Miller SR-300 User Owner's Manual

February 1983 FORM: OM-210( Effective With Serial No. JC622608 MODEL SR-200 SR-300 SR-400 SR-600 OWNERS £ % MANUAL = MILLER ELECTRIC MFG. CO. 718 5. BOUNDS ST. P.O. Box 1079 APPLETON, WI 54912 USA ADDITIONAL COPY PRICE 85 CENTS NWSA CODE NO. 4579 PRINTED IN U.S.A. 6: № I LIMITED WARRANTY EFFECTIVE: JUNE 1, 1979 This warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied, LIMITED WARRANTY - Subject to the terms and conditions hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants to its Distributor/ 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 Milter with respect to engines, trade accessories or other items manufactured by others. Such engines, trade accessories and other items are sold subject to the warranties of their respective manufacturers, if any . All engines are warranted by their manufacturer for one year from date of original purchase. Except as specified below, Miller's warranty does not apply to components having normal useful life of less than one (1) year, such as spot welder tips, relay and contactor points, MILLERMATIC parts that come in contact with the welding wire including nozzles and nozzle insulators where failure does not resuit from defect in workmanship or material. Miller shati 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 Equip- ment to the original user: : 1. Arc welders, power sources and components .. 1 year 2. Original main power rectifiers ................ 3 years {labor - 1 year only) 3. All weiding guns and feeder/guns ............ 90 days 4. Allother Millermatic Feeders. ................. 1 year 5. Replacement or repair parts, exclusive of labor . 60 days 6. Battertes. . . ........ LLL . 6 months provided that Miller is notified in writing within thirty (30) days of the date of such failure. SIDE Rs ere ль As a matter of general policy only, Miller may honor claims submitted by the original user within the foregoing periods. In the case of Miller's breach of warranty or any other duty with respect to the quality of any goods, the exclusive remedies therefore shall be, at Miller's option {1) repair or (2) replacement or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station or (4) payment of or credit for the purchase price {less reasonable depreciation based upon actual use) upon return of the goods at Customer's risk and expense. Upon receipt of notice of apparent defect or failure, Miller shall instruct the clai- mant on the warranty claim procedures to be followed. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA- TION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX- CLUDED AND DISCLAIMED BY MILLER. EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN WRITING, MILLER PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE BY COMMERCIAL /INDUSTRIAL USERS AND FOR OPERATION BY PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT AND NOT FOR CONSUMERS OR CONSUMER USE. MILLER" WARRANTIES DO NOT EXTEND TO, AND NO RESELLER IS AUTHORIZED TO EXTEND - MILLER'S WARRANTIES TO, ANY CONSUMER. =. =x er г O a a Yo SA Sw Te. «т J. № Je fr ©. я After this manual was printed, refinements in e appearing later in this manual. ERRATA SHEET April 18, 1983 FORM: OM-211 quipment design occurred. This sheet lists exceptions to data Quantity | | Model Part Replaced 200 | 300 | 400 xx No With Description Amp Amp Amp 8-8 026926 088810 STRIP, fibre.015x2-1/4x4-1/2............ 1 La 3 3 8-8 028386 088810 STRIP, fibre 015 x2-1/4x4-1/2.............. La a LL 3 8-16 601 798 605 074. BOLT, machine-hex hd 1/4-20x5 111111111111 2 8-16 601799 601797 BOLT, machine-hex hd 1/4-20 x5-1/2 ........... 2 8-18 016 879 Deleted | 8-19 605 540 Deleted **First digit represents page number - digits following dash represents item no. BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. E TABLE OF CONTENTS 1D in Section No. Page No. SECTION 1 — SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1-1. Introduction ........ e... e e. .eneadarenanenaananaronrarnrenadrvoe 1 1-2. General Precautions ........... 2. 00r2xsrierorameroevearororerdoro 1 1-3. ArcWelding .. «oo i ii ee ee ee ee eee 1-4, Standards Bookilet index .......... _.ee._..rerarerroravenorerdeooa 10 SECTION 2 — INTRODUCTION 2-1. General i ete ere ee eee ea 12 2-2. Receiving-Handling iii ee ia 12 2 - 3. Description 0. RR RR RR RR 0 12 2-4, Safety EEE 12 SECTION 3 — INSTALLATION 3-1. Location ..........e eee esaeada naa oraervarernvari era a arca 13 3-2. Electrical Input Connections .......... 2. sm0r0r ere eee 13 3-3. Secondary Welding Connections .......eoeeeererrreronrervore re». 14 3-4. Remote Amperage Control Connections ... .. reee. 14 SECTION 4 — FUNCTION OF CONTROLS 4-1. Power Switch ........ 2... ,0rrerarxieva vea erarecnr0 averareta 15 4-2. Range Switch ........ 222... ad, aanaa0udderere ua ea 0 15 4-3. Amperage Adjustment Control .......... _ 2.00 mresier0aevare ca. 15 4-4. Remote Amperage Control Receptacle & Switch ..................... 15 4-5. Polarity Switch ....... ee La 15 4-6. Duty Cycle «oe 4 4 4 a 4 a a a 4 a A a a 0 16 4- 7. Volt-Ampere Curve 111220400141 4 La La 41 LL 4 a Aa LL a Aa Ra a a ae 0 16 SECTION 5 — SEQUENCE OF OPERATION 5-1. Shielded Metal- Arc Welding ........... 2.2220. 0060 rr. 17 5-2. Shutting Down .......... ee e 17 SECTION 6 — MAINTENANCE 6-1. Fan Motor ........... it tee ite te ee 17 6-2, Transformer oot tt tt ee ee eee ee eee eee = 17 6-3. Rectifier ......._eceenmoaraaaadaonvarvarieondacodararnaorora y ae 17 6-4. Control Circuit Fusing ........_.-e-—re0nvasoerevrreneerereraredon. 17 SECTION 7 — TROUBLESHOOTING PARTS LIST SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE SECTION 1 - RÈGLES DE SÉCURITÉ POUR LE FONCTIONNEMENT DU POSTE DE SOUDAGE À Е ARC 1-1. INTRODUCTION - We learn by experience. Learning safety through personal experience, like a child touching a hot stove is harmful, wasteful, and un- wise. Let the experience of others teach you. r Safe practices developed from experience in the use of welding and cutting are described in this manual. Research, development, and field experience have evolved reliable equipment and safe installation, operation, and servicing practices, Accidents occur when equipment is improperly used or maintained. The reason for the safe practices may not always be given. Some are based on common sense, others may require technical volumes to explain. It is wiser to follow the rules, Read and understand these safe practices before attempting to install, operate, or service the equipment. Comply with these procedures as applicable to the particular equipment used and their instruction manuals, tor personal safety and for the safety of others. Failure to observe these safe practices may cause serious injury or death. When safety becomes a habit, the equipment can be used with confidence. These safe practices are divided into two Sections: 1 - General Precautions, common to arc welding and cutting; and 2 - Arc Welding {and Cutting) (only). Reference standards: Published Standards on safety are also available for additional and more complete procedures than those given in this manual. They are listed in the Standards index in this manual. ANS! Z49.1 is the most complete. The National Electrical Code, Occupational Safety and Health Administration, local industrial codes, and local inspection requirements also provide a basis for equipment installation, use, and service. 1-2. GENERAL PRECAUTIONS Different arc welding processes, electrode alloys, and 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 for specific technical data and precautionary 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 or glasses with side shields underneath, appropriate filter lenses or plates (protected by clear cover glass). This is a MUST for welding or cutting, (and chipping) to protect the eyes 1-1. INTRODUCTION - Contrairement à l’apprentissage de la vie, l'apprentissage de la sécurité par ex- périence personnelle, comme l'enfant qui touche un poêle chaud, est dangereux, imprudent et inutile. Instruisez-vous donc de l'expérience d'autrui. Des méthodes de sécurité issues de. l'expérience du soudage et du coupage sont décrites dans le manuel. La recherche, le progrès et l'expérience dans ce domaine ont développé un matériel fiable et des méthodes de sécurité pour l'installation, le fonctionnement et l'entretien. Des accidents se produisent lorsque le matériel est inadéquatement utilisé ou entretenu. La raison de ces méthodes de sécurité peut ne pas être toujours donnée. Certaines sont fondées sur le sens commun, d'autres demanderont à être expliquées par des livres techniques. il est plus sage de suivre les règies. Lisez et comprenez ces méthodes de sécurité avant d'essayer d'installer, de faire fonctionner ou de réparer l'appareil. Pour votre sécurité personnelle et celle d'autrui, conformez-vous à ces règies et aux manuels d'instructions. Manquer d'observer ces méthodes de sécurité pourrait entraîner des blessures graves ou mème la mort. Quand la sécurité devient une habitude, ie matériel peut alors être utilisé en toute confiance. Ces méthodes de sécurité sont divisées en deux sections: 1 - Précautions générales, communes au soudage et au coupage à l'arc, et 2 - Soudage à l'arc {et coupage} (uniquement). Normes de référence: Des publications des normes américaines de sécurité sont aussi à votre disposition pour d'autres modes opératoires plus complets que ceux du présent manuel. Elles sont données dans l'In- dex des Normes de ces règles de sécurité. ANS! Z49-1 est la plus complète. Les codes de FACNOR, les codes provinciaux et municipaux donnent aussi les exigences pour une installation, une utilisation et un entretien sûrs. 1-2. PRÉCAUTIONS GÉNÉRALES Plusieurs procédés du soudage à l'arc, des élec- trodes alliés, et les flux peuvent produire des vapeurs, gaz, et niveaux de rayonnement différents. Pour tout renseignement supplémen- taire à ce manuel, consultez aussi les fabricants des électrodes et des flux afin d'obtenir les renseignements techniques spécifiques et les mesures de précaution concernant leurs matériaux. A. Prévention des brûlures Portez des vêtements de protection - des gants à crispin spécialement désignés pour le soudage, un casque et des chaussures de sécurité. Boutonnez le col de votre chemise et les pattes de vos poches, et portez des pan- talons sans revers pour éviter que des étincelles et du laitier ne s'y introduisent. Portez un masque avec lunettes de sécurité ou avec écrans laté-raux de protection, des lunettes filtrantes ou des couvre-lentilles (protégés par un verre clair). Pour le soudage ou le coupage (et le burinage), il est OM-210 Page 1 pf fs mpm a on from radiant energy and flying metal. Replace cover glass when broken, pitted, or spattered. See 1-3A.2. Avoid oily or greasy clothing. A spark may ignite them. Hot metal such as electrode stubs and workpieces should never be handled without gloves. Medical first aid and eye treatment. First aid facilities and a qualified first aid person shouid 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 by persons intending to weld or cut. B. Toxic Fume Prevention Severe discomfort, illness or death can result from fumes, vapors, heat, or oxygen enrichment or depletion that welding {or cutting) may produce. Prevent them with adequate ventilation as described in ANS] Stan- dard 243.1 listed 1 in Standards index. NEVER ventilate with oxygen. | Lead -, cadmiurn -, zinc -, mercury -, and beryllium - bearing and similar materials, when welded (or cut} may produce harmful concentrations of toxic fumes. Ade- quate local exhaust ventilation must be used, or each person in the area as well as the operator must wear an air-supplied respirator. For beryllium, both must be used. Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed from the work surface, the area is weil ven- tilated, or the operator wears an air-supplied respirator. Work in a confined space only while it is being ven- tilated and, if necessary, while wearing an air-supplied respirator. Gas leaks in a confined space should be avoided. Leaked gas in large quantities can change oxygen concentration dangerously. Do not bring gas cylinders into a confined space. Leaving confined space, shut OFF gas supply at source to prevent possible accumulation of gases in the space if downstream valves have been accidently opened or left open. Check to be sure that the space is safe before re-entering it. Vapors from chlorinated solvents can be decomposed by the heat of the arc (or flame} to form PHOSGENE, a highly toxic gas, and other lung and eye irritating products. The ultraviolet (radiant) energy of the arc can also decompose trichloroethylene and per- chloroethylene vapors to form phosgene. DO NOT WELD or cut where soivent vapors can be drawn into the welding or cutting atmosphere or where the radiant Page 2 OBLIGATOIRE de protéger ses yeux contre l'énergie de rayonnement et les éclats de métal. Remplacez le verre protecteur lorsqu'il est brisé, piqué ou qu’il a reçu des projections. Voir 1.3A.2. Évitez de porter des habits imprégnés d'huile ou de graisse. Une étincelle pourrait les enflammer. Ne manipulez jamais sans gants un métal chaud tel que des chutes d’électrode et des pièces à souder. Premiers soins et traitement des yeux: Tout atelier devrait avoir à sa disposition un poste de premiers soins - ainsi qu’une personne compétente, à moins qu'ur, service médical ne soit à proximité pour soigner immédiate- ment les brûlures des yeux et de la peau. Portez des bouche-oreilles lorsque vous travaillez au plafond ou dans un espace restreint. Portez un casque lorsque d’autres personnes travaillent au plafond. Les personnes devant souder ou couper ne doivent pas employer des préparations inflammables pour leurs cheveux. B. Prévention des gax toxiques Les gaz, les vapeurs, la chaleur, un enrichissement ou un manque d'oxygène peuvent entraîner Un malaise, une maladie ou même la mort. Remédiez-y par la ventilation décrite dans la Norme ANSI Z49.1 paragraphe 1 de l'Index des Normes. NE ventilez JAMAIS à Гох- ygène. En soudant ou en coupant, les plomb, cadmium, zinc, mercure et béryllium ou autres matériaux semblables peuvent créer des concentrations nocives de gaz toxiques. On doit avoir recours à une ventilation aspirante adéquate du local, ou alors toute personne sur les lieux, de même que le soudeur, doit porter un masque à adduction d'air. On doit employer les deux pour le béryllium. Les métaux enrobés ou composés de matériaux émet- tant des gaz toxiques ne doivent pas étre chauffés a moins que l'enrobage ne soit ôté de la surface à travailler, que le local ne soit bien ventilé, ou que le soudeur ne porte un masque à adduction d'air. Ne travaillez dans un espace restreint que s'il est bien ventilé et, si nécessaire, portez un masque à adduction d'air. On doit éviter les fuites de gaz dans un espace restreint. Les fuites de gaz en grande quantité peuvent transformer dangereusement la concentration d'ox- ygène. N’amenez pas de bouteilles de gaz dans un espace restreint. En quittant un espace restreint, FERMEZ le robinet d'alimentation de gaz de la bouteille. Ainsi on pourra rentrer en toute sécurité dans la pièce, même si les robinets ‘’aval’’ ont été ouverts par accident, ou si on les a laissés ouverts. Les vapeurs de dissolvants chlorés peuvent être décom- posées par la chaleur de l’arc (ou de la flamme) et former du PHOSGENE, gaz très toxique, et d'autres produits irritant les poumons et les yeux. L'énergie ultra-violette de l'arc peut aussi décomposer les vapeurs de trichloroéthyléne et de perchloroéthylène pour former du phosgène. NE SOUDEZ PAS ou ne coupez pas dans des endroits où les vapeurs de dissoivants peuvent être attirées dans l'atmosphère de soudage ou de energy can penetrate to atmospheres containing even minute amounts of trichloroethyiene or per- chloroethylene. C. Fire and Explosion Prevention Causes of fire and explosion are: combustibles reached by the arc, flame, flying sparks, hot slag or heated material: 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, and (in electrical parts) of metallic particles that can cause short circuits. If combustibles are in area, do NOT weld or cut. Move the work if practicable, to an area free of combustibles. Avoid paint spray rooms, dip tanks, storage areas, ven- tilators. If the work cannot be moved, move combustibles at least 35 feet away out of reach of sparks and heat; or protect against ignition with suitable and snug-fitting, fire-resistant covers or shields. Walls touching combustibles on opposite sides should not be welded on (or cut). Walls, ceilings, and floor near work should be protected by heat-resistant covers or shields. Fire watcher must be standing by with suitable fire ex- tinguishing equipment during and for some time after welding or cutting if: a. appreciable combustibles {including building construction) are within 35 feet b. appreciable combustibles are further than 35 feet but can be ignited by sparks c. openings (concealed or visible) in floors or walls within 35 feet may expose combustibles to sparks d. combustibles adjacent to walis, ceilings, roofs, or metal partitions can be ignited by radiant or conducted heat, Hot work permit should be obtained before operation to ensure supervisor's approval that adequate precautions have been taken. After work is done, check that area is free of sparks, glowing embers, and flames. An empty container that held combustibles, or that can produce flammable or toxic vapors when heated, must never be welded on or cut, unless container has first been cleaned as described in AWS Standard A6.0, listed 3 in Standards index. This includes: a thorough steam or caustic cleaning {or a solvent or water washing, depending on the com- coupage et ou l'énergie de rayonnement peut pénétrer dans des atmosphères contenant des quantités même minuscules de trichioroéthylène ou de per- chloroéthylène. - C. Prévention des incendies et des explosions Les causes d'incendie et d'explosion sont les combustibles atteints par l'arc, la flamme, les étincelles, le laitier chaud ou les matériaux chauffés, le mauvais empioi des gaz comprimés et des bouteilles ainsi que les courts-circuits, Sachez que les éclats d'étincelies ou la chute du laitier peuvent s'infiltrer dans les fissures, le long des tuyauteries, par les fenétres et les portes et par les couvertures des murs ou du soi, sans que le soudeur portant des lunettes ne les voie. Les étincelles et les scories peuvent voler jusqu’à 35 pieds. Pour prévenir les incendies et les explosions: Veillez à ce que votre appareil soit propre et en état de marche, dénué d'huile et de graisse, et de particules de métal sur les pièces électriques qui pourraient entraîner des courts-circuits. Si des combustibles se trouvent à proximité, ne soudez pas, ne coupez pas. Si possible, déplacez votre travail loin des combustibles. Evitez les ateliers de peinture au pistolet, les cuves d'immersion, les entrepôts, les ven- tilateurs. Si cela n'est pas possible, placez les com- bustibies à au moins 35 pieds des étincelles et de la chaleur et protégez-les des étincelles avec des couvertures ou des écrans protecteurs adéquats, bien ajustés et ignifugés. On ne doit pas souder (ou couper} le côté opposé des murs touchant les combustibles. Les murs, plafonds et planchers proches du travail doivent être protégés par des couvertures ou écrans protecteurs ignifugés. Un surveillant doit se tenir à proximité avec un matériel de iutte contre l'incendie adéquat, pendant et quelque temps après le soudage ou le coupage si: a. Des quantités appréciables de combustibles {y compris une construction en chantier) se trouvent à moins de 35 pieds. b. Des quantités appréciables de combustibles sont à plus de 35 pieds mais peuvent être enflammées par des étincelles. c. Des ouvertures (cachées ou visibies) sur les planchers ou les murs à moins de 35 pieds peuvent exposer des combustibles aux étincelles. d. Les combustibles adjacents aux murs, plafonds, toits ou cloisons métalliques peuvent être enflammés par une chaleur rayon- nante ou transmise. Avant de commencer, avisez le contremaître pour qu'il s'assure que les précautions adéquates soient prises. Une fois le travail terminé, vérifiez qu'il n'y ait pas d'étincelles, de cendres ardentes ou de flammes dans ie local. On ne doit jamais souder ni couper sur un récipient ayant contenu des combustibles, ou pouvant produire des vapeurs inflammabies ou toxiques à la chauffe, à moins que le récipient n'ait été lavé au préalable, comme décrit dans la Norme AWS A6.0, figurant au paragraphe 3 de l'index des Normes. Cela comprend: un nettoyage à fond à la vapeur ou au caustique (ou un lavage avec dissolvant ou eau selon la solubilité du combustible) suivi d’une purge et d'une in- OM-210 Page 3 bustible’s solubility) followed by purging and inerting with nitrogen or carbon dioxide, and using protective equipment as recommended in A6.0. Waterfilling just below working level may substitute for inerting. A container with unknown contents should be cleaned (see paragraph above). Do NOT depend on sense of smell or sight to determine if it is safe to weld or cut. Hollow 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). D. Compressed Gas Equipment Standard precautions. Comply with precautions in this manual, and those detailed in CGA Standard P-1, PRECAUTIONS FOR SAFE HANDLING OF COM- PRESSED GASES IN CYLINDERS, listed 6 in Stan- dards index. 1. Pressure 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. Remove 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 pressure release. Repair. Do NOT attempt repair. Send faulty regulators for repair to manufacturer's designated repair center, where special techniques and tools are used by trained personnel. 2. Cylinders Cylinders must be handled carefully to prevent leaks and damage to their walls, valves, or safety devices: Avoid electrical circuit contact with cylinders including third rails, electrical wires, or welding circuits. They can produce short circuit arcs that may lead to a serious accident. (See 1-3C.) ICC or DOT marking must be on each cylinder. It is an assurance of safety when the cylinder is properly handled. Page 4 jection d'azote ou de gaz carbonique, en utilisant un équipement de protection comme recommandé dans l’'A6-0. L'atmosphère inerte peut être remplacée par un niveau d’eau arrivant au-dessous du travail à effectuer. Vous devez laver un récipient dont la nature de contenu est inconnue (voir paragraphe ci-dessus). NE vous fiez PAS 2a l'odorat ou a la vue pour dire si l'on peut ie souder ou ie couper en toute sécurité. Vous devez pratiquer un évent sur les pièces ou réci- pients creux avant de les souder ou couper: ils peuvent exploser. Atmosphères explosives: Ne soudez ni ne coupez jamais dans des lieux où l’air peut contenir des poussières, gaz ou vapeurs liquides inflammables (tels que l’essence). D. Gaz comprimé Précautions générales: Suivez les précautions de ce manuel, et celles décrites à la Norme CGA P-1 (Précau- tions de sécurité pour la manipulation de gaz comprimés en bouteilles), paragraphe 6 de l’Index des Normes. 1. Détendeurs de pression La soupape de sûreté d’un détendeur est destinée à pro- téger seulement le détendeur de la surpression. Elle n'a pas pour but de protéger les boyaux et le chalumeau: on protège ceux-ci par des soupapes de retenue conçues spécialement pour cette fonction. Ne montez jamais un détendeur sur une bouteille contenant un gaz différent de celui pour lequel ie détendeur a été conçu. Enlevez immédiatement un détendeur défectueux pour le faire réparer (d'abord, fermez le robinet de la bouteille). Les symptômes suivants dénotent la défec- tuosité du détendeur: Fuites - si le gaz fuit extérieurement. Ascension excessive - si la pression de débit continue à monter, le robinet du chalumeau étant fermé. Manomètre défectueux - si l'aiguille du manomètre ne s'écarte pas de la goupille de butée lors de la mise en pression, ou ne revient pas sur la goupille après l'échap- pement de la pression. Réparation. N'ESSAYEZ PAS de réparer vous-mêmes. Envoyez les détendeurs défectueux à réparer aux ateliers de réparation agréés du fabricant, où des techniques et des outils spéciaux sont utilisés par un personnel formé. 2. Bouteilles Les bouteilles doivent être manipulées avec soin pour prévenir les. fuites ou dégâts à leurs parois, robinets ou systèmes de sûreté. Évitez qu’un circuit électrique soit en contact avec les bouteilles, y compris les rails de contact, les fils électriques ou les circuits de soudage. Cela pourrait créer des arcs courts-circuits pouvant entraîner des accidents graves (Voir 1,3C.). Chaque bouteille doit porter les inscriptions ICC ou DOT. C'est un gage de sécurité pourvu que la bouteille soit bien manipulée. Identifying gas content. Use only cylinders with name of gas marked on them; do not rely on color to identify gas content. Notify supplier if unmarked. NEVER DEFACE or alter name, number, or other markings on a cylinder. it is illegal and hazardous. Empties: Keep valves closed, replace caps securely; mark MT; keep them separate from FULLS and return promptly. Prohibited use. Never use a cylinder or its contents for other than its intended use, NEVER as a support or roller. Locate or secure cylinders so they cannot be knocked over. Passageways and work areas. Keep cylinders clear of areas where they may be struck. Transporting cylinders. With a crane, use a secure support such as a platform or cradle. Do NOT lift cylinders off the ground by their valves or caps, or by chains, slings, or magnets, Do NOT expose cylinders to excessive heat, sparks, slag, and Нате, etc. that may cause rupture. Do not allow contents to exceed 130°F. Cool with water spray where such exposure exists. Protect cylinders particularly valves from bumps, falls, falling objects, and weather. Replace caps securely when moving cylinders. Stuck valve. Do NOT use a hammer or wrench to open a cylinder valve that can not be opened by hand. Notify your supplier. Mixing gases. Never try to mix any gases in a cylinder. Never refill any cylinder. Cylinder fittings should never be modified or exchang- ed. 3. Hose Prohibited use. Never use hose other than that designed for the specified gas. A general hose identification rule is: red for fuel gas, green for oxygen, and black for inert gases. Use ferrules or clamps designed for the hose (not or- dinary wire or other substitute} as a binding to connect hoses to fittings. No copper tubing splices. Use only standard brass fittings to splice hose. Avoid long runs to prevent kinks and abuse. Suspend hase off ground to keep it from being run over, stepped on, or otherwise damaged. Coil excess hose to prevent kinks and tangles. Protect hose from damage by sharp edges, and by sparks, slag, and open flame, Examine hose regularly for leaks, wear, and loose connections. Immerse pressured hose in water; bubbles indicate leaks. identification du gaz: N'utilisez que les bouteilies indi- quant la nature du gaz; ne vous fiez pas à la couleur pour reconnaître la nature du gaz. Adressez-vous 3 votre fournisseur si cela n’est pas indiqué. N'EFFACEZ ou ne modifiez JAMAIS les noms, numéros ou autres indications sur une bouteille. Cela est illégal et dangereux. Vides: Maintenez les robinets fermés, replacez bien les chapeaux; inscrivez ‘’Vides’’; séparez-les des “Pleines” et retournez-les rapidement. Emploi interdit: N'utilisez une bouteille ou son contenu que pour ce à quoi elle est destinée, mais JAMAIS comme support ou rouleau. Placez les bouteilles pour qu'elles ne tombent pas. Lors- qu'un détendeur (et un boyau) est monté sur elles, placez les ou attachez-les debout. Passages et lieux de travail. Enlevez les bouteilles d'un endroit où l'on pourrait les frapper. Transport des bouteilles. Âvec une grue, utilisez un support fiable tel qu'une plate-forme ou un cadre. NE SOULEVEZ PAS des bouteilles du sol par leur robinet ou chapeau, ou avec des chaînes, élinques ou aimants. N'EXPOSEZ PAS les bouteilles à une chaleur excessive, aux étincelles, au laitier et aux flammes, etc., pouvant causer leur rupture. Le contenant ne doit jamais dépasser 55°C. Refroidissez en pulvérisant de l’eau si nécessaire. Protégez les bouteilles et particulièrement les soupapes contre les chocs, les chutes, les chutes d'objets et la température. Remettez bien les chapeaux lorsque vous déplacez tes bouteilles. Robinet coincé. N’UTILISEZ PAS un marteau ou une clé métailique pour ouvrir un robinet de bouteille que l’on ne peut pas ouvrir à la main. Avisez votre fournisseur. Mélange de gaz. N'essayez jamais de mélanger des gaz dans une bouteille. Ne rechargez jamais une bouteille. Les éléments de la bouteille ne doivent jamais être modifiés ou remplacés. 3. Boyau Utilisation interdite. N'utilisez jamais un boyau autre que celui approprié au gaz indiqué. La règle générale d'identification est: rouge pour les gaz combustibles, vert pour l'oxygène, et noir pour les gaz inertes. Utilisez des bagues ou colliers appropriés au boyau (et non du fil ordinaire ou autre substitution) pour brancher les boyaux à l’appareillage. N'utilisez pas des raccords en cuivre. N'utilisez que des accessoires standard en laiton pour raccorder un boyau. Utilisez une petite longueur de boyau. Cela évitera les noeuds et l'usure prématurée. Suspendez le boyau au- dessus du sol pour éviter qu'il ne soit écrasé, piétiné ou endommagé. Enroulez le surplus de boyau pour éviter les noeuds et emméêlements. Evitez que le boyau ne soit endommagé par des tranchants, étincelles, laitier et flamme nue. OM-210 Page 5 Repair leaky or worn hose by cutting area out and splic- ing (1-2D3). Do NOT use tape. 4. 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 outlet away from people and sources of ignition. Wipe with a clean lintless cloth, Match regulator to cylinder. Before connecting, check that the regulator label and cylinder marking agree, and that the regulator inlet and cylinder outlet match. NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas. Tighten connections, When assembling threaded connections, clean and smooth seats where necessary. Tighten. If connection leaks, disassemble, clean, and retighten using properly fitting wrench. Adapters. Use a CGA adapter {available from your supplier) between cylinder and regulator, if one is required. Use two wrenches to tighten adapter marked RIGHT and LEFT HAND threads. Regulator outlet (or hose} connections may be iden- tified by right hand threads for oxygen and left hand threads (with grooved hex on nut or shank} for fuel gas. 5. Pressurizing Steps: Drain regulator of residual gas through suitable vent before opening cylinder (or manifold valve) by turning adjusting screw in {clockwise). Draining prevents excessive compression heat at high pressure seat by allowing seat to open on pressurization. Leave adjusting screw engaged slightly on single-stage regulators. Stand to side of regulator while opening cylinder valve. Open cylinder valve siowly so that regulator pressure in- creases slowly. When gauge is pressurized (gauge reaches regulator maximum) leave cylinder valve in following position: For oxygen, and inert gases, open fully to seal stem against possible leak. For fuel gas, open to less than one turn to permit quick emergency shutoff. Use pressure charts (available from your supplier) for safe and efficient, recommended pressure settings on regulators. Check for leaks on first pressurization and regularly there-after. Brush with soap solution (capful of Ivory Liquid* or equivalent per gallon of water). Bubbles indicate leak. Clean off soapy water after test; dried soap is combustible. E. User Responsibilities Remove leaky or defective equipment from service immediately for repair. See User Responsibility statement in equipment manual. *Trademark of Proctor & Gamble Page 6 Vérifiez régulièrement les fuites, l'usure et les rac- cordements lâches. Plongez le boyau sous pression dans de l’eau: les bulles indiqueront les fuites. Réparation. Coupez la partie percée ou usée, et rac- cordez (1-2D3). N’UTILISEZ JAMAIS de ruban adhésif. 4. Branchements corrects Avant de brancher le détendeur, nettoyez la sortie du robinet de la bouteille des impuretés qui peuvent obstruer les orifices et endommager les sièges. Sauf pour l’hydrogène, ouvrez momentanément le robinet, en éloignant la sortie des personnes et des sources inflammables. Essuyez avec un tissu propre et non graisseux. Appareillez le détendeur à la bouteille. Avant de brancher, vérifiez que la marque du détendeur et la description de la bouteille concordent, et que l’orifice d'entrée du détendeur et l'orifice de sortie de ia bouteille aillent ensemble. NE BRANCHEZ JAMAIS un détendeur conçu pour un gaz spécial (ou des gaz spéciaux) à une bouteille contenant d'autres gaz. Serrez les branchements. Lorsque vous assemblez des branchements filetés, nettoyez et polissez les sièges où c'est nécessaire. Serrez. Si les branchements perdent, démontez-les, nettoyez et resserez avec une clef adé- quate. Adaptateurs. Placez, si besoin est, un adaptateur CGA {en vente chez votre fournisseur) entre la bouteille et le détendeur. Avec deux clefs, serrez l'adaptateur fileté A DROITE et À GAUCHE. On peut reconnaître les branchements de sortie du détendeur (ou boyau)}) à l’aide du filetage à droite pour l'oxygène et à gauche (identifié par un écrou cannelé) pour les gaz combustibles. 5. Démarches de mise en pression Purgez le détendeur de résidu de gaz avant d'ouvrir la bouteille (ou le robinet de canalisation) en serrant la vis de réglage (dans le sens des aiguilles d'une montre). Cette opération permet au siège de haute pression de s'ouvrir à la mise en pression, supprimant ainsi toute surchauffe de compression. Maintenez la vis de réglage des détendeurs à simple détente légèrement engagée. Avant d'ouvrir le robinet de la bouteille, assurez-vous que les boyaux sont branchés et que les soupapes aval sont fermées. Tenez-vous latéralement au détendeur en ouvrant le robinet de la bouteille. Ouvrez-le lentement pour que la pression du détendeur monte progressivement. Lorsque le manomètre est mis sous pression (indique le max- imurmn} ie robinet de ia bouteille de gaz inerte ou d'ox- ygène devra être ouvert à fond pour assurer l'étanchéité et celui de la bouteille de gaz combustible ouvert de moins d’un tour pour pouvoir le refermer rapidement en cas d'urgence. Référez-vous aux tableaux de pression (distribués par votre fournisseur} pour un réglage recommandé de pression sûr et efficace sur les détendeurs. Vérifiez les fuites à la première mise en pression puis régulièrement, brossez avec une solution savonneuse (un bouchon d'Ivory Liquid* ou semblable par gallon d’eau). Les bulles indiquent une fuite. Enlevez l'eau savonneuse après examen: le savon sec est inflammable. *Marque de Commerce de Proctor & Gamble Е. Leaving Equipment Unattended Ciose gas supply at source and drain gas. G. Rope Staging-Support Rope staging-support should not be used for welding or cutting operation; rope may burn. 1-3. ARC WELDING - Comply with precautions in 1-1, 1-2, and this section. Arc Welding, properly done, is a safe process, but a careless operator invites trouble. The equipment carries high currents at significant voltages. The arc is very bright and hot. Sparks fly, fumes rise, ultraviolet and infrared energy radiates, weldments are hot, and compressed gases may be used. The wise operator avoids unnecessary risks and pro- tects himself and others from accidents. Precautions are described here and in standards referenced in index. A. Burn Protection Comply with precautions in 1-2, The welding arc is intense and visibly bright. its radiation can damage eyes, penetrate lightweight clothing, reflect from light-colored surfaces, and burn the skin and eyes. Skin burns resemble acute sunburn, those from gas-shielded arcs are more severe and painful. DON'T GET BURNED; COMPLY WITH PRECAU- TIONS. 1. Protective Clothing Wear long-sleeve clothing (particularly for gas-shielded arc) in addition to gloves, hat, and shoes (1-2A). Ás necessary, use additional! protective clothing such as leather jacket or sleeves, flame-proof apron, and fire- resistant leggings. Avoid outergarments of untreated cotton. Bare skin protection. Wear dark, substantial clothing. Button collar to protect chest and neck and button pockets to prevent entry of sparks. 2. Eye and Head Protection Protect eyes from exposure to arc. NEVER look at an electric arc without protection. Welding helmet or shield containing a filter plate shade no. 12 or denser must be used when welding. Place over face before striking arc. Protect filter plate with a clear cover plate. Cracked or broken helmet or shield should NOT be worn; radiation can pass through to cause burns. Cracked, broken, or loose filter plates must be replaced IMMEDIATELY. Replace clear cover plate when broken, pitted, or spattered. Е. Responsabilités de l'usager Ôtez immédiatement les parties percées ou défec- tueuses. Voir les Responsabilités de l’Usager du manuel de l'appareil. F. Appareil laissé sans surveillance Fermez l'alimentation de gaz à la source et purgez. G. Liens et supports temporaires Pour vos travaux de soudage ou de coupage, n'utilisez pas de la corde comme soutien, elle est inflammable. 1-3. SOUDAGE À L'ARC - Conformez-vous aux précautions des paragraphes 1.1 et 1.2 de cette section. Le soudage à l‘arc bien exécuté est sûr, mais Un soudeur négligent est un danger. Le poste de soudage transporte des courants élevés sous de fortes tensions. L'arc est très vif et chaud. Les étincelles volent, les vapeurs montent, l'énergie ultra-violette et infrarouge rayonnent, les soudures sont chaudes, et des gaz com- primés peuvent être utilisés. Le soudeur prudent évite les risques inutiles, se protège et protège autrui contre les accidents. Les précautions sont décrites ici et dans les normes données dans l‘Index. A. Protection contre les brûlures Conformez-vous aux précautions du paragraphe 1.2. L'arc de soudage est intense et visiblement vif. Son rayonnement peut blesser les yeux, traverser les habits légers, se réfléchir sur les surfaces claires, et brûler la peau et les yeux. Les brûlures de la peau ressemblent à un gros coup de soleil. Celles d'arcs sous gaz protecteur sont plus graves et plus douloureuses. NE VOUS BRULEZ PAS - SUIVEZ LES PRECAUTIONS. 1, Vétements de protection Portez des vétements á manches longues (surtout pour Varc en atmosphère inerte) avec gants, masque et chaussures (1.2A.}. Si nécessaire portez en plus une veste ou des manches en cuir, un tablier et des guétres ignifugés. De préférence ne portez pas de vétements en coton non traité. Protection de ia peau. Portez des vétements épais foncés. Boutonnez le col pour protéger la poitrine et le cou, et boutonnez les poches pour prévenir l'infiltration d'étincelles. 2. Protection des yeux et de la téte Évitez que vos yeux soient exposés à l'arc. NE regardez JAMAIS un arc électrique sans protection. Lorsque vous soudez, portez un écran ou masque avec verre filtrant teinté N° 12 ou plus foncé. Mettez-le sur le visage avant d'amorcer l'arc. Protégez le verre filtrant d’un couvre-verre clair. NE PORTEZ PAS un masque fendu ou brisé; le rayonnement peut s'infiltrer et causer des brûlures. Les verres filtrants fendus, brisés ou láches doivent étre remplacés IMMEDIATEMENT. Remplacez un couvre- verre brisé, piqué ou taché par des projections. OM-210 Page 7 Flash goggles with side shields MUST be worn under the helmet to give some protection to the eyes should the helmet not be lowered over the face before an arc is struck. Looking at an arc momentarily with unprotected eyes {particularly a high intensity gas-shieided arc) can cause a retinal burn that may ieave a permanent dark area in the field of vision. 3. Protection of Nearby Personnel Enclosed welding area. For production welding, a separate room or enclosed bay is best. In open areas, surround the operation with low-reflective, non- combustible screens or panels. Allow for free air circula- tion, particularly at floor level. Viewing the weld. Provide face shields for all persons who will be looking directly at the weld. Others working in area. See that alt persons are wearing flash goggies. Before starting to weld, make sure that screen flaps or bay doors are closed. B. Toxic Fume Prevention Comply with precautions in 1-2B. Generator engine exhaust must be vented to the outside air. Carbon monoxide can kill. C. Fire and Explosion Prevention Comply with precautions in 1-2C. Equipment's rated capacity. Do not overload arc welding equipment. it may overheat cables and cause a fire. Loose cable connections may overheat or flash and cause a fire. Never strike an arc on a cylinder or other pressure vessel, It creates a brittle area that can cause a violent rupture or lead to such a rupture later under rough handling. D. Compressed Gas Equipment Comply with precautions in 1-2D. E. Shock Prevention Exposed hot conductors or other bare metal in the welding circuit, or in ungrounded, electrically-HOT equipment can fatally shock a person whose body becomes a conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wet surface when welding, without suitable protection. Page B Vous devez portez des lunettes à écrans latéraux sous le masque pour protéger les yeux dans le cas où le masque ne serait pas abaissé sur le visage avant l’amorçage de l’arc. Regarder momentanément un arc sans protection (principalement un arc en atmosphère inerte à haute in- tensité) peut brûler la rétine et laisser un point sombre permanent dans le champ de vision. 3. Protection du personnel à proximité Local de soudage fermé. Pour le soudage de produc- ‘tion, il vaut mieux utiliser une salle séparée ou une baie fermée. Dans les locaux ouverts, entourez les travaux d'écrans ou panneaux peu réfléchissants et ininflam- mables. Laissez l'air circuler librement, particulièrement au niveau du sol. Donnez des masques aux personnes qui regarderont directement la soudure. Autres personnes travaillant sur les lieux. Veillez à ce que toutes les personnes portent les lunettes de protection. Avant d'attaquer la soudure, assurez-vous que les rebords d'écran ou les portes soient fermés. B. Prévention des gaz toxiques Suivez ies précautions du paragraphe 1.2B. L'échappe- ment du moteur de la génératrice doit être ventilé à l'air extérieur. L'oxyde de carbone peut tuer. C. Prévention des incendies et des explosions Suivez les précautions 1.2C. Puissance nominale de l’appareil. Ne surchargez pas le poste de soudage à l'arc. Cela peut surchauffer les câbles et causer un incendie. Les branchements lâches de câble peuvent surchauffer ou faire des étincelles et causer un incendie. N'amorcez jamais un arc sur une bouteille ou autre réci- pient sous pression. Cela créerait un point de rupture entraînant à pius ou moins longue échéance l'explosion du réservoir. D. Gaz comprimé Suivez les précautions 1.2D. E. Prévention des décharges électriques Des conducteurs chargés ou métal nu incorporés au circuit de soudage ou a un appareil chargé sans mise a la terre peuvent donner une décharge fatale a la personne dont le corps devient conducteur. NE SOUDEZ PAS DEBOUT, ASSIS, COUCHE, PENCHE sur une surface humide ni en contact avec une telle surface sans protection appropriée. To protect against shock: Keep body and clothing dry. Never work in damp area without adequate insulation against electrical shock. Stay on a dry duckboard, or rubber mat when damp- ness or sweat can not be avoided. Sweat, sea water, or moisture between body and an electrically HOT part - or grounded metal - reduces the body surface electrical resistance, enabling dangerous and possibly lethal currents to flow through the body. 1. Grounding the Equipment When arc welding equipment is grounded according to the National Electrical Code, and the work is grounded according to ANSI 249.1 “Safety In Welding And Cut- ting,” a voltage may exist between the electrode and any conducting object. Examples of conducting objects include, 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 off. When installing, connect the frames of each unit such as welding power source, control, work table, and water circulator to the building ground. Conductors must be adequate to carry ground currents safely. Equipment made electrically HOT by stray current may shock, possibly fatally. Do NOT GROUND to electrical conduit, or to a pipe carrying ANY gas or a flammable liquid such as oil or fuel. Three-phase connection. Check phase requirements of equipment before installing. If only 3-phase power is available, connect single-phase equipment to only two wires of the 3-phase line. Do NOT connect the equipment ground lead to the third (live) wire, or the equipment will become electrically HOT - a dangerous condition that can shock, possibly fatally. Before welding, check ground for continuity. Be sure conductors are touching bare metal of equipment frames at connections. If a line cord with a ground lead is provided with the equipment for connection to a switchbox, connect the ground lead to the grounded switchbox. If a three- prong plug is added for connection to a grounded mating receptacle, the ground lead must be connected to the ground prong only, If the line cord comes with a three-prong 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. 3. Connectors Fully insulated lock-type connectors should be used to join welding cable lengths. Pour vous protéger contre les décharges électriques, maintenez votre corps et vétements secs. Ne travaillez jamais dans un endroit humide sans isolation adequate contre les décharges électriques. Lorsque vous ne pouvez éviter l'humidité ou la sueur, placez-vous sur un caillebotis sec ou un tapis en caoutchouc. La sueur, l'eau de mer, ou l’humidité entre le corps et une pièce CHARGÉE, ou une pièce de métal à la masse, réduisent la résistance électrique de la surface du corps, permet- tant l'entrée de courants dangereux, voire mortels. 1, Mise à la terre de l'appareil Lorsque l'appareil de soudage à l'arc est mise à la terre suivant la norme National Electrical Code, et {a masse est mise à la terre suivant la norme ANSI Z49.1 Safety in Welding and Cutting,” une tension peut exister entre 'électrode et un objet conducteur. Certaines de ces objets sont par exemple (mais pas seulement), des bâtiments, des outils électriques, des établis, des châssis de postes de soudure, des pièces d'ouvrage, etc. Ne jamais touchez l'électrode ou des objets en métal avant d’avoir mis le poste de soudure à l'arrêt. À l'installation, branchez les châssis de chaque élément (source de courant, commande, établi et circuit d'eau) à la terre. Les conducteurs doivent pouvoir conduire les courants telluriques en toute sécurité. L'appareil chargé par les courants vagabonds peut donner une décharge risquant d’être mortelle. NE BRANCHEZ PAS VOTRE PRISE DE TERRE à une conduite électrique, ou à un tuyau de gaz ou de liquide inflammable tel que [huile ou un combustible. Connexion triphasée. Avant l'installation vérifiez la phase nécessaire à l'appareil. Si seul ie triphasé est disponible, ne branchez l'appareil monophasé qu’à deux des fils de la ligne triphasée. NE BRANCHEZ PAS le conducteur de terre de l'appareil au troisième fil (sous tension), autrement l'appareil serait chargé: condition dangereuse pouvant donner une décharge fatale. Avant le soudage, vérifiez si la prise de terre est uniforme. En branchant, assurez-vous que les conducteurs touchent le métal nu du châssis de l'appareil. Lorsqu‘un appareil doit être alimenté à partir d'un cof- fret d'alimentation, le conducteur de terre doit être relié à celui-ci. Si vous avez en plus une fiche à trois broches pour la terre, ne branchez le conducteur de terre qu'à la broche de terre. Si le cordon d'alimentation a une fiche à trois broches, reliez-le & une prise femelle tripolaire reliée à la terre. N’enievez jamais la broche de terre d'une fiche ou nutilisez jamais une fiche dont la broche de terre serait brisée. 2. Pince-électrodes Utilisez des pince-électrodes bien isolées. N'UTILISEZ PAS des pince-électrodes avec vis saillantes. 3. Connecteurs Utilisez des connecteurs a verrouillage bien isolés pour assembler de longs cábles. OM-210 Page 9 4. Cables Frequently inspect cables for wear, cracks and damage. IMMEDIATELY REPLACE those with excessively worn or damaged insulation to avoid possibly - lethal shock from bared cable. Cables with damaged areas may be taped to give resistance equivalent to original cable. Keep cable dry, free of oil and grease, and protected from hot metal and sparks. 5. Terminals And Other Exposed Parts. Terminals and other exposed parts of electrical units should have insulating covers secured before operation. 6. Electrode Wire Electrode wire becomes electrically HOT when the power switch of gas metal-arc welding equipment is ON and welding gun trigger is pressed. Keep hands and body clear of wire and other HOT parts. 7. Safety Devices Safety devices such as interlocks and circuit breakers should not be disconnected or shunted out. Before installation, inspection, or service, of equipment, shut OFF all power and remove line fuses (or lock or red-tag switches) to prevent accidental turning ON of power, Disconnect all cables from welding power source, and pull all 115 voits line-cord plugs. Do not open power circuit or change polarity while welding. If, in an emergency, it must be disconnected, guard against shock burns, or flash from switch arcing. Leaving equipment unattended. Always shut OFF and disconnect ali power to equipment. Power disconnect switch must be available near the welding power source. 1-4. STANDARDS BOOKLET INDEX - For more information, refer to the following standards or their latest revisions and comply as applicabie: 1. ANSI Standard 7249.1, SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society, 550 Le Jeune Rd, P.O. Box 351040, Miami, FL 33135. 2. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. 3. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the U.S. Govern- ment Printing Office, Washington, D.C. 20402. 4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND Page 10 4, Cábtes Vérifiez fréquemment l’usure, les fissures et | altération des câbles. REMPLACEZ IMMÉDIATEMENT ceux dont l'isolation serait trop usée ou aitérée pour prévenir les décharges mortelles provoquées par un câble dénudé. Vous pouvez enrouler les parties endommagées de ruban adhésif en épaisseur suffisante pour donner une résistance de câble neuf. Maintenez les câbles secs, dépourvus d'huile et de graisse et mettez-les à l'abri du métal chaud et des étinceiles. 5. Têtes de câbles et autres parties dénudées Avant la mise en marche, les têtes de câbles et autres parties dénudées d’un appareil électrique doivent être munies de leurs couvrefils isolants. 6. Fils-électrodes Le fil-électrode est chargé lorsque lorsque l'interrupteur d'alimentation du poste á souder au MIG est sur MAR- CHE et que l'on appuie sur la gâchette du pistolet. Évitez que les mains et le corps soient en contact avec le fil et autres éléments chargés. 7. Dispositif de sécurité Le dispositif de sécurité-verrouillage et coupe-circuit ne doit pas être débranché ou déshunté. Avant l'installation, l‘inspection ou la réparation de Гар- pareil, mettez l'alimentation sur ARRET et enlevez les fusibles généraux (ou verrouillez ies interrupteurs) pour éviter une remise en MARCHE accidentelle. Débran- chez tous les câbles de la source de courant ainsi que les prises des cordons d'alimentation en 115 volts. Lors du soudage, n’ouvrez pas le circuit d'alimentation et ne changez pas la polarité. S'il est débranché au cours d’une urgence, faites attention aux brûlures de décharge ou aux jaillissements d'étincelles. Appareil laissé sans surveillance. Mettez toujours sur ARRET et débranchez l'appareil. L'interrupteur d'arrét doit toujours se trouver a prox- imité de la source de courant. 1-4. INDEX DES NORMES - Pour plus de renseignements, référez-vous aux normes de "ACNOR ou aux normes américaines suivantes: 1. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING distribué par l'American Welding Society, 550 Le Jeune Rd, P.O. Box 351040 Miami, FL 33135 2. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING distribué par le Superintendent of Documents, U.S. Government Printing Office, Washington D.C. 20402 3. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, distribué par U.S. Government Printing Office, Washington, D.C. 20402. 10. 11. 12. 13. 14. 15. FACE PROTECTION obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018. ANSI Standard Z41.1, STANDARD FOR MEN'S SAFETY -TOE FOOTWEAR obtainable from the American National Standards institute, 1430 Broadway, New York, NY 10018 ANSI Standard 249.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PRO- CESSES obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018. | AWS Standard A6.0, WELDING AND CUT- TING CONTAINERS WHICH HAVE HELD COM- BUSTIBLES obtainable from the American Welding Society, 550 Le Jeune Rd., P.O. Box 351040, FL 33135. NFPA Standard 51, OXYGEN - FUEL GAS SYSTEMS FOR WELDING AND CUTTING obtainable from the National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210. NFPA Standard 70-1978, NATIONAL ELEC- TRICAL CODE obtainable from the National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210. NFPA Standard 518, CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210. CGA Pamphlet P-1, SAFE HANDLING OF COM- PRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association, 500 Fifth Avenue, New York, NY 10036. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103. American Welding Society Standard AWSF4.1 “Recommended Safe Practices for the Prepara- tion for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, obtainable from the American Welding Society, 550 Le Jeune Rd., P.O. Box 351040, Miami, FL 33135. ANS! Standard Z88.2 ‘Practice for Respiratory Protection” obtainable from the American Na- tional Standards Institute, 1430 Broadway, New York, NY 10018. 10. 11. 12. 13. 14. 15. ANSi Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION distribué par l'American National Standards Institute, 1430 Broadway, New York, NY 10018. ANSI] Standard Z41.1, STANDARD FOR MEN"S SAFETY - TOE FOOTWEAR distribué par l'addresse donnee en 4. ANSI Standard 749.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PRO- CESSES distribué par l’addresse donnee en 4. AWS Standard A6.0, WELDING AND CUT- TING CONTAINERS WHICH HAVE COM- BUSTIBLES distribué par l’addresse donnee en 1. NEPA Standard 51, OXYGEN - FUEL GAS SYSTEMS FOR WELDING AND CUTTING distribué par la National Fire Protection Associa- tion, 470 Atiantic Avenue, Boston, MA 02210 NFPA Standard 70-1978, NATIONAL ELEC- TRICAL CODE distribué par I'addresse donnée en 8 NFPA Standard 518, CUTTING AND WELDING PROCESSES distribué par l’addresse donnée en 8 CGA Pamphiet P-1, SAFE HANDLING OF COM- PRESSED GASES IN CYLINDERS distribué par la Compressed Gas Association, 500 Fifth Avenue, New York, NY 10036. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING distribué par la Cana- dian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY distribué par la National Welding Supply Association, 1900 Arch Street Philadelphia, PA 19103. American Weiding Societe Standard AWSF4.1 “Recommended Safe Practices for the Prepara- tion for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, distribué par I' American Welding Societe, 550 Le Jeune Rd., P.O. Box 351040, Miami, FL 33135 ANSI Standard Z88.2 ‘Practice For Respiratory Protection” distribué par l'American National Standards Institute, 1430 Broadway, New York, NY 10018. ; OM-210 Page 11 2-1. 2-4. Page 12 Input At Rated но Load Output A Welding pprox. Rated Welding Current Open- 60 Hz. Three-Phase Overall Weight Current Amperes Ranges Circuit |_ Amperes At Dimensions (Pounds) Model 60% Duty Cycle Amperes Volts | 230V | 460V | kva kw {Inches) Net | Ship 200 Amps A: 3-35 Height -47-3/8 200 Amperes @ 28 Volts B: 15-180 72 38 19 15.2 | 9.5 | Width -22-1/4 | 656 671 C: 40-300 Depth -33-1/8 A: 4-50 Height - 47-3/8 300 Amperes Somes 8: 30-285 | 72 58 | 29 [228 | 14.6| Width -22-1/4 | 717 | 732 C: 85-440 Depth - 33-1/8 A: b- 8b Height - 47-3/8 400 Amperes ones в: 30-360 | 72 78 | 39 | 31 [203] width -22.1/4 | 703 | 808 C: 110-540 Depth - 33-1/8 600 Amps A: 10-140 Height - 56-1/2 600 Amperes B: 60-460 | 70 112 | 56 | 445 |31.3| Width - 27-1/8 | 1162 | 1234 @ 40 Volts C: 200-675 Depth - 38-1/8 Figure 2-1. Specifications GENERAL This manual has been prepared especially for use in familiar- izing personnel with the design, installation, operation, maintenance, and troubleshooting of this equipment. All information presented herein should be given careful consideration to assure optimum performance of this equipment. RECEIVING-HANDLING Prior to installing this equipment, clean all packing material from around the unit and carefully inspect for any damage that may have occurred during shipment. Any claims for loss or damage that may have occurred in transit must be filed by the purchaser with the carrier. A copy of the bill of lading and freight bill will be furnished by the carrier on request if occasion to file claim arises. When requesting information concerning this equipment, it is essential that Model Description and/or Stock Number and Serial {or Style) Numbers of the equipment be supplied. DESCRIPTION This unit is a three-phase welding power source which pro- duces dc welding current. It is designed to be used as the welding power source for the Shielded Metal-Arc (Stick Elec- trode) Welding process. SAFETY Before the equipment is put into operation, the safety section at the front of this manual should be read completely. This will help avoid possible injury due to misuse or improper welding applications. The following definitions apply to CAUTION, IMPORTANT, and NOTE blocks found throughout this manual: Under this heading, installation, operating, and maintenance procedures or practices will be found that if not carefully followed may create a hazard to per- | sonnel. i IMPORTANT Under this heading, installation, operating, and maintenance procedures or practices will be found that if not carefully followed may result in damage to equip- i ment. I NOTE Under this heading, explanatory statements will be found that need special emphasis to obtain the most i efficient operation of the equipment. 3-1. LOCATION (Figure 3-1) A proper installation site should be selected for the welding power source if the unit is to provide dependable service, and remain relatively maintenance free. A proper installation site permits freedom of air movement into and out of the welding power source, and also least subjects the unit to dust, dirt, moisture, and corrosive vapors. A minimum of 18 inches of unrestricted space must be maintained between the welding power source front and rear panels and the nearest obstruction. Also, the underside of the welding power source must be kept completely free of obstructions. The installation site should also permit easy removal of the welding power source outer enclosure for maintenance functions. IMPORTANT Do not place any filtering device over the intake air passages of the welding power source as this would restrict the volume of intake air and thereby subject the welding power source internal components to an overheating condition and subsequent failure. War- 1 ranty is void if any type of filtering device is used. I Holes are provided in the welding power source base for mounting purposes. Figure 3-1 gives overall dimensions and the base mounting hole layout. On most welding power sources a lifting device is provided for moving the unit. However, if a fork lift vehicle is used for lifting the unit, be sure that the lift forks are long enough to extend completely under the base. IMPORTANT The use of lift forks too short to extend out of the opposite side of the base will expose internal components to damage should the tips of the lift forks penetrate the bottom of the unit. 4 HOLE. | 5/8 A , Em Cc Dai AA pas D —7 EL TB-900 525-1 Model A B C D E F G 2.3.8 |47-3/8 |33-1/8 |30-1/8 | 22-1/4 120 |1-1/2 |1-1/8 400 Amp 600 Amp | 56-1/2 | 38-1/8 |35-1/8 | 27-178 | 24-7/81|1-1/2 |1-1/8 Figure 3-1. Dimensional Drawing & Base Mounting Hole yout SECTION 3 - INSTALLATION 3-2. A. ELECTRICAL INPUT CONNECTIONS It is recommended that a line disconnect switch be installed in the input circuit to the welding power source, This would provide a safe and convenient means to completely remove all electrical power from the welding power source whenever it is necessary to i perform any internal function on the unit, | EC Before making electrical input connections to the welding power source, ‘machinery lockout procedures’ should be employed. If the connection is to be made from a fine disconnect switch, the switch should be padlocked in the open position. If the connection is made from a fuse box, remove the fuses from the box and padlock the cover in the closed position. If locking facilities are not available, attach a red tag to the line disconnect switch {or fuse box} to warn others 1 that the circuit is being worked on. I 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 welding power source nameplate. Con- sult the local electric utility if there is any question about the type of electrical system available at the installation site or how proper connections to the welding power source are to be made. Input Conductor Connections Do not connect the input conductors to the three- phase power supply until ail electrical input connec- I tions have been made to the we!ding power source. I The input conductors should be covered with an insulating material which conforms to local electrical standards. Table 3-1 is provided only as a guide for selecting the proper size input conductors and fuses. Table 3-1. Input Conductor and Fuse Size Model input Conductor Size - AWG Fuse Size In Amperes 208V 230v 450% 575V 208V | 230V | 460V | 575V 200 Amp Мо. 8 Мо. 8 Мо. 12 Мо. 12 60 60 30 30 {No.8} | (No.8) | (No. 14) | (No. 14} 300 Amp 400 Amp 600 Amp No, E No. 6 No. 10 Ma. 10 {No. 8) | (Мо. 8) | (No. 12} | (No. 121 No. 4 No. 4 No. 8 No, В 1 125 60 35 No. 8) | (No. 8) | No. 10) | (No. 8) | 195 No. 1/0 Мо. 2 No. 6 No. 8 (No. 6} | (No. 8) | (No. 8) (No. 8} 100 | 100 | 50 ; 40 200 175 90 70 Numbers in fl are ground conductor sizes. Insert the three input conductors plus one ground conductor through the access hole on the rear panel. This hole will accept standard conduit fittings. See Figure 3-2 for hole location and size. It is recommended that a terminal lug of adequate amperage capacity be attached to the ends of the input and ground conductors. The hole diameter in the terminal lug must be of proper size to accommodate | the line and ground terminal studs. I OM-210 Page 13 Connect the three input conductors to the terminals on the primary terminal board tine and connect the ground conductor to the ground terminal. {Refer to the input voltage label for identification of these terminals. See Figure 3-2 for location of this label.) The remaining end of the ground conductor should be connected to a proper ground. Use whatever grounding method that is acceptacle to the local electrical inspection authority. SIV E \ A ——.Ó—]]][2 The ground terminal is connected to the welding power source chassis and is for grounding purposes only. Do not connect a conductor from the ground terminal to any one of the line terminals as this will result in an electrically energized welding power i source chassis. I LN es С. Input input Voltage Voltage Label Jumper Links 1-3/4" Access 7 Hole U / round Line Terminals Figure 3-2. Input Conductor Connections Matching The Welding Power Source To The Avail- able Input Voltage The input voltage jumper links provided on the primary terminal board permit the welding power source to be operated from various line voltages. The various voltages from which this welding power source may be operated are stated on the welding power source nameplate and on the input voltage label. See Figure 3-2 for location of this label. The input voltage jumper links on this welding power source are positioned for the highest of the voltages stated on the nameplate. If the welding power source is to be operated from a line voltage which is tower than the highest voltage for which the unit was designed, the jumper links wiil have to be moved to the proper positions before operation of the welding power source commences. Figure 3-3 shows the various positions for which the jumper links may be set on the standard welding power source. If the input voitages on the welding power source nameplate differ from those shown in Figure 3-3, the input voltage jumper links must be positioned as shawn on the input voitage label. 230 VOLTS MAGS Me MAGA O GR. OL: ©» OL 460 VOLTS o (do ADE oldido O GR. OL, Ou» OLa 077 130 Figure 3-3. Input Voltage Jumper Link Arrangement Page 14 TA-900 872-2A If only one jumper link is required on each of the grouped terminals, it is recommended that the unused jumper links be placed across the terminals which are to be used. This will prevent losing the jumper links 1 which are not required for this connection. i 3-3. SECONDARY WELDING CONNECTIONS It is recommended that the welding cables be kept as short as possible, placed close together, and be of adequate current carrying capacity. The resistance of the welding cabies and connections cause a voltage drop which is added to the voltage of the arc. Excessive cable resistance may result in over- loading as well as reducing the maximum current output of which the welding power source is capable. The proper operation of any arc welding power source is to a great extent dependent on the use of welding cables and connections that are in good condition and of adequate size. An insulated electrode holder must be used to ensure the operator's safety. Table 3-2. Secondary Weld Cable Size WELDINGL TOTAL LENGTH OF CABLE { COPPER) IN WELD CIRCUIT AMPERES| *50 | 100 | 150 | 200 | 250 | 300 | 350 | 400 100 4 4 4 3 2 1 1/0 1/0 150 3 3 2 1 1/0 2/0 3/0 3/0 200 2 2 1 1/0 2/0 3/0 4/0 4/0 250 1 1 1/0 2/0 3/0 4/0 4/0 2-2/0 300 1/0 2/0 3/0 4/0 4/0 2-2/0 | 2-3/0 350 1/0 1/0 3/0 4/0 4/0 2-2/0 | 2-3/0 | 2-3/0 400 12/70 2/0 3/0 4/0 2-2/0 | 2-3/0 | 3-2/0 § 24/0 500 |3/0 3/0 4/0 2-2/0 | 2-3/0 | 2-3/0 | 2-4/0 | 3-3/0 600 |4/C 4/0 2-2/0 | 2-3/0 1 3-2/0 | 2-4/0 1 3-3/0 | 34/0 ADO? 624 NOTE: "A. 50 FEET OR LESS. *B. CABLE SIZE IS BASED ON DIRECT CURRENT (DC), 60% DUTY CYCLE AND EITHER A 4 VOLTS OR LESS DROP OR A CURRENT DENSITY OF NOT OVER 300 CIRCULAR MILS PER AMP, *C. WELD CABLE INSULATION WITH A VOLTAGE RATING TO WITHSTAND THE OPEN-CIRCUIT VOLY- AGE (OCV} OF THE WELDING POWER SOURCE MUST BE USED. WHILE MOST WELDING POWER SOURCES HAVE AN OPEN-CIRCUIT VOLTAGE OF LESS THAN 100 VOLTS, SOME WELDING POWER SOURCES OF SPECIAL DESIGN MAY HAVE HIGHER OPEN-CIRCUIT VOLTAGE. Use Table 3-2 as a guide for selecting the correct welding cable size for the anticipated maximum weld current that will be used. Table 3-2 takes into account the total cable length for the weld circuit. This means the length of the Electrode cable that connects the Electrode Holder to the welding power source and the Work or ground cable between the welding power source and the work piece. For example: H the Electrode cable is 75 feet long and the Work or ground cable is 25 feet long, select the size cable from Table 3-2 that is recommended for 100 feet. In a situation where a maximum weld current of 150 amperes is anticipated, No. 3 weld cable is recommended for both the Electrode and Work cables. To ensure that the weld current output will be in accordance with the labeling of the positions on the POLARITY SWITCH, connect the electrode holder cable to the ELEC- TRODE terminal and the work cable to the WORK terminal. Due to the fact that the 600 ampere model is not equipped with a Polarity Switch, the selection of weld current polarity is determined by the connecting of the secondary cables with respect to the secondary terminals. If straight polarity is desired, connect the work cable to the POSITIVE terminal and the electrode holder cable to the NEGATIVE terminal. For reverse polarity connect the work cable to the NEGATIVE terminal and the electrode holder cable to the POSITIVE terminal. REMOTE AMPERAGE CONTROL CONNECTIONS The REMOTE AMPERAGE CONTROL Receptacle, located on the front panel of the welding power source, provides a junction point for connecting a Remote Amperage Control to the amperage control circuitry in the welding power source. To connect the Remote Amperage Control to the REMOTE AMPERAGE CONTROL Receptacle, insert the three-pole plug from the Remote Amperage Control into the receptacle -———— SECTION 4. FUNCTION REMOTE AMPERAGE AMPERAGE ADJUSTMENT 4-3. CONTROL RECEPTACLE CONTROL Tel > A0 / CIRCUIT BREAKER STANDARD REMOTE AMPERAGE - CONTROL SWITCH POWER* RANGE SWITCH *POLARITY SWITCH ra ELECTRODE J 7 TERMINAL (POSITIVE ON. 600 AMPERE > WORK MODEL) TERMINAL (NEGATIVE ON 600 AMPERE MODEL) +200, 300, & 400 AMP MODELS ONLY Figure 4-1. Control Panel View 4-4, TA-900 525-2A 4-1. POWER SWITCH (200, 300, 8: 400 Ampere Models Only (Figure 4-1) Placing the POWER Switch in the ON position will energize the welding power source fan and control circuitry and place the welding power source in a ready-to-weld status. Placing the POWER Switch in the OF F position will shut the welding power source down. Placing the POWER switch in the OFF position does not remove power from all of the welding power source internal circuitry. Completely terminate all electrical power to the welding power source by employing “machinery lockout procedures” before attempting any inspection or work on the inside of the unit, If the welding power source is connected to a disconnect switch, padlock the switch in an open position. If connected to a fuse box, remove the fuses and padlock the cover in the closed position, If the unit is connected to a circuit breaker, or other disconnecting device without locking facilities, attach a red tag to the device to warn others that the circuit I is being worked on. I 4-2. RANGE SWITCH (Figure 41) - a The Range Switch provides the capability of being able to select from three coarse amperage ranges. The amperage range of each switch position is displayed on the welding power source nameplate. The range which is labeled A is the low amperage range, B the medium range, and C the high range. If the amperage desired should fall in the overlapping area of two ranges, it is recommended that the lower of the two ranges be used, as better fine amperage adjustment will be obtained in the lower of the two ranges. 4-5. IMPORTANT. Do not change the position of the Range switch while welding or under load, as this causes arcing across the contacts of the switch. This arcing causes the contacts I to become pitted and eventually inoperative. I aan ml « a Late eee rie and rotate the plug as far as it will turn in a clockwise direction. Once fully rotated, the plug will be locked in the receptacle and will not pull out under stress. OF CONTROLS AMPERAGE ADJUSTMENT CONTROL (Figure 4-1} The AMPERAGE ADJUSTMENT Control, located on the upper center portion of the front panel, provides a means of obtaining the exact amperage desired within the range selected by the Range Switch. Rotating the control in a clockwise direction will increase the amperage output. The contacts of the AMPERAGE ADJUSTMENT Con- trol are of the continuous contact type, thereby making it possible to adjust the amperage output while i welding. i The three amperage range scales which surround the AMPERAGE ADJUSTMENT Control are labeled A, B, & C. Each of these lettered scales corresponds to one of the three Range Switch positions which are similarly marked. This is done so that the operator will know which scale to read from for the range being used, REMOTE AMPERAGE CONTROL RECEPTACLE & SWITCH (Figure 4-1} If a Remote Amperage Control is to be used, make connections from the Remote Amperage Contral to the REMOTE AMPERAGE CONTROL Receptacle as instructed in item 3-4. When remote control of the amperage is desired, it is essential that the REMOTE AMPERAGE CONTROL Switch be placed in the REMOTE position, Likewise, if a Remote Amperage Control is not to be utilized, the switch must be in the STANDARD position. When in the STANDARD position, only the AMPERAGE ADJUSTMENT Control on the front panel will control the amperage. When a Remote Amperage Control is being used, it should be noted that the Remote Amperage Contol is funetioning as a - fine amperage adjustment of the AMPERAGE ADJUST- MENT Control setting on the welding power source. For example: If the AMPERAGE ADJUSTMENT Control on the welding power source is set at the mid-range position, the Remote Amperage Control will provide (from its min. to max. positions) fine amperage adjustment of one half of the welding power source output for the current range selected by means of the Range Switch. If full adjustment through use of the Remote Amperage Cantrol of the current range selec ted is desired, the AMPERAGE ADJUSTMENT Control on the welding power source must be set at the maximum position. POLARITY SWITCH (200, 300, & 400 Ampere Models Only) (Figure 4-1) The POLARITY SWITCH provides a means of selecting either dc straight or de reverse polarity without having to change the secondary cable connections. Placing the POLARITY SWITCH fully to the left will provide STRAIGHT polarity; fully to the right will provide RE- VERSE polarity. Do not change the position of the POLARITY SWITCH while welding or under load, as this causes arcing across the contacts of the switch. This arcing causes the contacts to become pitted and eventually inoperative. 1 OM-210 Page 15 4-6. DUTY CYCLE (Figure 4-2) 4-7. Page 16 minimum curves shown. RATED OUTPUT= 1000 900 | 800 | na | 700 Ps 5 “09 | > 600 Ca PONS 2 500 > | + e TN | TN a fog | = So < 400 = zo | DD a m} = 300 Np N z Dn 250 ча i “ 2 | Nop | Mp 200 DD | > 150 > 30 35 40 50 60 70 80 90100 % DUTY CYCLE DB-900 525-1 Figure 4-2. Duty Cycle Chart The duty cycle of a welding power source is the percentage of a ten minute period that a welding power source can safely be operated at a given output. This welding power source is rated at 60 percent duty cycle. This means that the welding power source can be safely operated at rated load for six minutes out of every ten. During the remaining four minutes, the unit should idle to permit proper cooling. If the welding amperes are decreased, the duty cycle will increase. Figure 4-7 enables the operator to determine the safe output of the welding power source at various duty cycles. IMPORTANT Exceeding the indicated duty cycle will cause the welding power source to overheat and thereby cause 1 damage to the welding power source. | VOLT-AMPERE CURVE (Figure 4-3) The volt-ampere curve shows the output voltage available at any given output current within the limits of the minimum and maximum AMPERAGE ADJUSTMENT Control setting for each of the three ranges that can be selected through use of the Range Switch. Load voltage is predetermined to a large degree by arc characteristics. With the use of the volt-ampere curve, it is possible to determine the amperage required for a specific load voltage. With reference to the volt-ampere curve {Figure 4-3), the curve shows the maximum and minimum settings of the AMPERAGE ADJUSTMENT Control only. Curves of other settings will fall between the maximum and DC VOLTS o Co ъ Ln o 0 o o o DC VOLTS + in о © 2 о 80 70 60 250 wl © > 40 a 30 20 10 200 Ampere Model 50 100 150 200 250 300 350 400 450 500 DC AMPERES B-002 526 300 Ampere Model 100 1200 300 400 500 600 700 800 DC AMPERES B-002 528 400 Ampere Model E ] 1 100 200 300 400 500 600 700 800 900 1000 B-002 531 600 Ampere Model 200 400 600 800 1900 1200 1400 DC AMPERES B-002 962 Figure 4-3. Volt-Ampere Curves — SECTION 5 - SEQUENCE OF OPERATION 5-1. Never, under any circumstances, operate the welding power source with any portion of the outer enclosure removed. In addition to being a hazard, improper cooling may result in damage to the welding transformer and the welding power source components. Warranty is void if the welding power source is operated with any portion of the outer enclosure | removed. SHIELDED METAL-ARC (STICK ELECTRODE) WELDING (Figure 5-1) 1. Make electrical input connections as outlined in Section 3-2. 2. Make secondary welding connections as outlined in Section 3-3. 3. Select the proper electrode for the welding application and insert it into the etectrode holder. 4. it a Remote Amperage Control is used, connect the plug from the Remote Amperage Control into the REMOTE AMPERAGE CONTROL Receptacle. Place the STANDARD-REMOTE Switch in the REMOTE position. 5. Place the Range Switch in the desired position. 6. Place the POLARITY Switch in the desired position. “CAUTION \ Ь ;]——;—;oe;o—L— Prior to welding, it is imperative that proper protective clothing (welding coat and gloves) and eye protection {glasses and/or welding helmet) be put on. Failure to comply may result in serious or permanent bodily | damage. | 5-2. ла | TB-900 525-1 Figure 5-1. Shielded Metal-Arc Welding Connections 7. Rotate the AMPERAGE ADJUSTMENT Control for the approximate desired welding current. 8. Place the POWER Switch in the ON position. 9, Commence welding. 10. Readjust the AMPERAGE ADJUSTMENT Control if necessary. SHUTTING DOWN 1. Break the arc. 2. Allow the welding power source to idle for 3 minutes with no load applied. 3. Place the POWER Switch in the OFF position. 6-1. 6-2. A CAUTION : | o; —;];.;;]] odo Be sure the branch circuit or main disconnect switch is open or electrical input circuit fuses are rernoved before attempting any inspection or work on the inside of the welding power source. Placing the POWER Switch on the welding power source in the OFF position does not remove voltage from the power terminals inside of the welding power source. The 600 ampere models are not equipped with a power switch, and voltage is present in all circuitry when the welding power source is connected to primary input power. FAN MOTOR All models are equipped with an exhaust fan and rely on forced draft for adequate cooling. The fan motor is manufactured with lifetime lubricated sealed ball bearings and no attention should be required. TRANSFORMER Occasional blowing out of the dust and dirt from around the transformer is recommended. This should be done periodically depending upon the location of the unit and the amount of dust and dirt in the atmosphere. The welding power source outer enclosure should be removed and a clean dry air stream should be used for this cleaning operation. 6-3. 6-4. RECTIFIER It is recommended that the rectifier be cleaned occasionally by blowing it out with compressed air. This cleaning operation is necessary so that maximum cooling will be accom- plished by the air stream, This should be done periodically, depending upon the location of the unit and the amount of dust and dirt in the atmosphere. It will be necessary to remove the outer enclosure for this cleaning operation. CONTROL CIRCUIT PROTECTION The CONTROL OVERLOAD breaker (on 200, 300 € 400 ampere models) or the contra circuit fuse {on 600 ampere models) provides overload protection to control circuit components. Should the circuit breaker trip or fuse open, weld output would go to the minimum of the range selected. The circuit breaker must be manually reset to the ON position. OM-210 Page 17 —: SECTION 7 - TROUBLESHOOTING It is assumed that proper installation has been made, according to Section 3 of this manual, and that the welding power source has been functioning properly until this trouble Hazardous voltages are present on the internal cir- developed. cuitry of the welding power source as long as power is a connected to the unit. Disconnect power before Use this chart in conjunction with the circuit diagram while attempting any inspection or work on the inside of the performing troubleshooting procedures. If the trouble is not unit. Troubleshooting of internal circuitry should be remedied after performing these procedures, the nearest performed by qualified personnel only. Factory Authorized Service Station should be contacted. In L—];];— od all cases of equipment malfunction, the manufacturer's The following chart is designed to diagnose and provide recommendations should be strictly followed. remedies for some of the troubles that may develop in this welding power source. TROUBLE PROBABLE CAUSE REMEDY No output ar weiding current. Open line fuse. Replace fuse. POWER switch (St) defective (200, 300, and 400 ampere | Replace switch {51}. models only). Erratic weld current. Loose welding connections. Secure connections. Bad or damp electrodes. Use new dry electrodes. Fan does not run, POWER switch (S1) defective (200, 300, and 400 ampere Replace switch {81}. models only). Fan motor (FM) defective. Replace fan motor (FM). Line fuse open. Replace fuse. Welding current low. Amperage Low line voltage. Use correct voltage, Adjustment Control does not control current. Use of welding cable which is too long or too small for | Use proper size cable, welding current employed. Loose connections to workpiece or welding cable | Secure connections. connections, CONTROL OVERLOAD breaker {CB1} ar fuse (F1) open. *Replace fuse {F1). REMOTE AMPERAGE CONTROL switch {82) inthe remote | Either place REMOTE position with no remote amperage control connected to the | AMPERAGE CONTROL switch REMOTE AMPERAGE CONTROL receptacle (RCt1}. (82) in the STANDARD position or connect a remote amperage control to the REMOTE AMPERAGE CONTROL receptacle (RC1). *If it becomes necessary to replace any fuse in the welding power source, ensure that a fuse of the proper size is used. T E с PT | 35-GR. I GR. -GROUND | I B -BRASS 5 LOC GR. C -COPPER I | „” Te POA eee | 37-8 REY JE-C REMOTE CONTROL RECEPTACLE LOPTIONAL—EXTRA> FRONT VIEW ELECTRODE WORK “METERS OPTIONAL EXTRA) \ TOF INSIDE VIEW RANGE SWITCH Circuit Diagram No. A-085 134 Figure 7-1. Circuit Diagram For 200 Ampere Model Page 18 Fe === | 35-GR. 1 GR. ~GROUND | 5 | B -BRASS LO=0 | | C -COPPER | ” > Lolo tir Lou | 37-B RC1 36-C REMOTE CONTROL RECEPTACLE , LOPTIONAL-EXTRA? FRONT VIEW L O=-0 51 . . . TE 4 rT Z o— GRD. 27 Cama | 28 29 22 | ELECTRODE WORK | : 1% I ' de * METERS 19 (OPTIONAL-EXTRA) 23 TOP INSIDE VIEW e Lui ы Ч Dl CS. 1 La SR: 35] hal ww Da RANGE SWITCH Circuit Diagram No. A-085 150 Figure 7-2. Circuit Diagram For 300 & 400 Ampere Models i T4 с | | | GR. -GROUND L | B -BRASS 35-GR. | L нс. REMOTE CONTROL > ~ COPTIONAL- EXTRA? 77-B ACI 35-C RECEPTACLE FRONT VIEW METERS COPTIONAL-EXTRA) À Y POSITIVE NEGATIVE 29 TOP INSIDE VIEW RANGE SWITCH EA Circuit Diagram No. CA-900 633-1C1 Figure 7-3, Circuit Diagram For 600 Ampere Model OM-210 Page 19 February 1983 FORM: OM-210 Effective With Serial No. JC622608 MODEL SR-200 SR-300 SR-400 SR-600 ся bed AA К hn er a de ROSY OM-210 Page 1 TD-800 579-C Figure À - Main Assembly Quantity Model Нет Dia. Part 200 | 300 | 400 | 600 No. _ Mkgs. No. Description Amp | Amp | Amp | Amp Figure À Main Assembly | 1 014 607 PANEL, side .................oe_rececervrrverarenen. 2 2 2 1 014 637 PANEL, side ..........._ee.ecoorerreroneererenrereen.. 2 2 Figure B PANEL, front-w/components(Pg3).................. 1 1 1 1 3 SRI 086 135 RECTIFIER, silicon diode (FigCPg®6) .................. 1 1 3 SR1 086 133 RECTIFIER, silicon diode (FigCPg8) .................. 1 SR1 086 132 RECTIFIER, silicondiode (FigCPg6) .................. 1 4 014 604 COVER .....................0 sm. aaacadoroecere co 1 1 1 4 014 636 COVER ...........esvmeccerveareeeoocenreneenvame. 1 5 014 630 BAFFLE, air..............eo.eeecs0uaarevadarearenva. 1 1 1 5 017 003 BAFFLE, air. ..........oececernoererrerarianane neon. 1 6 SR2 035 914 RECTIFIER, integrated 30 amp 400 volts ............... 1 1 1 VR2 082 722 VARISTOR, 0.6 watt 175 volts de ............—..__ ee ec. 1 1 1 7 010 493 BUSHING, snapb/8ID7/8hole ...................... 1 1 1 8 015 548 BAFFLE, aif...........eecaccrecarerareorare derri . 1 1 1 8 017 006 BAFFLE, air. .............e ee. renacaanvevranacarene o 1 9 TE] 038 145 TERMINAL, primary {РА Е Рад 9) ...................... 1 1 1 9 TEI 038 699 TERMINAL, primary {FIgEPg9) ..............c....... 1 10 Figure F PANEL, rear -w/components (Pg9)................... 1 1 1 1 11 MA1,T1 **032 035 AMPLIFIER & TRANSFORMER (FigDPg8)............ 1 11 MA1,T1 **032 036 AMPLIFIER & TRANSFORMER (FigDPg8)............ 1 11 MA1,T1 **032 037 AMPLIFIER & TRANSFORMER (FigD Pg8) ............ 1 11 MA1,T1 **036 327 AMPLIFIER & TRANSFORMER (FigD Pg8)............ 1 12 016 873 BAFFLE, air. ........c ii e... rasaueodrvaaerooraa 1 1 1 028 578 BAFFLE, air-front.............c.cc cin. 1 028 577 BAFFLE, air - left hand ................e.0e00.0eacónos 1 028 579 BAFFLE, air - rear............—.o ceceecsrrecareraneno 0 1 028 580 BAFFLE, air-righthand ............ ccc. viii. 1 13 016 876 BASE ...... iii i i ic ree 1 1 1 13 017 007 BASE RR KR RR RG 1 14 2 023 193 STABILIZER ..........e.ecomvvrurrarereeernerenveam. 1 14 Z 023 194 STABILIZER ..........eee0eercxrnarvareraoaroeeorerve. 1. 14 Z 023 195 STABILIZER ..................e.r0s0necenereare nen 1 14 Z 023 196 STABILIZER ...........—..o_e.eeseoceoaraaereeonao. 1 010 876 HANGER, MinerallicNo. 1 ................ iia... 1 1 010 926 HANGER, MinerallicNo.2 .......... ccc. 1 1 Parts For Optional Equipment A 025 603 METER, amp de 0-300 12211120 aa ea aa ea a 0e 00 1 A 025 608 METER, amp de 0-500 ................—reservrrenereos 1 A 025 611 METER, ampdc0-600 ..........—...._.—.emeecrevocrooao 1 A 025 610 METER, amp de 0-800 ............e.ee0rereverree e... 1 \ 025 604 METER, voltdc 0-100 ........ eerie 1 1 1 1 103 965 WRAPPER, meter box...........ee_—ee_ereeeorcoorer 1 1 1 1 103 966 PANEL, front-meterbox ............ civ... 1 1 1 1 103 967 PANEL, rear - meter box .........eoo.-eeeexvvesecremo. 1 1 1 1 **Replace at Factory or Factory Authorized Service Station. BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-210 Page 2 Model Item Dia. Part | 200 & 300 | 400 | 600 No. Mkgs. No. Description Amp Amp | Amp Figure B Panel, Front - W/Components (Fig A Pg 2 Item 2) 1 014 215 DOOR, access - lower front... KL ae 7 1 1 027 944 DOOR, access-lowerfront. ............ cco... 1 2 019 602 KNOB, pointer .........o_weowrereeocaroracerearec0rrrar. 1 1 1 3 NAMEPLATE (order by model Et serial number). ............. 1 1 1 4 Fi *012 601 FUSE, plug 10 amp ..........e.eenresrerooreeneem ee 1 4 CB1 079 530 CIRCUIT BREAKER, magnetic SPST 10 amp 125 volts dc .... 1 1 5 080 463 PLATE, switchon-offcontroloverload .................... 1 1 6 1020 299 PANEL, front ..........w_ee.ercoreverorarerciacenr ran A 1 1 1 6 1014 633 PAÑNEL, front .............oeer.eccrococereraaerevec 0D 1 047 497 LABEL, generalprecautionary .............. ccc... 1 1 1 012 602 HOLDER, fuse - plug ..........e-ce...ereserrorrrerecene,. 1 7 RE 039 607 RECEPTACLE, twistlock 3P3W 20 amp 250 volts ............ 1 1 1 8 52 011 609 SWITCH, toggle SPDT 10amp12bvolts................... 1 1 1 SR2 037 601 RECTIFIER, controf ..........e_.e.eéeocccorenmereenrarenDen. 1 9 016 907 SWITCH & RHEOSTAT (FigB1Pg4)...................... 1 9 016 908 SWITCH E RHEOSTAT(FigB1Pgd)............. count. 1 9 016 909 SWITCH & RHEOSTAT (FigB1Pg4)...................... 1 10 581 *011 789 SWITCH, toggle 3PST 60 amp .............eérreccrvrcoro. 1 1 11 S3 011 619 SWITCH, polarity (Fig B3 Pg 6) .............essrecererares 1 1 12 021 932 STRIP, insulation - polarityswitch . . ....................... 1 1 13 039 047 TERMINAL, power output{FigB2Pgb}.................... 2 2 13 038 612 TERMINAL, poweroutput(FigB2Pgb}.................... 1 TC-016826-D Figure B - Panel, Front- W/Components *Recommended Spare Parts. tWhen ordering a component originally displaying a precautionary label, the label should also be ordered. BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. Page 3 Quantity Model Item Dia. Part 200 & 300 | 400 | 600 No. Mkgs. No. Description Amp Amp | Amp © 5 © Figure B1 Switch & Rheostat {Fig B Pg 3 Item 9) © > 8 o > > 1 $10 011 762 SWITCH, range (consisting of) ............._e._rií.eeeees... 1 1 $10 011 956 SWITCH, range (consistingof} ........................... 1 1 S10 011 957 SWITCH, range (consistingof} .............. ccc... 1 2 011 642 . BRACKET, mtg - switch {consistingof) ................... 1 1 1 3 010 671 .. SPRING... i iii i ti te cette cere 1 1 1 4 019 610 HANDLE |... ii i ee eee cate eee 0 1 1 1 5 011 643 .BRACKET, switch - rear ..........—eecreorrereneversavaee 1 1 1 6 011 621 .PLATE ASSEMBLY (consisting of) .............._..reseco. 1 6 011 691 . PLATE ASSEMBLY (consistingof) ....................... 1 6 011 692 . PLATE ASSEMBLY (consistingof) ....................... 1 7 100 623 .. СШЮЕ, го!ог............ ei ee ieee ieee 3 3 3 8 100 622 ..SHIM, rotor .................eecesxdocerroneaeoarem.. 3 3 3 9 011 968 ..PLATE..........erecsrerearanmareaaonacareraraneaceno 1 2 2 10 011 980 ..ROTOR ................a00snvreracerereeeeerrerecveroo 1 2 2 11 011 644 ..CONTACT, stationary ...........—..ooeereecnverdoccvreo 9 9 11 011 098 .. CONTACT ASSEMBLY, stationary (consisting of) ......... 9 011 644 ...CONTACT, stationary . .........._eevecoroerrrorenmec A. 2 010 135 ... SPACER, copper.024thick .............. coin. 1 010 134 ... SPACER, copper1/16thick .......................... 1 010 133 ...SPACER, copper1/8thick............. coo cool. 1 12 011 645 .. CONTACT ASSEMBLY, movable (consistingof) .......... 3 3 13 011075 ...SPRING, pressure ............_eeeoroeceresrearracamo 1 1 14 011 953 ... CONTACT, movable cia iat. 2 2 15 011 074 ...SPRING, pressure ............—.eeeeecereaareaaran e 1 1 12 011 906 ... CONTACT ASSEMBLY, movable (consisting Of)......... 3 13 011 076 ...SPRING, pressure ........_..-.reseeanoerroaoere recon. 1 14 011 953 ... СОМТАСТ, тоуаЫе - соррег ....................5..... 2 011 967 ...CONTACT, movable - bronze .................c....... 2 010 135 ... SPACER, copper.024 thick ............ cc. ivan, 1 010 134 ... SPACER, copper1/16thick ............... cv... 1 010 133 ...SPACER, copper1/8thick.............. iii... 1 15 011074 ... SPRING, pressure 2ER н квн во,, 1 16 030 654 SHAFT, current CONTrO| | ieee aa 1 1 1 17 602 355 PIN, cotter 3/32 x 1/2 ...............eece00enmrsraerevar ere. 1 1 1 18 Ri *030 041 RHEOSTAT, WW 15 ohm 150 watt ............eeeoeereoo 1 1 1 Includes Le ltems 586 .-— TC-016 908 *Recommended Spare Parts. BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. | | OM-210 Page 4 112 Figure B1 - Switch & Rheostat Item No. Figure B2 al al al NOOO BUN = Part No, 601 879 039 044 601 880 039 045 039 049 601 976 601 840 601 839 038 900 038 847 038 613 602 247 602 217 Description Terminal, Power Output (Fig B Pg 3 Item 13) МОТ, Пех {0 1/2-13 ............ BUSBAR ..................... NUT, hexjam 1/2-13 ....... SE TERMINAL BOARD, black ....... TERMINAL BOARD, red. ........ "= § ®m ®m KON NR a EU = = SR чай "= = = = = = wv wv w d & EB F¥ и и # 4 ни чин и р = ®E EE & ни = = § = 4 =m =m = mE ни ни ники нина ни Ps чан нива а и тт т 4 4 4 4 4 в о # 4 FF N A&A 4 ля в = = EE ¥ 3 NE =: = чт акки нии нии ня ши нии ни = хх кин ини Ч на ЖЖ SCREW, cap - hex hd 1/2-13 x 1-1/2 1111110140 iia. NUT, brass - hexjam 1/2-13 ..... NUT, brass - hex full 1/2-13 ...... STUD, brass 1/2-13x2-1/4 ..... BUS BAR, terminal power output . TERMINAL BOARD, power output WASHER, flat- SAE1/2 ........ WASHER, lock - external tooth 1/2 TB-005 763-B = = = = = §g O & m =m = = = W E EUA 4 = & = =m F т т нон PF F # 4 FF & & 4 Ts Fp EN A&A Fg = FF § = 2 = § 3 "= = = == = =m #& =m =m =m #% нивы ¥ = mw F нон & ® F FF OF mx F FF wv =» + + + + 4 4 ¥ вв вн ив ни А дин дни ни & 3g NF ® Figure B2 - Terminal, Power Output Model 200, 300 & 400 Amp = = =o] 039047 BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. Page 5 600 Amp 038 612 NN =a NN A ТА-038 612-А tem Part : No. No. Description Quantity Figure B3 011619 Switch, Polarity (Fig B Pg 3 Item 11) 1 011 948 GUIDE, contact ..........e_——erceccoraorrirenerereatdanaanerenae0nanaóe 2 2 024 694 BEARING ............ i ie eet ie tea 1 3 103634 MOUNTING BOARD . «ooo et 4 a aa a a ee a a a da ee a uen aan» 1 4 016 911 BRACKET, mtg-switch ............... fe eee eee 2 5 103 633 BAR, bus. ............eoecerdcrenaraa ttt eee eee ae ea 2 6 019 603 KNOB, ball .......... ee a a da ea 8 A Mae RR A Re eee 0 ea a ae a ae ue e 00 1 7 010 805 HANDLE..............esereeriarararaanaracarevrenaraververrcecorervorera. 1 8 038 769 PLATE, movable with components (consisting Of) ...............e-ee.reervervo 1 9 103 632 PLATE. ott i ie tt tte ete cette ee tee RR 1 10 011 645 . CONTACT ASSEMBLY, movable (consistingof) ............... cc... ..... 2 11 011 953 ..CONTACT, switch ...........e.c_eerees0anvsnvadedurervacoreare co 0 e. 2 12 011 074 ..SPRING, pressure .........—.ec_errecarearrnrenarenereramenenearareri e 1 13 011075 ..SPRING, pressure ........._._.c_—eec_orerrecrirenownrrecanerereraneavan Zen 1 1 1 er < — “— | < ТР e © © q EE > | Includes | item 13 12 11 jp \ NN { 1 9, 8% A Sn 7 | pt b я > TB-011 619-A qs € | \ Figure B3 - Switch, Polarity o | | \ o 3 4 3 2 TB-031 140-4 Figure C - Rectifier, Silicon Diode Quantity Model Item Dia. Part 200, 300 | 400 | 600 No. Mkgs. No. Description Amp Amp | Amp À À = Figure C Rectifier, Silicon Diode (Fig À Pg 2 Item 3) © © © 8 = © 1 VS1,R2 044 482 SUPPRESSOR ..... iii ieee tinea aan 1 1 1 2 D1-6 037 305 DIODE, 150 amp 300 volts SP ....0.0.00000000 0e aa 1e 1 a ann 0 6 2 D1-6 037 956 DIODE, 275 amp 300 volts SP ...............esereeevrreme. 6 6 3 031 688 CAPACITOR, ceramic 0.01 uf 500 volts dc w/3/16 terminals. . . 3 3 3 4 031 689 CAPACITOR, ceramic 0.01 uf 500 volts dc w/3/16 & 1/4 terminals © titi ei see eet teeta ear morra 3 3 3 BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. | OM-210 Page 6 a 2 | E 2 . e ADT a NN y y et [ oh o р 7 Re TTD ve o Mo 4 а Y \ y No 7 J | 1 q A Бо Es E E moo E = р: Ц Wa N ry le я Ly { = JJ > A 17 \ X ri Я y Z7 TC-036 321-A Figure D - Amplifier & Transformer Page 7 Model 300 | 400 Amp | Amp 600 Amp Part 200 No. Dia. Mkgs. [tem No. Description Figure D Amplifier & Transformer {Fig A Pg 2 Item 11) 032 035 032 036 032 037 | 036 327 CWD,CF CWD,CF CWD,CF CWD,CF **033 769 **033 652 **033 654 **033 787 COIL, control dc COIL, control dc COIL, control dc ........22200 000 0e ane ee a na ea eu 0 00 COIL, control dc NE #4 ¥ ® ¥ m A ss ss ss ss ss ss ss ss X +! — incl FD FD FD FD PRI PRI РА! PRI PRI PRI PRI PRI SEC SEC SEC SEC **031 937 **031 936 **033 bbb **025 067 **033 766 **033 773 COIL, control ac COIL, control ac COIL, control ac COIL, control ac COIL, priw/30 voltswinding. ........................ 1 COIL, pri w/30 volts winding............-.ce—m_._.—2em.. 1 **033 779 COIL, priw/30voltswinding......................... 1 **033 784 COIL, priw/30voltswinding......................... 1 **033 767 COIL, pri... coo i es i re . 2 **033 774 COIL, oT rene. 2 **033 780 COIL, pri. ...............00ssme0rr0caresvrvereneee.. 2 **033 785 COIL, pri. . ........eee.essdracrrrraracinrecnererIe¡AZ». 2 **033 768 COIL, sec ......... ...e0enervarivraaar recaer. 3 **033 775 COIL, sec ............e-esxveooreracanererenvenren. 3 **033 781 COIL, sec .........e..e_e0enrrererearaceracerea A. | 3 **033 786 COIL, SEC 2000ER KK RR eae 3 **027 029 AMPLIFIER & TRANSFORMER SUBASSEMBLY (con- siting Of) oii i ia 1 AMPLIFIER & TRANSFORMER SUBASSEMBLY (consisting of) AMPLIFIER & TRANSFORMER SUBASSEMBLY (consisting of) AMPLIFIER & TRANSFORMER SUBASSEMBLY (consisting of)... ea | 1 . STRIP, 1/16 x 33/64 x 3-3/4 ..........e.errevicen. 6 | . STRIP, 1/16 x2-15/32 x4-1/8 . STRIP, 1/16 x 2-15/32 x4-1/2 . STRIP, .015 x2-1/2X4.........—.—.—e—ereeorvaverome. 3 3 . STRIP, .015 x2-1/2x4-1/2 ........—e—eeeorecrreovo. . WEDGE, 1/8 x 1 x 4-1/2 , WEDGE, 3/8 x 1/2 X 5-1 /Z 0er 11000 6 6 . STRIP, 1/16 x 3-1/2 x 4-1/2 ‚ 5ТА!Р, 1/16 х 3-15 732 х 4-3/8 ..................... 4 . STRIP, 1/16 x 3-15/32 x 4-7/8 . STRIP, 1/16 x 3-15/32 x 5-3/8 . STRIP, 1/16 x3-15/32 x 8-5/8 . STRIP, 3/16 x 5/8 x 4-15/32 . STRIP, 1/4 x5/8 x4-11/16 . STRIP, 1/2 x 5/8 x 4-15/32 WEDGE, 1/8x1/2x4-11/16.......... co. ci. 6 . BOLT, machine-hexhd 1/4-20x5-1/2 .............. 2 , BOLT, machine-hexhd1/4-20x6 .................. . BOLT, machine - hex hd 1/4-20 x 6-1/2 LSTUD, 1/4-20 x10. oe eee 2 , BRACKET, mtg-terminalboard. .................... 2 2 2 . BRACKET, mtg-terminalboard..................... 2 .BAR, clamping-core . ....... iii ia 2 2 2 2 . TUBING, No. 3 {order by ft) ift 2ft 2 ft **028 377 о о ол А 5 5 00 (0 00 6) № № № № — aaa **028 378 EE EU EN ¥# ® mE mE mE mE 2 ®m 4 mw #& # #% EF a KK Kr KF **028 379 < 7 026 315 7 024 984 7 024 203 8 026 926 8 9 © : = = # = E HE ния ня = Us = §g § = & =m =m d k 028 386 023 066 026 293 026 736 11 - 026 316 11 ‚ 024 205 11 024 206 11 027 931 010 404 13 010 403 010 402 15 027 146 16 601 797 601 798 601 799 16 028 389 17 103 922 17 016 914 18 016 879 19 605 540 a со 5 ww Lo OD O Nas A =m =m & 4d mw нии нии ня + ru = = = à ния вина к тн вия DÉ da o N CO ©) © © © ©) (D CO) N **Replace at Factory or Factory Authorized Service Station. BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-210 Page 8 Quantity Model Нет Dia. 200, 300 @| 600 No. Mkgs. Description 400 Amp | Amp = Figure E Terminal, Primary (Fig A Pg 2 item 9) > co 8 = 1 GO1 835 NUT, brass - hex 10-32 1.122200 2 LL ALL a a ae ae a a a ee a a a a aa 24 1 601 836 NUT, brass-hexjam 1/4-20 .... iii tiie cians 36 026 754 INSULATION ti i 4 4 ea da 1 A 4e ee ee de a La da a a ra a ne .. 12 2 038 058 TERMINAL BOARD ......1112 4012 4 aa aa ee a a ae a da a a aa a a ae a aa uen 1 2 038 669 TERMINAL BOARD .....22020002 202 aa a ea a aa ae a a aa a a a aa ae a ea 1 3 038 887 STUD, brass 10-32 x 1-3/8 w/hex collar ......1222112 401 a na ea aa nan 12 3 038 890 STUD, brass 1/4-20 x2-1/8.................es0ere2er0srecve da vD.. 12 4 010 913 WASHER, flat - brass 3/16 ID x 1/2 0D ........... v2.2... aa ane 12 4 010 915 WASHER, flat - brass 1/4 1D x5/8 OD ..................m0 0er. 12 010 910 WASHER, flat - SAE 3/8............—..0íre;rvecacereerarenecer ace, 3 602 213 WASHER, lock - split 3/8 ...............0.00s0ercrresereoreore cena 3 5 038 618 LINK, jumper.........__.eo_eeeovedecoyenmareraoenrearrerereecareanea 6 5 038 652 LINK, jumper...........__eeeecesaodedarenireaaereaaareaenareneon 6 038 134 LINK, jumper 1/8 x 3/4 x 3-3/4 111111111012 4 4 4 a a ea rre: ese. 1 038 135 LINK, jumper 1/8 x3/4 x4-1/4 i ieee 1 6 601 836 NUT, brass-hex-jam 1/4-20 ...... ci iia, 6 6 601 838 NUT, brass-hex jam 3/8-16........ iii iii ities 12 7 010 915 WASHER, flat-brass1/41Dx5/80D .............................. 6 6 8 038 888 STUD, brass 1/4-20x1-1/2w/hexcollar ........................... 3 8 038 804 STUD, brass 3/8-16 xX 2-1/2... iii ie ee evens 3 1 и a TC-016 824-A TA-038 145-A Figure F - Panel, Rear - W/Components , . . Quantity Figure E - Terminal Assembly, Primary — | Model item Dia. Part 200, 300 &! 600 No. Mkgs. No. Description 400 Amp | Amp Figure F Panel, Rear - W/Components (Fig A Pg 2 Item 10) 1 FM 032603 MOTOR, fan 230 volts (consisting of) ..............eí_eenvrvreneve. 1 024 601 .BEARING........—..re.eeredrareceerrarernaeeavonveorrerarene. 2 1 FM 032605 MOTOR, SP 1/4 hp230 voltsac............_.eeseenesroecareon 2. 1 2 014 601 WINDTUNNEL, 14 inch............o_e.eeerenveorerarer een ea 0 1 2 014 602 WINDTUNNEL, 18 inch.........reeereraooracoarecmecaver exe. 1 3 032 604 BLADE, fan 60 hz 14 inch 3 wing 19 deg or 3 032 611 BLADE, fan50hz14inch3wing23deg.......................... 1 3 032 606 BLADE, fan 60 hz 18 inch 3 wing 22 deg or 3 032 613 BLADE, fan50hz18inch3wing26deg.......................... 1 4 014 605 PANEL, rear... cove eter ae KAM 1 4 014 638 PAÑNEL, rear ........._eeereveorvrrrorreearanenranereaoreraneno 1 Page 9 BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.

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