
The welding arc is intense and visibly
1.
Viewing the weld. Provide face shields for all persons
who will be looking directly at the weld.
with
Explosion Prevention
precautions
in 1-2C.
Equipments rated capacity. Do not overload arc weld
ing equipment. It may overheat cables and cause a fire.
Loose cable connections may overheat
fire.
or
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.
K.
Compressed Gas Equipment
Comply with precautions
L
in 1 -2D.
Shock Prevention
Exposed hot conductors or other bar 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
against
shock:
Keep body and clothing dry. Never work in damp area
adequate insulation against electrical shock.
on
a
Stay
dry duckboard, or rubber mat when dampness
or sweat can not be avoided. Sweat, sea water, or mois
ture between body and an electrically HOT part-or
grounded metal-reduces the body surface electrical re
sistance, enabling dangerous and possible lethal cur
rents to flow through the body.
without
1.
Grounding
the
Equipment
When arc welding equipment Is grounded according to
the National Electrical Code, and the work is grounded
according to ANSI Z49.1 usafety In Welding And Cut
ting, a voltage may exist between the electrode and any
conducting object. Examples of conducting objects in
clude, but are not limited to, buildings, electrical tools,
work
benches, welding power source cases,
workpieces, etc. Never touch the electrode and any
metal object unless the welding power source Is oft.
When installing, connect the frames of each unit such as
welding power source, control, work table, 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 f atally. Do NOT GROUND to electrical conduit, orto a pipe
carrying ANY gas ortlammable liquid such as oil or fuel.
Three-phase connection. Check phase requirements of
equipment before installing. If only 3-phase power is
available, connect single-phase equipment to only two
wires of the 3-phase line. Do NOT connect the equip
ment ground lead to the third (live) wire, or the
equipment will become electrically HOT-a dangerous
condition that can shock, possibly fatally.
Be sure
Before welding, check ground for continuity.
conductors are touching bare metal of equipment
frames at connections.
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 threeIf
a
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.
2.
Electrode Holders
Fully insulated electrode holders should be used. Do
NOT use holders with protruding screws.
esses
may not be
equipped with welding power
output on-off control devices. With such equip
ment the electrode is
electrically HOT when the
power switch is turned ON. Never touch the
electrode unless the welding power source is.
off.
7.
Safety Devices
Safety devices
such as Interlocks and circuit breakers
should not be disconnected or shunted out.
Before installation, inspection, or service, of equipment,
shut OFF all power and remove, line fuses (or lock or
red-tag switches)
to prevent accidental turning ON of
Disconnect
all cables from welding power
power.
source, and pull all 115 volts line-cord plugs.
Do not open power circuit or change polarity while weld
ing. If, in an emergency, it must be disconnected, guard
against shock bums, or flash from switch arcing.
Leaving equipment unattended. Always shut OFF and
disconnect all power to equipment.
Power disconnect switch must be available
welding power
near
M.
3.
Protection For Wearers of Electronic LIfe
port Devices (Pacemakers)
Connectors
Fully insulated lock-type connectors
join welding cable lengths.
4.
should be used to
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 sparks.
the
source.
Sup
Magnetic fields from high currents can affect pacemaker
operation. Persons wearing electronic life support
equipment (pacemaker) should consult with theirdoctor
before going near arc welding, gouging, or spot welding
operations.
1-4.
STANDARDS BOOKLET INDEX
For more information, refer to the following standards
their latest revisions and comply as applicable:
or
protected
1.
ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING obtainable from the American Welding
Society, 550 N.W. LeJeune Ad, Miami, FL 33126.
Terminals and other exposed parts of electrical units
should have insulating covers secured before opera
tion.
2.
NIOSH, SAFETY AND HEALTH IN ARC WELDING
5.
6.
Terminals And Other
Exposed Parts
AND GAS WELDING AND CUTTING obtainable
from the Superintendent of Documents, U.S. Gov
ernment Printing Office, Washington, D.C. 20402.
Electrode
3.
a.
Equipment with output on/off control (contactor)
Welding power
metal
sources for use with the
gas
welding (GMAW), gas tungsten arc
welding (GTAW) and similar processes nor
mally are equipped with devices that permit onoff 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.
b.
OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the Superintendent
of Documents, U.S. Government Printing Office,
Washington, D.C.
arc
20402.
4.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainable from the Amen
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 National Standards Institute, 1430
Broadway, New York, NY 10018.
6.
contactor)
ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES
Welding power sources used with shielded
metal arc welding (SMAW) and similar proc
obtainable from the American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Equipment without output on/off control (no
F2544
Page
5
7.
8.
9.
AWS Standard A6.0, WELDING AND CUTTiNG
CONTAINERS WHICH HAVE HELD COMBUS
TIBLES obtainable horn the American Welding So
ciety, 550 N.W. LeJeune Rd. Miami, FL 33126.
ferson Davis
22202.
M9W 1R3.
13. NWSA booklet, WELDING SAFETY BIBLIOGRA
PHY obtainable from the National Welding Supply
Association, 1900 Arch Street, Philadelphia, PA
19103.
Standard 70, NATIONAL ELECTRICAL
CODE obtainable from the National Fire Protection
Association, Batterymamh Park, Quincy, MA
NFPA
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
from the American Welding Society, 550 N.W.
LeJeune Ad, Miami, FL 33126.
14. American
02269.
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Batterymarch Park, Quincy,
MA 02269.
11. CGA
VA
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the Ca
nadian Standards Association, Standards Sales,
178 Rexdale Boulevard, Rexdale, Ontario, Canada
NFPA Standard 51, OXYGEN-FUEL GAS SYS
TEMS FOR WELDING, CUTTING, AND ALLIED
PROCESSES obtainable from the National Fire
Protection Association, Batterymarch Park, Quincy,
MA 02269.
Protection Association,
Highway, Suite 501, Atlington,
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA
TORY PROTECTION, obtainable from the Ameri
can National Standards Institute, 1430 Broadway,
Pamphlet P-i, SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS obtainable
from the Compressed Gas Association, 1235 Jet-
New York, NY 10018.
SECTiON 2- INTRODUCTION
Rated
Welding
Amperes 100%
Range
Max. OpenCircuit
Voltage
Duty Cycle
Amperes Input At
Rated Load Output
Weight
Dimensions
60 Hz Three-Phase
200V
230V
460V
575V
KVA
KW
Net
Ship
1155 lbs.
1370 lbs.
(524 kg)
(686 mm)
Length: 27in
(686mm)
(621 kg)
Height:37in.
.
(940mm)
1200A@
20-1500
80V
Amperes
ioov~c
~ss
~o
FIgure
160
21.
128
128
104
Width:271n.
SpecificatIons
8
X
Figure
F2544 Pape 6
2-2.
~PS
Volt-Ampere Curves
B-i 16 834
VOLT-AMPERE CURVES (Figure 2-2)
2-1.
end of Section 1,
Safety Rules
Welding Power Source.
show the voltage and amper
volt-ampere
of
the welding power source.
age output capabilities
The
curves
DUTY CYCLE
2-2.
(FIgure 2-3)
duty cycle of a welding power source is the percent
age of a ten minute period that a welding power source
can be operated at a given output without causing over
heating and 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.
WARNING statements include installation, operation,
and maintenance procedures or practices which if not
carefully followed could
or
result in serious
personal injury
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 to this equipment.
CAUTION: EXCEEDING DUTY CYCLE RAT
ING will damage the welding power source.
Do not exceed indicated duty cycles.
A third signal word. IMPORTANT highlights instruc
tions which need special emphasis to obtain the most ef
ficient operation of this equipment.
RECEIVING-HANDLING
GENERAL INFORMATION AND SAFETY
Before installing this equipment, clean all packing mate
rial from around the unit and 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
facturer on request If occasion to tile claim arises.
General
Information presented in this manual and
various la
on
bels, tags, and plates on the unit pertains to equipment
design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed forthe safe and effective use of this
B.
Arc
ent levels of hazard.
2-4.
2-3.
Operation Of
Safety instructions specifically pertaining to this unit ap
pear throughout this manual highlighted by the signal
words WARNING and CAUTION which identify differ-S
The
a
For
equipment.
When
requesting Information concerning this equip
ment. it is essential that Model Description and Serial
Number of the equipment be supplied.
Safety
The
installation, operation,
and
maintenance,
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
2-5.
DESCRIPTION
This unit is
three-phase,
constant current dc welding
solid-state control. The dc output is
designed for use with spray arc equipment. A separate
control module is required for setting output parameters.
power
ble codes such as, but not limited to, those listed at the
a
source with
3000
2500
in
2000
8
1550
A
500
200
A
IOOZ
1000
5
20
30
25
~
~JTY
40
50
60
70
50
90
00
CYCLE
8-118 833
FIgure
2-3.
Duty Cycle Chart
F2544 Pac~e 7
SECTION 3- INSTALLA11ON
3.1.
A.
LOCATION
a
WARNiNG:
FALLING
cause serious
EQUIPMENT can
Injury and equip
personal
damage.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, trailer, or any other heavy
options, accessories, or devices.
ment
Use
unit.
If
welding cables
1.
Keep cables as short as possible, and place cables
close together. Excessive cable length adds resis
tance which may reduce output or cause overload
ing of the unit.
2.
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: lithe cable to spray gun is 25 feet (7.5
mm) long and work cable is 25 feet (7.5 mm) long,
too short will expose internal
components damage should the tips of the lift
forks penetrate the bottom of the unit.
Using lift forks
to
select the size cable recommended in Table 3i
50 feet
causes overheat
possible damage to Internal parts.
Maintain at least 18 inches (457mm) of unre
stricted space on all sides of unit, and keep un
for
(15 m).
WeldIng Cable Size
Table 3-1.
and
TOTA LLEN GTH OF CABLE (COPPERHN WELD CIPC%JIT
WELDING
50
AMPERES
100
derside free of obstructions.
100
4
4
150
Do not place any filtering device over the in
take air passages of this welding power source.
200
2
1
2
1
Warranty Is void
If any
1/0
2/0
260
300
350
400
500
600
700
600
900
1000
1250
1500
type of filtering device Is
used.
This welding power source has a lifting device for mov
ing the unit and holes in the base for mounting purposes.
The location should allow sufficient room to remove the
top cover and side panels for installation, maintenance,
and repair procedures.
3/0
3/0
4/0
2-210
2-3/0
2-3/0
3-2/0
24/0
3-3/0
3-4/0
1/0
2/0
3/0
3/0
4/0
2-2(0
150
2
2
1
1/0
2/0
3/0
3/0
4/0
2-310
2-2/0
2-3/0
2-3/0
2-3/0
3-2/0
24/0
3-3/0
3-4/0
24/0
24/0
3-3/0
3-4/0
200
250
300
2
2
1
1
1/0
1/0
2/0
3/0
4/0
4/0
2.2/0
2-3/0
24/0
24/0
3-3/0
24/0
4-3/0
2/0
3/0
4/0
4/0
2.2/0
2-3/0
3-2/0
3-3/0
3-3/0
34/0
4-3/0
4-4/0
2/0
3/0
4/0
4/0
2.2/0
2.3/0
2-3/0
24/0
3-4/0
3-4/0
4-4/0
4-4/0
350
400
1/0
1/0
3/0
3/0
4/0
4/0
4/0
2-2/0
2-2(0
2-3/0
2-3/0
2-3/0
3-2/0
2-4/0
2-4/0
3-3/0
3-4/0
44/0
4-4/0
4-4/0
4-4/0
3-3(0
4.4/0
44/0
A~2 623
NOTE:
A.
B.
IMPORTANT:
The welding power source must be lo
cated so that the Control Module cord can reach the
welding power source. The control module may be in
stalled into a control console.
C.
The service life and operating efficiency of this unit are
reduced when the unit Is subjected to high levels of dust,
SOFEETOR 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
CIRCULAR MILS PER AMP.
WELD CABLE INSULATION WITH A VOLTAGE
RATING TO WITHSTAND THE OPEN-CIRCUIT VOLT
AGE 4OCV) OF THE WELDING POWER SOURCE MUST
BE USED. WHILE MOST WELDING POWER SOURCES
HAVE AN OPEN-CIRCUIT VOLTAGE OF LESS THAN
100 VOLTS. SOME WELDING POWER SOURCES OF
SPECIAL DESIGN MAY HAVE HIGHER OPEN-CIRCUIT
VOLTAGE.
A-002 623
dirt, moisture, corrosive vapors, and extreme heat.
3-2.
ordered with this unit, the
ensure the best weld
ing performance:
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.
Ing
were not
steps listed should be followed to
equipment of adequate capacitytoliftthe
RESTRICTED AIR FLOW
Welding Cables
-
3.
Do not
4.
Install correct size lugs of adequate amperage ca
pacity onto ends of both cables for connecting to
work clanp, spray gun, and weld output terminals.
5.
Install spray gun onto cable following manufactur
ers instructions. An insulated spray gun must be
used to ensure operator safety.
6.
Install work
use
damaged
or
frayed
cables.
WELD OUTPUT CONNECTIONS
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.
.~
~
clamp
onto cable.
B.
Socket J:
installation
115 volts
input
with a normally-open,
switch.
NEGATIVE
POSITIVE
+
Socket K:
115 volts
input
WARNING: ELECTRIC SHOCK
applied
Socket L:
Shut down unit and disconnect input power
employing lockout/tagging procedures before
making welding cable connections.
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.
of
Connect end of spray gun cable to POSITIVE
24
momentary
contact
from external circuitfor
Designed for use
contactor control.
with a normally-closed,
switch.
can kill.
Do not touch IWe electrica! parts.
1.
from external circuit for
Designed for use
applied
contactor control.
volts
dc
momentary contact
unregulated; fused
at
1
ampere.
Socket M:
Output voltage signal;
Socket N:
+15 volts dc rectifier caution signal. Present
when rectifier is overheated or there is
I volt per 10 volts.
unbalanced output.
Socket P:
(+)
Transformer caution signal. Normally-open
relay activates to potential of pin F (control
circuit common) when the transformer is
overheating.
weld output terminal.
2.
Socket A:
Fan motor signal. Normally-open, relay
activates to potential of pin F (control circuit
common) when the fan motor is operating.
SocketS:
Chassis
Socket T:
115 vac return for
Connect one end of work cable to NEGATIVE ()
weld output terminal and remaining end to
workpiece.
IMPORTANT: For Electrode NegatWe/Straight Polarity
connections, reverse cable connections to weld output
terminals; electrode becomes negative.
common.
Input
contactor control.
3-3. CONTROL MODULE RECEPTACLE INFOR
MAT1ON AND CONNECTiON (Figure 3.1)
The 1 7-socket Amphenol receptacle RC2 provides a
connection point for the Control Module. To make con
nections, align keyway, insert Control Module plug fully
into receptacle, and rotate threaded collar fully clock
wise. A properly connected Control Module is neces
sary for unit operation.
The command signals required and the output signals
available at the sockets of receptacle RC2 are as fol
lows:
Socket A:
Reference
+l0vdc
TA.1Il 059
Figure 3-1. Front VIew Of 17-Socket Amphenol
Receptacle With Socket LocatIons
voltage for output command;
3-4.
Socket B:
Output command signal.
Socket C:
Not used.
Socket D:
Output
Socket E:
Output
INPUT
contactor control.
current
signal;
A.
1
volt
per
150
amperes.
Socket F:
Control circuit
Socket G:
Not used.
Socket H:
+24
common.
ampere.
dc
unregulated; fused
at
1
ElectrIcal Input
Requirements
This welding power source is designed to be operated
from a three-phase 60 Hertz, ac power supply which has
a line voltage rating that corresponds with one of the
electrical input voltages shown on the nameplate. Con
sult the local electric utility if there is any question about
the
volts
ELECTRICAL INPUT CONNECTIONS
site
type of electrical system available
at the installation
how proper connections to the
source are to be made.
or
welding power
F2544 Pacie 9
B. Matching The Welding Power Source To The
Available Input Voltage
a
WARNING: ELECTRIC SHOCK
can kill.
Do not touch live electrical parts.
Shut down unit and disconnect input power
employing lockout/Tagging procedures before
inspecting or seivicing.
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.
the available line
voltage label.
input
Input Conductor Connections
C.
Table 3-2 provides guidelines for selecting the propet
size input conductors and line fuses. The input conduc
tor should be covered with an insulating material that
complies with national, state, and local electrical codes.
Table 3.2.
Input Conductor And
Input Conductor Size AWG
200V
I
230V
Fuse Size
Fuse Size In Amperes
-
1460V1575V 200VI230V
500MCML~MCM~
(1)
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. II in a bag,
proper installation is necessary before operation.
shown on the
voltage positions
(2)
110
1
(4)
(6)
600
500
I~0%hI
575V
300
200
lnputconckictor sizes are based on National Electrical Code specifi
caflons for allowable ampacWesof 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
ground onductor sizes.
Install terminal
tugs of adequate amperage capacity and
Input and ground conductors.
correct stud size onto the
a
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Install
a
a
fusible line disconnect switch in the
to the welding power source.
input circuit
provides a sate and convenient means to
completely remove all electrical power from the
welding power source whenever It Is necessary
to inspect or service the unit.
on in
Install and connect
lows:
1.
welding power source.
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 powerconnec
tions.
Remove the top cover and reposition or Install, If appli
cable, the jumper links onto the terminal board to match
F2544
Page
10
kill.
Do not connect the ground conductor to an in
put line before making input connections to the
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.
can
Do not connect an input conductor to the
ground terminal in the unit.
put line terminal.
This
Employ lockoutiTagging procedures
WARNING: ELECTRIC SHOCK
as
fol
Obtain and Install a proper strain relief connector
into rear panel access hole ( hole accepts standard
conduit
2.
Input and ground conductors
fittings).
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
tactor.
4.
Connect ground conductor to ground terminal next
to contactor.
5.
Connect remaining end of ground conductor to a
proper ground. Use a grounding method that is ac
ceptable to the local electrical Inspection authority.
6.
Reinstall and
secure
top
cover onto
unit.
SECTION 4- OPERATOR CONTROLS
4-1.
PILOT LIGHT
pilot light, when Iffliminated, 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
OPERATION
a
WARNING:
ELECTRIC SHOCK can kIlI
MOVING PARTS can cause serious iniury;
IMPROPER AIR FLOW AND EXPOSURE TO
ENVIRONMENT can damage Internal parts.
Keep all covers and panels in place while op
erating.
if the
welding power
and
CONTROL MODULE RECEPTACLE
The Control Module receptacle RC2 provides a connec
tion point forthe remote control module. See Section 3-3
for connection information.
Install and connect unit
2.
Install and connect Control Module as instructed in
Section 301 this manual and control console Owners
according
Manual.
Prepare any remaining equipment
for the
applica
tion.
5.
source is
operated with any portion of the outer enclosure
to Section 3.
1.
3.
Do not touch live electrical parts.
Warranty Is void
4-3.
problem
SEQUENCE OF OPERATION
SECTION 5
5-1.
from overload. If CB1 opens, correct the
manually reset CBI.
5-2.
Turn on power to welding power
and begin operation.
source contactor
SHUTTING DOWN
removed.
1.
Stop operation.
ARC RAYS, SPARKS, AND HOT SURFACES
can burn eyes and skin; NOISE can damage
2.
Turn off power to
hearing.
3.
Turn off all
Wear con-ect eye, ear, and
welding power
source contactor.
auxiliary equipment.
body protection.
FUMES AND GASES can seriously harm
your health.
Ventilate to keep from breathing fumes and
gases.
If ventilation is
inadequate,
use
approved
breathing device.
HOT METAL, SPATTER AND SLAG can
and bums.
cause fire
Watch for fie.
Have a fire
howto use it.
extinguisher nearby, and know
Allow work and equipment to cool be fore han
dling.
MAGNETIC FIELDS FROM HIGH CURRENTS
affect pacemaker operation.
can
Wearers should consult with their doctors be
fore
going
near arc
welding, gouging,
or
spot
welding operations.
See Section 1
Arc
Safety Rules For Operation Of
Power Source for basic welding
Welding
safety information.
F2544 Pa~:1e 11
SECTION 6
-
MAINTENANCE & TROUBLESHOOTING
6-2.
ROUTINE MAINTENANCE
6-1.
IMPORTANT: Every six months inspect the labels on
this unit for legibility. All precautionary labels rrvst be
maintained in a clearly readable state and replaced
when necessary. See Parts List for part number of pre
FAN MOTOR
This unit is equipped with an exhaust fan and relies on
forced draft for adequate cooling. The fan motor is
manufactured with lifetime sealed
no maintenance.
bearings
and
re
quires
cautionary labels.
6-3.
WARNING: ELECTRIC SHOCK
can kill.
Do not touch live electrical parts.
OVERLOAD PROTECTiON
a
Shut down unit arid disconnect
WARNING: ELECTRIC SHOCK
can kill.
Do not touch live electrical parts.
input power
employing lockout/tagging procedures before
inspecting, maintaining, or servicing.
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
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.
off and red-tagging circuit breaker
connecting device.
HOT SURFACES
Allow cooling
or
other dis
can cause severe
burns.
period before servicing.
Troubleshooting of internal parts
formed only by qualified person.
to be per
a
CAUTION: IMPROPER FUSES
unit
Be
sure
replacement
fuses
can
damage
are same
size,
type, and rating (see Parts List).
Table 6-1. MaIntenance Schedule
A.
.
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
Transformer And Rectifier ProtectIon
MAINTENANCE
FREQUENCY
The main transformer and rectifier assembly are pro
tected from overload by three normally-closed thermo
stats TP1, TP2, and TP3. TPI and TP2 are located in
the main transformer, and TP3 is located in the rectifier
assembly. If overheating of the transformer and/or recti
fier occurs, the associated thermostat(s) will open
deenergizing the output contactor. The welding power
source signals the control console and weld output
ceases. If this condition occurs, allow a cooling period
before resuming operation.
6-18).
B.
A.
Weld Cables
Every three months inspect cables for breaks in insula
Repair or replace cables if insulation breaks are
present. Clean and tighten connections at each inspec
tion.
tion.
B.
Internal
CleanIng
Blow out or vacuum dust and dirt from around the inter
nal con~onents. 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.
F2544 Pa~~ 12
Circuit Board ProtectIon (FIgure 6-1)
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
on the rear of the circuit board mounting bracket inside
the unit. It Is necessary to remove the unit top cover to
gain access to the fuses.
C.
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 windtunnel by the input conduc
tor strain relief. It is necessary to remove the nght side
panel to gain access to this fuse.
Component Access
Compartment
Block
Gate Connectors
With Red And Whits
Board PCi
(A) Circuit
Board P~3
Terminal Strip And
Control R.ctifi.r
Mount maid. IS.s Parts Ust)
Wy.
Circuit BOard
Pc2
Ru.: TA-090 925-A
Figure
6-4.
6-1.
Component
TROUBLESHOOTING CHART
a
WARNING: ELECTRIC SHOCK can kill.
DO not touch live electrical parts.
Shut down unit arid disconnect input power
employing lockoutiTagging procedures before
inspecting, maintaining, 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.
MOVING PARTS can cause serious
Keep
Injury.
clear of moving parts.
HOT SURFACES can cause severe burns.
Allow
Locations
It is assumed that the unit was properly Installed and
connected according to Section 3 of this manual, the op
erator is familiar with the function of controls, the weld
ing power source was working properly, and the trouble
is not process related.
The following chart is designed to diagnose and provide
remedies for some of the troubles that may develop in
this welding power source.
Use this chart in conjunction with the circuit diagram
while performing troubleshooting procedures. If the
trouble is not remedied after performing these proce
dures, contact the nearest Factory Authorized Service
Station. In all cases of equipment malfunction, the
manufacturers recommendations should be strictly fol
lowed.
cooling pericd before servicing.
Troubleshooting of internal parts
only by qualified persons.
to be per
formed
F?544 P2c:e 1~3
Table 6-2.
PROBABLE CAUSE
TROUBLE
No weld output; unit
completely inoperative
TroubleshootIng
Une disconnect switch in the OFF
position.
Line
REMEDY
Place line disconnect switch in the
ON position.
Replace line fuse(s).
fuse(s) open.
Improper electrical input connections.
Input voltage jumper links
position.
not in proper
See Section 3-4 for proper
connections.
See Section 3-4 B for proper
link
Main transformer Ti and/or main
rectifier SRI and SR2 assembly
input
jumper
position.
Allow the unit to cool down
(see Section 6-3).
overheating (thermal shutdown).
Erratic weld output
Poor and/or in~roper
connections.
No 24 volts control circuits.
Fuse(s)
Fan does not
Fuse F4
F2544 Pa~~ 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).
/
253
D-12
No.
Diagram
Circuit
Diagram
CIrcuit
6-2.
Figure
to to to to to to
to to
0
Dia.
Mkgs.
Part
No.
Descnptuon
Quantity
CIRCUIT BREAKER, manual reset 1 pole 15 amp 250 volts
CAPACITOR (consisting of)
1
Complete Assembly
CB1
053 283
090 476
Cl 4,15
R4
Cl 7,18
C21 ,24
CR12.4
CR3
Dl
FM
000 859
601 394
083 332
094 206
097 749
059 266
106 462
115 325
032 633
011 850
032 617
059 585
114425
220 UI 35 volts dc
CAPACITOR, electrolyte
RESISTOR, carbon 2 watt 10K ohm
CAPACITOR, ceramic 0.003 UI 3000 volts
CAPACITOR, (consisting of)
CAPACITOR, ceramic 0.05 Ut 500 volts dc
RELAY, enclosed 120 volts ac DPDT
RELAY, enclosed 24 volts dc DPDT
DIODE, 1 amp 400 volts SP
MOTOR, 1/4 hp 230 volts ac 1625 rpm (consisting of)
SWITCH, motor
BLADE, fan 50 hz 20 inch 3 wing 24 deg
070 404
WINDTUNNEL, 20 inch
BAR, support, windtunnel
FUSE, miniature glass sb blo 1 amp
HOLDER, fuse
FUSE, cartridge 30 amp 600 volts
HOLDER, fuse
POS,NEG
093 342
115185
106 585
115149
110375
027645
090 469
072 566
081 379
115397
SENSOR, current
CIRCUIT CARD, control (pg 20)
CIRCUIT CARD, SCR firing (pg 22)
ENCLOSU RE, circuit caids
STAND-OFF, support
LIGHT, indicator red lens 125 volts ac
HOUSING, terminal header 10 pin
HOUSING, terminal header 8 pin
HOUSING, terminal header 12 pin
TERMINAL ASSEMBLY, power output (consisting of)
RC2
115148
038847
601 840
601 839
038900
602247
605787
097 869
Fl ,2
012 643
098 376
012639
F4
HAl ,2
PCI
PC2,3
PL1
PLG51 ,56,57
PLG52,53
PLG 50
R5
SRi
SCR1-12
C1-12
TP3
SR3
TEl
F2544
Page
16
039 210
115 429
109091
048420
012 786
086 354
025 248
028516
035 914
114 545
038669
038 621
038652
026754
038 620
1
2
1
2
1
2
3
1
1
1
1
1
1
2
1
1
1
1
2
I
2
1
12
1
3
2
1
1
TERMINAL BOARD
1
BUSBAR
NUT, brass-hex jam 1/2-13
2
8
NUT, brass-hex jam 1/2-13
STUD, brass 1/2-13 x 2-1/4
4
4
WASHER, flat-SAE 1/2
WASHER, lock-internal tooth 1/2
RECEPTACLE, 17 socket MS-3102A-20-29S
RESISTOR, WW fixed 375 watt 1.2 ohm
RECTIFIER, SCR main (consisting of)
THYRISTOR, SCR 865 amp 300 volts
CAPACITOR, ceramic 0.01 UI 500 volts dc
THERMOSTAT, NC
CLAMP, diode/rectifier
STAND-OFF, 1/4-20 x 1-1/4
PIN,springl/8x1/4
RECTIFIER, integrated
BLOCK,
LINK, jumper
4
1
1
1
12
12
1
4
8
24
30 amp 400 volts
TERMINAL ASSEMBLY, pn (consisting of)
TERMINAL BOARD
terminal 30 amp 4
4
pole
1
1
1
1
6
INSULATION
12
LINK, jumper
2
Dia.
Mkgs.
Part
No.
Description
Quantity
Complete Assembly
115 152
STUD, 1/4-20 x 1-3/4
NUT, brass-hex jam 1/4-20
WASHER, flat-brass 1/4 ID x 5/8 00
WASHER, lock-internal tooth 1/4
WASHER, fIat-brass 3/16 ID x 1/2 CD
TRANSFORMER, power main (consisting of)
COIL, pri/sec LH
115153
~C0lL,pri/seccenter&RH
2
TP1,2
026 181
115399
Wi
048 731
099 044
048599
THERMOSTAT, NC
TRANSFORMER, interphase
INTERLOCK, NO
CONTACTOR, 3 pole 110-120/220 volts (consisting of)
2
T2
~COlL
STABILIZER
STUD, connection
BLOCK, terminal 20 amp 8 pole
BLOCK, terminal 15 amp ii pole
LINK jumper
CATCH, spring loaded
RETAINER, screw No.2
FASTENER, screw hd No. 2
NUT, speed No.2
1
~ ~9
601 836
010 915
602 209
010 913
Ti
W
115 385
Zi
115 338
iT
072 253
2T
038 659
3T
106 699
038 618
605 583
010 855
010 853
010357
026 627
080509
015 722
010 494
115 189
098639
098519
098 634
098 432
122206
098428
+098 429
109 035
057357
12
24
12
12
2
I
1
1
1
1
1
1
1
1
2
,
2
2
2
2
GASKET, lifting eye
GROMMET, SCA No. 8/10 panel hole
GROMMET, 1-1/4 ID x 1-1/2 mtg hole
BUSHING, snap-in 1-3/8 ID
NAMEPLATE (order by model & serial number)
BRACKET, mtg-terminal
1
BASE
1
FRAME, mtg-transformer
FRAME, center base
PANEL, rear
PANEL, front
PANEL, side
COVER, top
LABEL, warning electric shock can kill,
BUSHING, snap-on 15/16 ID x 1-1/8
1
I
1
1
I
1
1
i
I
2
1
etc
1
1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
F2544
Page
17
Dia.
Mkgs.
A52,54,56,59
A55,57,58
C61
Part
No.
Descnption
Quantity
115 185
CIrcuit Card, Control
052 133
009 159
000 347
IC,linear4l36
IC,linear358
CAPACITOR, tantalum 0.33 uf 35 volts
073 739
072 130
CAPACITOR, ceramic 0.1 uf 50 volts dc
CAPACITOR, tantalum 1 uf 35 volts dc
CAPACITOR, electrolyte 100 uf 35 volts dc
CAPACITOR, tantalum 0.47 uf 35 volts
CAPACITOR, ceramic 0.001 uf 1000 volts
CAPACITOR, mylar 0.22 Ut 50 volts
DIODE, signal 0.020 amp 75 volts SP
14
DIODE, 1 amp 400 volts SP
TRANSISTOR, PNP 0.6 amp 40 volts
TRANSISTOR, NPN 200MA 40 volts
RESISTOR, carbon film 0.25 watt 10K ohm
RESISTOR, carbon film 0.25 watt 15K ohm
1
4
3
...
1
C64-70,79,80,89,
91-94100
C71 ,92, 100
C85,86
C87,88, 102
039 482
C99
Cl 08
053 992
000 348
D57-62,78,84,89,90
038 585
028 351
D86
026 202
Q52
035 842
Q55,64
R74,75
R77,94
037 200
000 885
039332
9*~~
ciol
(__.)
+~
3
2
3
1
1
10
1
2
2
2
RI96~9~
~R~7
Ret: D-096 881
COMPONENTS TO BE REPLACED
BY QUALIFIED PERSONNEL ONLY
CIrcuit Card, Control
F2544
Page
18
Dia.
Mkgs.
Part
No.
115
R79
R80,84,85,1 19-1 24,
152-154,159,160,
168,173
R81
185
RESISTOR, carbon film 0.25 watt 10K ohm
035827
082 179
RES1STOR,carbonfitm0.25watt 10K ohm
POTENTIOMETER, cermet 25 turn 0.5 watt 25K ohm
RESISTOR, metal film 0.25 watt 26.7K ohm
RESISTOR, metal film 0.25 watt 3.32K ohm
RESISTOR, metal film 0.25 watt 2.67K ohm
RESISTOR, carbon film 0.25 watt 100 ohm
RESISTOR, carbon film 0.25 watt 5.1K ohm
RESISTOR, metal film 0.25 watt 110K ohm
095 828
R92
115 530
R93
035 823
084 206
R96-98,1 15,117,204
052 137
Ri 16,118
R148,149,151
161,172,195,196
071 237
R155
R164,167
RI 69,201
R170,197
R181
R182
R190
R202203
R208
R210
RC5O
RC51
RC52,53
U52
VR5O
VR51
VR52
039 331
039 330
003 272
039 334
035 201
035 888
009 173
035824
035 896
089 175
084 205
082178
092 648
089 346
089 345
084 197
095268
081 832
046932
091 256
Quantity
CircuIt Card, Control (Contd)
039 108
R86,88
R87,89,90
R150
Description
RESISTOR,
RESISTOR,
RESISTOR,
RESISTOR,
RESISTOR,
1
16
1
2
3
1
I
6
2
carbon film 0.25 watt 4.7K ohm
carbon film 0.25 watt 3.9K ohm
carbon film 0.25 watt I meg ohm
7
carbon film 0.25 watt 27K ohm
2
1
1
carbon film 0.25 watt lOOK ohm
film 0.25 watt 2.2K ohm
POTENTIOMETER, cermet 20 turn 0.5 watt 5K ohm
RESISTOR, carbon film 0.25 watt 270 ohm
2
RESISTOR, carbon
2
1
1
RESISTOR, carbon film 0.25 watt 33K ohm
RESISTOR, metal film 0.25 watt 10K ohm
RESISTOR, carbon film 0.25 watt 3.3K ohm
POTENTIOMETER, cermet 25 turn 0.5 watt 10K ohm
RESISTOR, WW fixed zero ohm
TERMINAL, header 12 pIn
TERMINAL, header 10 pIn
TERMINAL, header 8 pin
IC,interface2ll
IC, linear 78M15
IC,lInear7gl5
IC, linear 317L
1
2
I
1
1
1
1
2
1
1
1
1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
F2544
Page
19
Dia.
Mkgs.
Part
No.
Description
Quantity
106585
Circuit Card, SCR Firing Circuit
A1,2
096275
2
Cl -3
035 834
C4,5
C6-9,16-18
090 573
C10-15
C19-24
000 340
C25
000 348
D1-6
037 449
IC,linear324
CAPACITOR, metal film 1.5 uf 100 volts
CAPACITOR, electrolyte 10 uf 50 volts
CAPACITOR, ceramic 0.1 UI 50 volts dc
CAPACITOR, ceramic 0.01 uf 50 volts
CAPACITOR, mylar 0.033 UI 100 volts dc
CAPACITOR, tantalum 0.47 uf 35 volts
DIODE, zener 15 volts 1 watt SP
07-9,10-12
026202
DIODE, 1 amp 400 volts SP
6
R1-3
000 885
3
R4
039 331
R5
035 848
R7,8,10,11
052 183
035 888
RESISTOR, carbon film 0.25 watt 10K ohm
RESISTOR, carbon film 0.25 watt 4.7K ohm
POTENTIOMETER, cermet 25 turn 0.5 watt 10K ohm
RESISTOR, carbon film 0.25 watt 20K ohm
RESISTOR, carbon film 0.25 watt 2.2K ohm
RESISTOR, carbon film 0.25 watt lOOK ohm
RESISTOR, carbon film 0.25 watt 22K ohm
RESISTOR, carbon 0.25 watt 150 ohm
RESISTOR, carbon 0.25 watt 270 ohm
RESISTOR, carbon film 0.25 watt 10K ohm
RESISTOR, WW fixed zero ohm
TERMINAL, header 12 pin
TERMINAL, header 10 pIn
TERMINAL, header 6 pin
R9
R12-23
R24-29
R30-35
R36-41
R42-47
RC5O
RC51
RC52
T1-6
U1-3
073 739
035 833
035 884
035 886
074 026
035 257
035 827
092 648
089 346
089345
084 196
035 846
097767
.
TRANSFORMER, pulse
IC, interface 3634
3
2
7
6
6
1
6
1
1
4
1
12
6
6
6
6
19
1
1
1
6
3
Ret. 0-106 587
COMPONENTS TO BE REPLACED
BY QUALIFIED PERSONNEL ONLY
CIrcuit Card, Firing CircuIt
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
F2544
Page
20