Miller | KB076607 | Owner Manual | Miller SYNCROWAVE 500 User manual

Miller SYNCROWAVE 500 User manual
November 1991
FORM: OM-350S
Effective With Serial No. KB076607
MODEL:
SYNCROWAVE® 500 (Basic)
SYCNROWAVE® 500 W/Pulser
OWNER’S MANUAL
IMPORTANT: Read and understand the entire contents of this manual, with
special emphasis on the safety material throughout the manual, before
installing, operating, or maintaining this equipment. This unit and these
instructions are for use only by persons trained and experienced in the safe
operation of welding equipment. Do not allow untrained persons to install,
operate, or maintain this unit. Contact your distributor if you do not fully
understand these instructions.
SB-127 872
MILLER ELECTRIC Mfg. Co.
A Miller Group Ltd., Company
P.O. Box 1079
Appleton, WI 54912 USA
Tel. 414-734-9821
PRINTED IN U.S.A
OM-350S - 11/91
RECEIVING-HANDLING
Before unpacking equipment, check carton for any
damage that may have occurred during shipment. File
any claims for loss or damage with the delivering carrier. Assistance for filing or settling claims may be obtained from the distributor and/or the equipment manufacturer’s Transportation Department.
When requesting information about this equipment, always provide the Model Designation and Serial or Style
Number.
Use the following spaces to record the Model Designation and Serial or Style Number of your unit. The information is located on the rating label or nameplate.
Model
Serial or Style No.
Date of Purchase
TABLE OF CONTENTS
Section No.
Page No.
SECTION 1 − SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1.
1-2.
1-3.
1-4.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standards Booklet Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
4
5
SECTION 2 − SAFETY PRECAUTIONS AND SIGNAL WORDS
2-1.
2-2.
General Information And Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Alert Symbol And Signal Words . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
SECTION 3 − SPECIFICATIONS
3-1.
3-2.
3-3.
Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
8
SECTION 4 − INSTALLATION OR RELOCATION
4-1.
4-2.
4-3.
4-4.
Site Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transporting Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Front Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
9
11
SECTION 5 − OPERATOR CONTROLS
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
5-7.
5-8.
5-9.
5-10.
5-11.
5-12.
5-13.
5-14.
5-15.
Power Switch And Pilot Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Amperage Adjustment Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Amperage Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Polarity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC/DC Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output (Contactor) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Frequency Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Postflow Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crater Fill Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Balance Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulser (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preflow Time (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spot Time (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
13
13
13
14
14
15
15
15
16
16
16
16
17
18
Section No.
Page No.
SECTION 6 − SEQUENCE OF OPERATION
6-1.
6-2.
6-3.
6-4.
6-5.
Gas Tungsten Arc Welding (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Tungsten Arc Welding - Pulsed Arc (GTAW-P) . . . . . . . . . . . . . . .
Gas Tungsten Arc Spot Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shielded Metal Arc Welding (SMAW) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutting Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
19
19
20
20
SECTION 7 − MAINTENANCE & TROUBLESHOOTING
7-1.
7-2.
7-3.
7-4.
7-5.
7-6.
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115 Volts Control Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tungsten Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
21
21
23
23
23
SECTION 8 − ELECTRICAL DIAGRAMS
Diagram 8-1. Circuit Diagram For Welding Power Source . . . . . . . . . . . . . . . .
Diagram 8-2. Wiring Diagram For Welding Power Source . . . . . . . . . . . . . . . .
26
28
SECTION 9 − CERTIFICATION FOR HIGH FREQUENCY ARC WELDING EQUIPMENT
9-1.
9-2.
9-3.
9-4.
9-5.
9-6.
9-7.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-Frequency Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guidelines For Installation Of High-Frequency Assisted Arc
Welding Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Guidelines Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
30
31
31
31
33
33
SECTION 10 − PARTS LIST
Figure 10-1. Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-2. Panel, Rear w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-3. Terminal Assembly, Pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-4. Reactor & Transformer, Power Main . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-5. HF Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-6. Panel, Front (Lower Section) w/Components . . . . . . . . . . . . . . .
Figure 10-7. Panel, Front (Upper Section) w/Components . . . . . . . . . . . . . . .
Figure 10-8. Switch, Range/Polarity/Selector . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-9. Contact Board Assembly, Switch Selector AC/DC . . . . . . . . . . .
Figure 10-10. Contact Board Assembly, Switch Selector AC/DC . . . . . . . . . .
Figure 10-11. Contact Board Assembly, Switch Polarity . . . . . . . . . . . . . . . . . .
Figure 10-12. Spot Timer And Preflow Timer . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-13. Pulser Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-14. Rectifier, SCR Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
35
35
36
37
38
40
42
43
44
45
46
47
48
LIST OF CHARTS AND TABLES
Table 3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart 3-1. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart 3-2. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 4-1. Weld Cable Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 4-2. Input Conductor And Fuse Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart 5-1. Pulsed Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 7-1. Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 7-2. Tungsten Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 7-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
7
7
10
12
17
21
22
24
SECTION 3 − SPECIFICATIONS
Table 3-1. Specifications
Model
Without PFC*
Amperes Input At
Rated Load Output**
60 Hz Single-Phase
NEMA
Max.
Class I (60) Welding OpenRated Output Ranges Circuit
At 60%
Amperes Voltage
Duty Cycle
500 Amperes
At 40 Volts
25-625
200V
230V
235
204
102
81.5
47
206
180
90
72
41.4
80
With PFC*
*Power Factor Correction.
**Using ac current at balance SMAW process.
460V 575V kVA kW
A
B
Weight
26
Net
Ship
887 lbs. 902 lbs.
(402 kg) (409 kg)
Inches Millimeters
C
I
E
A
2-3/4
70
B
44-1/4
1124
C
9/16
14
D
31-1/4
794
E
25-1/2
648
F
2-13/16
71
G
22-3/4
578
H
19
483
I
1-7/8
48
H
G
D
F
SB-127 872
Figure 3-1. Dimensional Drawing
Chart 3-1. Volt-Ampere Curves
Chart 3-2. Duty Cycle
SB-059 427-A
SB-059 128-A
OM-350 Page 7
3-1.
VOLT-AMPERE CURVES (Chart 3-1)
RATED OUTPUT
The volt-ampere curves show the voltage and amperage output capabilities of the welding power source.
Voltage and amperage adjustment is provided by the
AMPERAGE ADJUSTMENT control. Curves of other
settings fall between the curves shown.
3-2.
DUTY CYCLE (Chart 3-2)
The duty cycle is the percentage of a ten minute period
that a welding power source can be operated at a given
output without overheating and damaging the unit. This
welding power source is rated at 60% duty cycle when
operated at 500 amperes. The unit can be operated at
500 amperes for six consecutive minutes, but it must operate at no load for the remaining four minutes to allow
proper cooling. If the welding amperes decrease, the
duty cycle increases.
Refer to the Duty Cycle Chart (Chart 3-2) to determine
the output of the welding power source at various duty
cycles.
CAUTION: EXCEEDING THE DUTY CYCLE
RATINGS will damage the welding power
source.
• Do not exceed indicated duty cycles.
3-3.
DESCRIPTION
This unit produces constant current ac/dc weld output
for the Gas Tungsten Arc (GTAW) or Shielded Metal Arc
Welding (SMAW) process. This unit requires singlephase input power of the voltage specified on the nameplate.
The Syncrowave welding power source produces
square wave ac weld output. The 500 in the product designation refers to rated weld output (see Table 3-1 for
specifications).
Optional equipment can include a preflow timer, spot
timer, water valve, and pulser.
SECTION 4 − INSTALLATION OR RELOCATION
IMPORTANT: Read entire Section 9 on equipment that
produces output in the radio frequency range, such as
high-frequency arc starters, for site selection information and installation requirements before beginning the
installation procedure.
4-1.
CAUTION: RESTRICTED AIRFLOW can
cause overheating and possible damage to
internal parts.
• Maintain at least 18 inches (457 mm) of unrestricted space on all sides of unit, and keep
underside free of obstructions.
• Do not place any filtering device over the intake air passages that provide airflow for
cooling this unit.
Warranty is void if any type of filtering device is
used at intake air passages.
SITE SELECTION
Select an installation site which provides the following:
1.
Correct input power supply (see unit nameplate)
2.
Shielding gas supply (if applicable)
3.
Water supply (if applicable)
4.
Adequate ventilation and fresh air supply
5.
No flammables
6.
A clean and dry area
7.
Proper temperature that avoids extremes of heat
or cold
8.
Proper airflow around unit
9.
Adequate space for removing top cover and
outer panels for installation, maintenance, and
repair functions.
Base mounting holes provide the capability to install and
secure the unit on a running gear or in a permanent location. Figure 3-1 gives overall dimensions and base
mounting hole layout. A permanent installation site for
securing the unit should allow sufficient space on all
sides and above the unit to open access door(s), or remove top cover and outer enclosure panels for maintenance and repair functions.
OM-350 Page 8
4-2.
TRANSPORTING METHODS
This welding power source is equipped with a lifting eye
for moving the unit during installation. Weight capacity
of the lifting eye only allows for supporting the welding
power source.
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Disconnect input power conductors from
deenergized supply line BEFORE moving
welding power source.
FALLING EQUIPMENT can cause serious
personal injury and equipment damage.
• Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other heavy accessories or devices.
•
Use equipment of adequate capacity to lift
the unit.
• If lifting or moving this unit with lift forks under
the base, be sure that lift forks are long
enough to extend beyond opposite side of the
base.
Using lift forks too short can damage internal
parts if tips of the lift forks penetrate the unit
base, or may cause personal injury and/or
equipment damage if unit falls off the lift forks.
4-3.
LOWER FRONT PANEL CONNECTIONS
(Figure 4-2)
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
•
Turn off welding power source before making
connections.
To gain access to the 115 VOLTS AC receptacle and circuit breaker, REMOTE CONTACTOR AND CURRENT
CONTROL receptacle, GAS connections, optional
COOLANT connections, weld output terminals, high
frequency spark gaps, and HIGH FREQUENCY INTENSITY control, it is necessary to open and secure the
lower front access door.
insert plug into receptacle, and rotate threaded collar
fully clockwise.
The command signals required and output signals available at receptacle RC2 by means of the welding power
source circuitry are as follows:
Socket A:
24VAC available to remote contactor control when contact closure is provided between Sockets A and B.
Socket B:
24VAC available to remote contactor control when contact closure is provided between Sockets A and B.
Socket C:
Remote amperage control potentiometer
clockwise (CW).
Socket D:
PC1 circuit common.
Socket E:
Remote amperage control potentiometer
wiper.
IMPORTANT: When contact closure is provided between sockets A and B, the welding power source
24VAC contactor control circuit is energized.
A
A. REMOTE CONTACTOR AND CURRENT CONTROL Receptacle Information And Connections (Figures 4-1 and 4-2)
The 14-socket REMOTE CONTACTOR AND CURRENT CONTROL receptacle RC2 provides a connection point between an optional remote control and the
welding power source contactor and amperage control
circuitry. To connect the remote control, align keyway,
C
D
J
K
B
L
I
N
H
M
E
G
F
Ref. S004-A
Figure 4-1. Front View Of 14-Socket
Receptacle
Remote Contactor
And Current Control
Receptacle
115 Volts AC
Receptacles
Work Output
Terminal
Gas Valve Inlet
High Frequency
Spark Gaps
(See Section 7-4)
Gas Valve Outlet
♦
♦
Electrode Output
Terminal
Coolant Valve Outlet
Coolant Valve Inlet
115 Volts Control
Circuit Breaker
(See Section 7-2)
♦Optional Assessories
Access
Openings
High Frequency
Intensity Control
(See Section 5-8)
SC-144 405
Figure 4-2. Lower Front Panel
OM-350 Page 9
B. GAS Connections (Figure 4-2)
The GAS VALVE INLET and GAS VALVE OUTLET fittings have 5/8-18 right-hand threads. Obtain proper
size, type, and length hose, and make connections as
follows:
1.
Connect hose from shielding gas supply regulator/flowmeter to GAS VALVE INLET fitting.
2.
Connect shielding gas hose from torch to GAS
VALVE OUTLET fitting.
C. COOLANT Connections (Optional) (Figure 4-2)
CAUTION: OVERHEATING Gas Tungsten
Arc Welding (GTAW) torch can damage
torch.
• If using a water-cooled torch and recirculating
coolant system, make connections directly
from the coolant system to the torch hoses.
Do not use coolant connections on the welding power source.
The COOLANT VALVE INLET and COOLANT VALVE
OUTLET fittings have 5/8-18 left-hand threads. Obtain
proper size, type, and length hose, and make connections as follows:
1.
Connect hose from coolant supply to COOLANT
VALVE INLET fitting.
2.
Connect coolant hose from torch to COOLANT
VALVE OUTLET fitting.
To obtain full rated output from this unit, it is necessary to
select, prepare, and install proper weld cables. Failure
to comply in any of these areas may result in unsatisfactory welding performance.
1. Weld Cable Selection
Use the following guidelines to select weld cables:
a. Use the shortest possible cables, and place cables close together. Excessive cable lengths
may reduce output or cause unit overload due
to added resistance. Excessive cable length
also increases high frequency radiation (see
Section 9).
b. Use weld cable with an insulation voltage rating
equal to or greater than the maximum opencircuit voltage (ocv) of the welding power
source (see Table 3-1 for unit maximum ocv rating).
c.
D. 115 VOLTS AC Duplex Receptacle (Figure 4-2)
The duplex receptacle provides up to 15 amperes of 115
volts ac for operating accessory equipment. The unit
must be energized before output is available at this receptacle.
E. WELD OUTPUT CONNECTIONS (Figure 4-2)
RATED OUTPUT
Select welding cable size according to maximum weld output and total length of connecting
cables in weld circuit. For example, if a 25 foot
(7.5 m) electrode holder (torch) cable is used
with a 25 foot (7.5 m) work cable, select the cable size recommended in Table 4-1 for 100 feet
(30 m) or less. The maximum recommended
cable length when using high frequency is 50 ft.
(15 m).
d. Do not use damaged or frayed cables.
2. Weld Cable Preparation
a. Install correct size lugs of adequate amperage
capacity onto ends of both cables for connecting to work clamp, electrode holder if applicable, and weld output terminals.
Table 4-1. Weld Cable Size
Total Cable (Copper) Length In Weld Circuit Not Exceeding*
100 ft. (30 m) Or Less
Welding
Amperes
10 To 60% 60 Thru 100%
Duty Cycle
Duty Cycle
150 ft.
(45 m)
200 ft.
(60 m)
250 ft.
(70 m)
300 ft.
(90 m)
350 ft.
(105 m)
400 ft.
(120 m)
10 Thru 100% Duty Cycle
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
3
2
1
1/0
2/0
3/0
4/0
4/0
250
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
350
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
400
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
500
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-3/0
600
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of more than 300 circular mils per
ampere.
S-0007-A/7-91
OM-350 Page 10
b. If applicable, install electrode holder onto weld
cable following manufacturer’s instructions. An
insulated electrode holder must be used to ensure operator safety.
c.
Install work clamp onto cable.
3. Weld Cable Connections
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down welding power source, and disconnect input power employing lockout/tagging procedures before inspecting or installing.
Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnecting device.
a. For Gas Tungsten Arc Welding (GTAW)
1.
2.
Connect torch cable or connector to ELECTRODE weld output terminal. Be sure that
the torch connector does not touch the access door when closed.
A. Electrical Input Requirements
Operate the welding power source from a single-phase,
60 Hertz, ac power supply. The input voltage must
match one of the electrical input voltages shown on the
input data label on the unit nameplate. Contact the local
electric utility for information about the type of electrical
service available, how proper connections should be
made, and inspection required.
B. Jumper Link Installation (Figures 4-3 and 4-4)
WARNING: Read precautionary information at beginning of entire Section 4-4 before proceeding with this installation.
Jumper links are used to allow the equipment to operate
from different line voltages. The jumper links may be in a
bag attached to the input terminal board or installed on
the input terminal board for the highest voltage shown
on input voltage label.
1.
Remove right side panel.
2.
Compare position of jumper links on the input terminal board to the voltage link arrangement
shown on input voltage label.
CAUTION: INCORRECT INPUT VOLTAGE
JUMPER LINK PLACEMENT can damage
unit.
• Position jumper links as shown on the input
voltage label (see Figures 4-3 and 4-4).
• Store unused jumper links across linked terminals.
Connect work cable to WORK weld output
terminal.
IMPORTANT: Weld polarity is determined by the position of the Polarity switch (See Section 5-4).
b. For Shielded Metal Arc Welding (SMAW)
1.
Connect end of electrode holder cable to
ELECTRODE weld output terminal.
2.
Connect work cable to WORK weld output
terminal.
IMPORTANT: Weld polarity is determined by the position of the Polarity switch (See Section 5-4).
4-4.
IMPORTANT: If the input voltages stated on nameplate
or rating label are different from those in Figure 4-3,
check the input voltage label in the unit or call Factory
Service Department.
3.
Install jumper links onto the input terminal board
to match the available input line voltage.
ELECTRICAL INPUT CONNECTIONS
INPUT
IMPORTANT: Read and comply with entire Section 9
regarding high-frequency equipment location and installation requirements before making electrical input
connections.
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down welding power source, and disconnect input power employing lockout/tagging procedures before inspecting or installing.
Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnecting device.
S-048 604-A
S-081 896-A
Figure 4-3. Input Voltage Labels
OM-350 Page 11
Input Terminal
Board
Ground
Conductor
Line Disconnect
Switch
Input Voltage
Jumper Links
Line
Terminals
1-3/4 in (44.5 mm)
Access Hole
Ground Terminal
Input Voltage Label
SB-127 873
Figure 4-4. Location Of Electrical Input Connections And Components
C. Welding Power Source Input Power Connections (Figure 4-4)
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Install a fusible line disconnect switch in the
input circuit to the welding power source.
• Connect input conductors to the welding
power source before connecting to the singlephase input power.
• Read and follow safety information at beginning of entire Section 4-4.
The line disconnect switch provides a safe and
convenient means to completely remove all
electrical power from the welding power source
whenever it is necessary to inspect or service
the unit.
1.
2.
Use Table 4-2 as a guide to select input conductors for the installation. The input conductors
should be covered with an insulating material that
complies with national, state, and local electrical
codes.
Install terminal lugs of adequate amperage capacity and correct stud size onto the input and
ground conductors.
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Do not connect an input conductor to the
ground terminal in the unit.
• Do not connect the ground conductor to an input line terminal.
Incorrect input connections can result in an electrically energized welding power source chassis. The ground terminal is connected to the
welding power source chassis and is for grounding purposes only.
OM-350 Page 12
Table 4-2. Input Conductor And Fuse Size*
Model
Without
PFC**
With
PFC**
Input
Voltage
Input
Conductor
Size
(AWG)
Ground
Conductor
Size
(AWG)
Fuse
Size In
Amperes
200
250MCM
2
350
230
3/0
4
300
460
3
8
175
575
4
8
125
200
3/0
4
300
230
2/0
4
300
460
3
8
150
575
6
8
110
*Conductor size is based on the 1990 Edition of the National Electrical Code (NEC) specifications for allowable
ampacities of insulated copper conductors, having a temperature rating of 167°F (75°C), with not more than three
single current-carrying conductors in a raceway (Article 310
of NEC). (The ground conductor is not counted as a currentcarrying conductor.)
*Fuse size is based on not more than 200 percent of the
rated input amperage of the welding power source (Article
630 of NEC).
**Power Factor Correction.
3.
S-0092/9-90
Obtain and install a standard conduit strain relief
connector into the rear panel access hole.
4.
Insert conductors through strain relief installed in
Step 3. Route conductors to the input terminal
board.
5.
Connect input conductors to line terminals on the
input terminal board (see Figure 4-4).
6.
Connect the ground conductor to the ground terminal (see Figure 4-4).
7.
Connect remaining end of ground conductor to a
suitable ground. Use a grounding method that
complies with all applicable electrical codes.
8.
Connect remaining ends of input conductors to a
deenergized line disconnect switch.
9.
Secure the input cable in the strain relief.
10.
Reinstall right side panel.
11.
Use Table 4-2 as a guide to select line fuses for
the disconnect switch. Obtain and install proper
fuses.
SECTION 5 − OPERATOR CONTROLS
5-1.
POWER SWITCH AND PILOT LIGHT (Figure
5-1)
POWER
V
ON
OFF
Placing the POWER switch in the ON position energizes
the welding power source. The pilot light and fan motor
come on indicating that the unit is receiving input power.
Placing the POWER switch in the OFF position shuts
down the welding power source and fan, and turns off
the pilot light.
5-2.
AMPERAGE ADJUSTMENT CONTROL (Figure 5-1)
AMPERAGE ADJUSTMENT
A
The AMPERAGE ADJUSTMENT control allows the operator to select the desired amperage for the welding
process. The AMPERAGE ADJUSTMENT control adjusts the output within a range of 25 to 625 amperes.
The scale surrounding the control is an actual current
value.
IMPORTANT: The AMPERAGE ADJUSTMENT control may be adjusted while welding.
5-3.
If remote current control is desired, make connections to
the REMOTE CONTACTOR AND CURRENT CONTROL receptacle as instructed in Section 4-3A. Place
the AMPERAGE CONTROL switch in the REMOTE 14
position.
When a remote amperage control is used, the control
functions as a fine adjustment for the AMPERAGE ADJUSTMENT control setting on the welding power
source. For example, if the AMPERAGE ADJUSTMENT control on the welding power source is set at midrange, the remote amperage control provides (from its
minimum to maximum positions) fine amperage adjustment of one half the welding power source output. If full
adjustment of the amperage is desired, the AMPERAGE ADJUSTMENT control on the welding power
source must be set at the maximum position.
If remote amperage control is not desired, place the AMPERAGE CONTROL switch in the PANEL position.
With this switch in the PANEL position, the front panel
AMPERAGE ADJUSTMENT control has complete control of the output.
5-4.
POLARITY SWITCH (Figure 5-1)
ELECTRODE
NEGATIVE
DO NOT SWITCH
UNDER LOAD
( )
ELECTRODE
POSITIVE
(+)
AMPERAGE CONTROL SWITCH (Figure 5-1)
AMPERAGE CONTROL
A
PANEL
REMOTE 14
The Polarity switch allows the operator to select either
dc-ELECTRODE POSITIVE or dc-ELECTRODE NEGATIVE polarity without having to change the output cable connections. To ensure that weld output matches
the dc polarity positions, make weld output connections
as instructed in Section 4-3.
The Polarity switch has no effect on the welding operations when the AC/DC switch is in the AC position.
OM-350 Page 13
CAUTION: ARCING can damage switch
contacts.
• Do not change the position of the Polarity
switch while welding or under load.
The AC/DC switch allows the operator to select AC or
DC output without changing weld output cable connections.
CAUTION: ARCING can damage switch
contacts.
• Do not change the position of the AC/DC
switch while welding or under load.
Arcing causes the contacts to become pitted
and eventually inoperative.
Arcing causes the contacts to become pitted
and eventually inoperative.
5-5.
AC/DC SWITCH (Figure 5-1)
AC
5-6.
START AMPERAGE (Figure 5-1)
A. Start Amperage Switch
DC
WARNING: ELECTRIC SHOCK can kill.
• Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.
• Use AC output ONLY if required for the welding process.
• If AC output is required, use remote output
control.
• Read and follow Safety Rules at beginning of
this manual.
Placing the START AMPERAGE switch in the ON position activates the start circuitry. When this switch is in
the OFF position, weld output goes to the setting of the
AMPERAGE ADJUSTMENT control for arc starting.
The START AMPERAGE circuitry permits the operator
to select an amperage setting for arc starting that is
above or below the setting of the AMPERAGE ADJUSTMENT control. The starting amperage is available
for the first second of the weld. After this time, the weld
amperage steps up or down to the setting of the AMPERAGE ADJUSTMENT control.
♦ Spot Time
Switch
Voltmeter
AC And DC
Amperage
Adjustment
Control
Ammeter
AC And DC
Start Amperage
Amperage Switch
Control
Switch
Power
Switch
♦ Preflow
Control
♦ Preflow
Output
Contactor
Switch
Switch
♦ ♦Pulser
Switch
Crater Fill
Switch
Pilot
Light
High
Frequency
Switch
♦
Spot Time
Control
♦
% On Time
Control
♦ ♦ Pulses Per
Second Control
♦♦
AC Balance
Control
AC/DC
Switch
♦OPTIONAL
♦♦OPTIONAL Pulser Models Only
Polarity
Switch
Start Amperage
Control
Figure 5-1. Front Panel View
OM-350 Page 14
Background
Amperage Control
Postflow
Time
Control
Ref. SC-144 405
B. Start Amperage Control
WARNING: USING HIGH FREQUENCY WITH
THE SHIELDED METAL ARC WELDING
(SMAW) PROCESS can result in serious personal injury.
• Place the HIGH FREQUENCY switch in the
OFF position before using the Shielded Metal
Arc Welding (SMAW) process.
The START AMPERAGE control allows the operator to
select the desired starting amperage for the welding
process. The scale surrounding the START AMPERAGE control is calibrated in increments from 1 to 100 but
is not meant to be an amperage or voltage reading.
Read the meters whenever it is necessary to know the
amperage and voltage output.
5-7.
OUTPUT (CONTACTOR) SWITCH (Figure
5-1)
OUTPUT CONTACTOR
The attempted use of high frequency to establish an arc with a stick electrode could cause an
arc to form between the electrode holder and
operator.
The HIGH FREQUENCY switch allows the operator to
choose whether high frequency is used or not and for
how long.
1. START
START
ON
REMOTE 14
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
•
Do not touch the weld output terminals when
the contactor is energized.
• Do not touch torch or electrode holder and
work clamp at the same time.
If the OUTPUT/CONTACTOR switch is ON,
open-circuit voltage is present at the weld output
terminals as long as the welding power source is
energized.
If remote contactor control is desired, make connections to the REMOTE CONTACTOR AND CURRENT
CONTROL receptacle as instructed in Section 4-3A.
Place the OUTPUT (CONTACTOR) switch in the REMOTE 14 position. Open-circuit voltage is present at the
weld output terminals whenever the remote contactor
switch is closed.
If a remote contactor control is not used, place the OUTPUT (CONTACTOR) switch in the ON position.
5-8.
HIGH FREQUENCY CONTROLS (Figures 4-2
and 5-1)
High frequency turns on when the contactor is energized. Once an arc is established, high frequency turns
off. High frequency turns on any time the arc is broken to
aid in restarting the arc.
2. OFF
OFF
High frequency is not available. The HIGH FREQUENCY switch must be in the OFF position while doing Shielded Metal Arc Welding (SMAW).
3. CONTINUOUS
CONTINUOUS
High frequency turns on when the contactor is energized and remains on for the duration of the weld.
B. High Frequency Intensity Control (Figure 4-2)
The HIGH FREQUENCY INTENSITY control (located
on lower front panel) governs the strength of the high
frequency. Rotating the control clockwise increases the
intensity of the high frequency.
High frequency is used during Gas Tungsten Arc Welding (GTAW) to aid starting and maintaining the welding
arc.
IMPORTANT: As the high frequency intensity is increased, the possibility of interfering with local electronic devices, especially communication equipment,
also increases. Set the HIGH FREQUENCY INTENSITY control as low as practical to avoid such interference.
A. High Frequency Switch (Figure 5-1)
5-9.
HIGH FREQUENCY
POSTFLOW TIME CONTROL (Figure 5-1)
IMPORTANT: The POSTFLOW TIME control and gas
valve (and optional coolant valve) will not work unless
the OUTPUT (CONTACTOR) switch is in the REMOTE
14 position and a Remote Contactor Control is conOM-350 Page 15
nected to the REMOTE CONTACTOR AND CURRENT
CONTROL receptacle.
The scale surrounding the control goes from 0 to 10.
The scale is not an amperage or voltage value.
The POSTFLOW TIME control provides a means of
selecting the length of time shielding gas and coolant, if
applicable, flow after the arc is extinguished. The scale
surrounding the control is calibrated in seconds (0 to
60). Rotating the control clockwise increases postflow
time.
IMPORTANT: For the AC BALANCE control to work
properly, the electrode cable must be connected to the
ELECTRODE output terminal and the work cable must
be connected to the WORK output terminal.
The postflow time delay circuitry begins to time out
when the arc is extinguished and the contactor is
opened. When postflow time is finished, the shielding
gas and coolant, if applicable, valve(s) close.
5-10. CRATER FILL SWITCH (Figure 5-1)
The crater fill circuitry provides a gradual taper of the
weld output for ending welds made using the Gas Tungsten Arc Welding (GTAW) process.
Placing the CRATER FILL switch in the IN position activates the crater fill circuitry. When this switch is in the
OUT position, crater fill is not available and the weld
ends using the setting on the AMPERAGE ADJUSTMENT control. The crater fill circuitry should not be used
with the Shielded Metal Arc Welding (SMAW) process.
IMPORTANT: When using the crater fill circuit, be sure
that the POSTFLOW TIME control is adjusted to a minimum of 8 to 10 seconds. If the POSTFLOW TIME control is adjusted to a time less than 5 seconds, the shielding gas and coolant flow ceases before the end of the
crater fill current taper.
5-11.
AC BALANCE CONTROL (Figures 5-1 and
5-2)
The AC BALANCE control changes the ac output
square wave. Rotating the control towards 10 provides
deeper penetration. Rotating the control towards 0 provides more cleaning action of the workpiece which is
necessary when welding oxide forming materials such
as aluminum or magnesium.
When the control is in the BALANCED position, the
wave shape provides equal penetration and cleaning
action. The BALANCED position is recommended for dc
Gas Tungsten Arc Welding (GTAW).
OM-350 Page 16
5-12. METERS (Figure 5-1)
AMPERAGE
A
VOLTAGE
V
The meters are internally connected to the weld output
terminals. The meters are provided to monitor the welding operation and serve as an indication of the welding
process. They are not intended for exact current or voltage measurements. The ammeter indicates the output
current of the unit. The voltmeter indicates the voltage at
the output terminals. This may not be the actual voltage
at the welding arc (due to cable resistance, poor connections, etc.).
5-13. PULSER (Optional) (Figure 5-1)
Pulsing refers to the alternate raising and lowering of the
weld output at a periodic rate. The raised portions of the
weld output are controlled in width, height, and frequency, forming pulses of weld output. These pulses
and the lower amperage level between them (called the
background amperage) alternately heat and chill the
molten weld puddle. The combined effect gives the operator better control of penetration, bead width, crowning, undercutting, and puddle sag in out-of-position
welding, specifically vertical up.
The BACKGROUND AMPERAGE control, PULSES
PER SECOND control, % ON TIME control, and the
PULSER switch operate independently of the other
welding power source controls, including the start current controls. If the CRATER FILL switch is in the IN position, both the peak and background output currents
decrease by the same proportion.
Pulsing operations may be performed when the AC/DC
switch is in either the AC or DC position.
IMPORTANT: The Pulser controls may be adjusted
while welding.
50% Electrode
Positive
50% Electrode
Negative
32% Electrode
Positive
68% Electrode
Negative
55% Electrode
Positive
45% Electrode
Negative
S-0164-A
Ref. SD-116 740-A
Figure 5-2. Square Wave Function Of AC Balance Control
A. PULSER Switch
ON
rounding the PULSES PER SECOND control is calibrated in the number of pulses available per second
(0.25 to 10). Rotating the control clockwise increases
the number of pulses per second.
D. BACKGROUND AMPERAGE Control (Chart 5-1)
OFF
Placing the PULSER switch in the ON position activates
the pulsing circuitry in the welding power source. The %
ON TIME and PULSES PER SECOND controls are active and weld output is determined by the settings of the
BACKGROUND AMPERAGE control and the AMPERAGE ADJUSTMENT control. When this switch is in the
OFF position, the pulser controls are not active, and
weld output is determined by the setting of the AMPERAGE ADJUSTMENT control.
If the PULSER switch is placed in the ON position before
welding, the pulser circuitry turns on and begins pulsing.
When the contactor is energized, pulsed weld output is
available. Because the pulser circuitry is already pulsing
when the contactor is energized, it cannot be determined where in the pulse cycle the weld will start.
The BACKGROUND AMPERAGE control sets the weld
output background level. The AMPERAGE ADJUSTMENT control sets the peak amperage level during
pulsed welding.
Chart 5-1. Pulsed Output
50% On Time
Peak
Amperage
Background
Amperage
80% On Time
If the PULSER switch is placed in the ON position after
the contactor is energized, pulsed weld output is available starting with peak amperage as set on the AMPERAGE ADJUSTMENT control.
B. % ON TIME Control (Chart 5-1)
The % ON TIME control varies the percentage of time
during each output pulse that the AMPERAGE ADJUSTMENT control sets weld output amperage (peak
amperage). The scale surrounding the % ON TIME control is calibrated in percent (5 to 95) and should not be
read as a time value. Rotating the control clockwise increases peak amperage on time.
20% On Time
Pulses Per
Second
SA-112 022
C. PULSES PER SECOND Control (Chart 5-1)
These controls act independently; therefore, it is possible to set a background amperage higher than the peak
amperage.
The PULSES PER SECOND control varies the number
of output pulses generated per second. The scale sur-
The scale surrounding the BACKGROUND AMPERAGE control is calibrated in percent (0 to 100) and
OM-350 Page 17
should not be read as an amperage or voltage value.
Rotating the control clockwise increases amperage.
When remote amperage control is employed, only the
peak level is remotely controlled; the background level
is still established by the position of the BACKGROUND
AMPERAGE control.
5-14. PREFLOW TIME (Optional) (Figure 5-1)
IMPORTANT: The OUTPUT CONTACTOR Switch
must be in the REMOTE 14 position and a remote contactor control must be connected to the REMOTE CONTACTOR AND CURRENT CONTROL receptacle to obtain preflow of shielding gas (and coolant if applicable).
A. PREFLOW TIME Switch
ON
5-15. SPOT TIME (Optional) (Figure 5-1)
IMPORTANT: The AMPERAGE CONTROL switch
must be in the PANEL position, the OUTPUT CONTACTOR switch must be in the REMOTE 14 position, and a
remote contactor control must be connected to the REMOTE CONTACTOR AND CURRENT CONTROL receptacle for the spot time circuit to work.
The spot time circuitry allows the operator to make Gas
Tungsten Arc (GTAW) spot welds. Spot time begins at
arc initiation. The remote contactor control must remain
closed during the spot weld cycle. If the arc is broken or
the contactor is opened during the spot time cycle, the
timer stops but does not reset. When the spot time has
ended, weld output stops. Postflow starts when the remote contactor control is opened. The spot timer resets
after the contactor is opened.
A. SPOT TIME Switch
OFF
ON
B. PREFLOW TIME Control
The PREFLOW TIME control circuitry allows gas (and
coolant if applicable) to flow before the arc is started.
Preflow time begins when the contactor switch is
closed. Once the preflow time ends, the gas valve (and
coolant valve) remain energized, the contactor closes,
and weld output is available.
The PREFLOW TIME control allows the operator to
choose the length of time gas (and coolant if applicable)
flows before the contactor closes and weld output is
available. The scale surrounding the control is calibrated in seconds (0 to 15). Rotating the control clockwise increases preflow time.
Placing the PREFLOW TIME switch in the ON position
activates the preflow time control circuitry. Placing the
switch in the OFF position disables the preflow time control, circuitry and welding begins when the contactor
switch closes. The switch should be OFF when performing Shielded Metal Arc Welding (SMAW).
OFF
Placing the SPOT TIME switch in the ON position activates the spot weld circuitry in the welding power
source. Placing the switch in the OFF position disables
the spot weld circuitry. The switch should be in the OFF
position while doing Shielded Metal Arc Welding
(SMAW).
B. SPOT TIME Control
The SPOT TIME control allows the operator to set the
desired spot time. The scale surrounding the control is
calibrated in seconds (0 to 5). Rotating the control clockwise increases the spot time.
If the SPOT TIME control is set at one second or less
and the START AMPERAGE switch is ON, spot weld
amperage is governed by the setting of the START AMPERAGE control.
SECTION 6 − SEQUENCE OF OPERATION
OM-350 Page 18
WARNING: ELECTRIC SHOCK can kill;
MOVING PARTS can cause serious injury;
IMPROPER AIRFLOW AND EXPOSURE TO
ENVIRONMENT can damage internal parts.
• Do not touch live electrical parts.
WARNING: ELECTRIC SHOCK can kill.
• Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.
• Use AC output ONLY if required for the welding process.
• If AC output is required, use remote output
control.
• Read and follow Safety Rules at beginning of
this manual.
•
Keep all covers and panels in place while
operating.
Warranty is void if the welding power source is
operated with any portion of the outer enclosure
removed.
ARC RAYS, SPARKS, AND HOT SURFACES
can burn eyes and skin; NOISE can damage
hearing.
• Wear correct eye, ear, and body protection.
FUMES AND GASES can seriously harm
your health.
• Keep your head out of the fumes.
•
•
Ventilate to keep from breathing fumes and
gases.
If ventilation is inadequate, use approved
breathing device.
HOT METAL, SPATTER, AND SLAG can
cause fire and burns.
• Watch for fire.
•
•
•
Keep a fire extinguisher nearby, and know
how to use it.
If AC/DC switch has been placed in DC position,
place Polarity switch in desired position (see Section 5-4).
8.
Place START AMPERAGE switch in desired position, and select start amperage if necessary
(see Section 5-6).
9.
Adjust AMPERAGE ADJUSTMENT control to
desired setting (see Section 5-2).
10.
Rotate AC BALANCE control to desired position
(see Section 5-11).
11.
Place OUTPUT (CONTACTOR) switch in desired position (see Section 5-7).
12.
Place AMPERAGE CONTROL switch in desired
position (see Section 5-3).
13.
Place HIGH FREQUENCY switch in desired position and rotate HIGH FREQUENCY INTENSITY control to desired position (see Section
5-8).
14.
Place CRATER FILL switch in desired position
(see Section 5-10).
15.
Rotate POSTFLOW TIME control to desired position (see Section 5-9).
16.
If PREFLOW TIME is available, place switch in
desired position and rotate control to appropriate
time setting (see Section 5-14).
17.
If SPOT TIME is available, place switch in OFF
position.
18.
If PULSER is available, place switch in OFF
position.
19.
Adjust remote controls as necessary.
20.
Turn on shielding gas and coolant as required.
21.
Wear welding helmet with proper filter lens according to ANSI Z49.1.
22.
Place Power switch in ON position.
23.
Begin welding.
Do not use near flammable material.
Allow work and equipment to cool before
handling.
MAGNETIC FIELDS FROM HIGH CURRENTS can affect pacemaker operation.
• Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
See Section 1 - Safety Rules For Operation Of
Arc Welding Power Source for basic welding
safety information.
6-1.
7.
GAS TUNGSTEN ARC WELDING (GTAW)
WARNING: Read and follow safety information at beginning of entire Section 6 before
proceeding.
1.
Install and connect unit according to Section 4.
2.
Select and obtain proper tungsten electrode (see
Table 7-2).
3.
Prepare tungsten electrode according to Section
7-3, and insert into torch.
4.
Wear dry insulating gloves and clothing.
5.
Connect work clamp to clean, bare metal at workpiece.
6.
Place AC/DC switch in desired position (see Section 5-5).
6-2.
GAS TUNGSTEN ARC WELDING - PULSED
ARC (GTAW-P)
WARNING: Read and follow safety information at beginning of entire Section 6 before
proceeding.
1.
Prepare unit as instructed in Section 6-1, Steps 1
through 17.
OM-350 Page 19
2.
Place PULSER switch in ON position.
2.
Select and obtain proper electrode.
3.
Rotate % ON TIME control to desired position
(see Section 5-13B).
3.
Wear dry insulating gloves and clothing.
4.
4.
Rotate PULSES PER SECOND control to desired position (see Section 5-13C).
Connect work clamp to clean, bare metal at workpiece.
5.
5.
Rotate BACKGROUND AMPERAGE control to
desired position (see Section 5-13D).
Place AC/DC switch in desired position (see Section 5-5).
6.
Adjust remote controls as necessary.
7.
Turn on shielding gas and coolant as required.
8.
Wear welding helmet with proper filter lens according to ANSI Z49.1.
9.
Place Power switch in ON position.
10.
6-3.
WARNING: ELECTRIC SHOCK can kill.
• Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.
• Use AC output ONLY if required for the welding process.
• If AC output is required, use remote output
control.
• Read and follow Safety Rules at beginning of
this manual.
Begin welding.
GAS TUNGSTEN ARC SPOT WELDING
WARNING: Read and follow safety information at beginning of entire Section 6 before
proceeding.
1.
Prepare unit as instructed in Section 6-1, Steps 1
through 10.
2.
Place OUTPUT (CONTACTOR) switch in REMOTE 14 position.
3.
Place AMPERAGE CONTROL switch in PANEL
position.
4.
Place HIGH FREQUENCY switch in desired position and rotate HIGH FREQUENCY INTENSITY control to desired position (see Section
5-8).
6.
If AC/DC switch has been placed in DC position,
place Polarity switch in desired position.
7.
Place START AMPERAGE switch in desired position, and select start amperage if necessary
(see Section 5-6).
8.
Adjust AMPERAGE ADJUSTMENT control to
desired setting (see Section 5-2).
9.
Rotate AC BALANCE control to desired position
(see Section 5-11).
10.
Place OUTPUT (CONTACTOR) switch in ON position.
11.
Place AMPERAGE CONTROL switch in desired
position (see Section 5-3).
12.
Place HIGH FREQUENCY switch in OFF position.
5.
Place CRATER FILL switch in OFF position.
6.
Rotate POSTFLOW TIME control to desired position (see Section 5-9).
13.
Place CRATER FILL switch in OUT position.
7.
If PREFLOW TIME is available, place switch in
desired position, and rotate control to desired
time setting (see Section 5-14).
14.
The POSTFLOW TIME control is not functional.
15.
If PREFLOW TIME is available, place switch in
OFF position.
8.
Place SPOT TIME switch in ON position, and set
spot time (see Section 5-15).
16.
If SPOT TIME is available, place switch in OFF
position.
9.
If PULSER is available, place switch in desired
position, and adjust controls accordingly (see
Section 5-13).
17.
If PULSER is available, place switch in OFF
position.
18.
Adjust remote controls as necessary.
10.
Turn on shielding gas and coolant as required.
19.
11.
Wear welding helmet with proper filter lens according to ANSI Z49.1.
Wear welding helmet with proper filter lens according to ANSI Z49.1.
20.
Insert electrode into insulated electrode holder.
12.
Place Power switch in ON position.
21.
Place Power switch in ON position.
13.
Begin welding.
22.
Begin welding.
6-4.
1.
SHIELDED METAL ARC WELDING (SMAW)
6-5.
WARNING: Read and follow safety information at beginning of entire Section 6 before
proceeding.
1.
Stop welding.
2.
Allow welding power source to idle for three
minutes.
3.
Place Power switch in OFF position.
Install and connect unit according to Section 4.
OM-350 Page 20
SHUTTING DOWN
4.
Turn off shielding gas and coolant supplies if
used.
WARNING: HIGH CONCENTRATION OF
SHIELDING GAS can harm health or kill.
• Shut off gas supply when not in use.
SECTION 7 − MAINTENANCE & TROUBLESHOOTING
7-1.
ROUTINE MAINTENANCE
IMPORTANT: Every six months inspect the labels on
this unit for legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
when necessary. See Parts List for part number of precautionary labels.
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
•
Shut down welding power source, and disconnect input power employing lockout/tagging procedures before inspecting, maintaining, or servicing.
Lockout/tagging procedures consist of padlocking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other disconnecting device.
MOVING PARTS can cause serious injury.
Keep away from moving parts.
•
HOT SURFACES can cause severe burns.
Allow cooling period before servicing.
•
Maintenance to be performed only by qualified
persons.
Table 7-1. Maintenance Schedule
Frequency*
Maintenance
Every Month
Units in heavy service environments:
Check labels, weld cables, clean
internal parts.
Every 3 Months
Check weld cables (see Section
7-1B).
Every 6 Months
Check all labels (see IMPORTANT block, Section 7-1). Clean
internal parts (see Section 7-1C).
*Frequency of service is based on units operated
40 hours per week. Increase frequency of maintenance if usage exceeds 40 hours per week.
A. Fan Motor
This unit is equipped with an exhaust fan and relies on
forced draft for adequate cooling. The fan motor is
manufactured with lifetime sealed bearings and requires no maintenance.
B. Weld Cables
WARNING: Read and follow safety information at beginning of entire Section 7-1 before proceeding.
Every three months inspect cables for breaks in insulation. Repair or replace cables if insulation breaks are
present. Clean and tighten connections at each inspection.
C. Internal Cleaning
WARNING: Read and follow safety information at beginning of entire Section 7-1 before proceeding.
Every six months blow out or vacuum dust and dirt from
the inside of the welding power source. Remove the
outer enclosure, and use a clean, dry airstream or vacuum suction for the cleaning operation. If dusty or dirty
conditions are present, clean the unit monthly.
OM-350 Page 21
7-2.
115 VOLTS CONTROL CIRCUIT PROTECTION (Figure 4-2)
If any of the control circuits and/or the 115 VOLTS AC
receptacle are overloaded, circuit breaker CB1 will
open, and the welding functions of the unit will cease.
However, the pilot light will remain on, indicating the
presence of line voltage up to the main transformer, and
the fan will continue to operate. If CB1 opens, correct
the problem, and manually reset the circuit breaker.
7-3.
TUNGSTEN PREPARATION: IDEAL
Stable Arc
Straight Ground
Flat
(the Dia. Of This
Flat Governs
Amperage Capacity)
TUNGSTEN ELECTRODE (Figures 7-1 and
7-2, and Table 7-2)
Use Table 7-2 to select the correct size and type tungsten electrode. Prepare the tungsten electrode using
the following guidelines. A properly prepared tungsten
electrode is essential in obtaining a satisfactory weld.
TUNGSTEN PREPARATION: WRONG
Arc Wander
Point
1-1/2 Times
Electrode
Diameter
2-1/2 Times
Electrode
Diameter
Radial Ground
S-0162
Figure 7-2. Tungsten Preparation
A. For AC Or DC Electrode Positive Welding (Figure 7-1)
AC And DC
Electrode Positive
DC Electrode
Negative
Figure 7-1. Properly Prepared Tungsten
Electrodes
OM-350 Page 22
S-0161
Ball the end of tungsten electrodes used for ac or dc
electrode positive welding before beginning the welding
operation. Weld amperage causes the tungsten electrode to form the balled end. The diameter of the end
should not exceed the diameter of the tungsten electrode by more than 1-1/2 times. For example, the end of
a 1/8 in. (3.2 mm) diameter tungsten electrode should
not exceed 3/16 in. (4.8 mm) diameter.
Table 7-2. Tungsten Size
Amperage Range - Polarity - Gas Type
Electrode Diameter
Pure Tungsten
(Green Band)
DC-Argon Electrode
Negative/Straight Polarity
DC-Argon Electrode
Positive/Reverse Polarity
AC-Argon Using
High Frequency
AC-Argon Balanced
Wave Using High Freq.
.010”
.020”
.040”
1/16”
3/32”
1/8”
5/32”
3/16”
1/4”
Up to 15
5-20
15-80
70-150
125-225
225-360
360-450
450-720
720-950
*
*
*
10-20
15-30
25-40
40-55
55-80
80-125
Up to 15
5-20
10-60
50-100
100-160
150-210
200-275
250-350
325-450
Up to 10
10-20
20-30
30-80
60-130
100-180
160-240
190-300
250-400
Up to 25
15-40
25-85
50-160
135-235
250-400
400-500
500-750
750-1000
*
*
*
10-20
15-30
25-40
40-55
55-80
80-125
Up to 20
15-35
20-80
50-150
130-250
225-360
300-450
400-500
600-800
Up to 15
5-20
20-60
60-120
100-180
160-250
200-320
290-390
340-525
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Up to 20
15-35
20-80
50-150
130-250
225-360
300-450
400-550
600-800
Up to 15
5-20
20-60
60-120
100-180
160-250
200-320
290-390
340-525
2% Thorium Alloyed
Tungsten
(Red Band)
.010”
.020”
.040”
1/16”
3/32”
1/8”
5/32”
3/16”
1/4”
Zirconium Alloyed
Tungsten
(Brown Band)
.010”
.020”
.040”
1/16”
3/32”
1/8”
5/32”
3/16”
1/4”
*NOT RECOMMENDED
The figures listed are intended as a guide and are a composite of recommendations from American Welding
Society (AWS) and electrode manufacturers.
S-0009/8-88
B. For DC Electrode Negative Welding (Figures 7-1
and 7-2)
CAUTION: HOT FLYING METAL PARTICLES
can injure personnel, start fires, and damage equipment;TUNGSTEN CONTAMINATION can lower weld quality.
• Shape tungsten electrode only on grinder
with proper guards in a safe location wearing
proper face, hand, and body protection.
• Do not use same wheel for any other job or
the tungsten will become contaminated.
•
Shape tungsten electrodes on a fine grit, hard
abrasive wheel used only for tungsten shaping. Grind tungsten electrodes so that grinding marks run lengthwise with the electrode.
These procedures reduce the possibility of
the tungsten electrode transferring foreign
matter into the weld and help reduce arc wander and instability at lower currents.
Grind the end of the tungsten electrode to a taper for a
distance of 2 to 2-1/2 electrode diameters in length. For
example, the ground surface for a 1/8 in. (3.2 mm) diameter tungsten electrode should be 1/4 to 5/16 in. (6.4
to 8.0 mm) long.
OM-350 Page 23
For additional information, see your distributor for a
handbook on the Gas Tungsten Arc Welding (GTAW)
process.
7-4.
SPARK GAP ADJUSTMENT (Figure 7-3)
6.
Tighten screws A.
7.
Close and secure both doors.
7-5.
It is necessary to readjust the spark gaps every three to
four months or when intermittent operation occurs. Normal spark gap setting for this unit is 0.008 in. (0.208
mm).
BOARD
HANDLING
PRECAU-
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
•
High-frequency output varies with the spark gap setting.
When a great amount of high frequency is necessary,
the spark gaps can be adjusted to 0.010 in. (0.254 mm).
This increases high-frequency radiation which increases interference with communications equipment.
It is suggested that a minimum spark gap setting of
0.004 to 0.008 in. (0.102 to 0.203 mm) be used.
Turn off welding power source, and disconnect input power employing lockout/tagging
procedures before inspecting, maintaining, or
servicing.
Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnecting device.
IMPORTANT: Spark gaps widen and points deteriorate
with normal usage. Every three months check and
maintain the spark gap setting to ensure consistent
welding results and compliance with FCC radiation
regulations. Do not clean or dress points. Replace the
entire point when the tungsten section has completely
disappeared.
CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit boards.
• Put on properly grounded wrist strap
BEFORE handling circuit boards.
• Transport circuit boards in proper staticshielding carriers or packages.
• Perform work only at a static-safe work area.
This unit is provided with a spark gap assembly located
behind an access door on the left side of the lower front
panel (see Figure 4-2). To adjust the spark gaps, proceed as follows.
INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
• Be sure that plugs are properly installed and
aligned.
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
EXCESSIVE PRESSURE can break circuit
board.
• Use only minimal pressure and gentle movement when disconnecting or connecting
board plugs and removing or installing board.
•
Turn off welding power source, and disconnect input power employing lockout/tagging
procedures before inspecting, maintaining, or
servicing.
Lockout/tagging procedures consist of padlocking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other disconnecting device.
CIRCUIT
TIONS
7-6.
TROUBLESHOOTING (Table 7-3)
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
•
C
C
B
A
B
A
S-0043
Figure 7-3. Spark Gap Adjustment
1.
Open lower front panel access door.
2.
Open spark gap access door.
3.
Loosen screws A on both sides.
4.
Place feeler gauge of proper thickness between
points C.
5.
Apply slight pressure to points B so feeler gauge
is held firmly in gap.
OM-350 Page 24
Shut down welding power source, and disconnect input power employing lockout/tagging procedures before inspecting, maintaining, or servicing.
Lockout/tagging procedures consist of padlocking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other disconnecting device.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
Troubleshooting to be performed only by
qualified persons.
It is assumed that the unit was properly installed according to Section 4 of this manual, the operator is familiar
with the function of controls, the welding power source
was working properly, and that the trouble is not related
to the welding process.
The following table is designed to diagnose and provide
remedies for some of the troubles that may develop in
this welding power source. Use this table in conjunction
with the circuit diagram while performing troubleshooting procedures. If the trouble is not remedied after performing these procedures, contact the nearest Factory
Authorized Service Station. In all cases of equipment
malfunction, strictly follow the manufacturer’s procedures and instructions.
Table 7-3. Troubleshooting
TROUBLE
PROBABLE CAUSE
REMEDY
No weld output; unit completely Line disconnect switch in the Place line disconnect switch in the ON position.
inoperative; pilot light PL1 off. OFF position.
Line fuse(s) open.
Check and replace line fuse(s).
Improper electrical input con- See Section 4-4 for proper input connections.
nections.
Input voltage jumper links not in See Section 4-4 for proper jumper link position.
proper position.
Power switch S1.
Replace Power switch S1.
No weld output; fan and pilot OUTPUT
(CONTACTOR) Place S4 in the ON position if no remote control
light PL1 on.
switch S4 position.
is used. Place S4 in the REMOTE position, and
be sure remote control is connected to the REMOTE CONTACTOR AND CURRENT CONTROL receptacle RC2 (see Sections 4-3 and
5-7).
Remote control device.
Check and repair, or replace remote control device.
Circuit Board PC1.
See Section 7-5, and contact nearest Factory
Authorized Service Station.
Unit provides only maximum or Hall device HD1.
minimum weld output.
Circuit Board PC1.
Weld output always above or Hall device HD1.
below set values.
Replace HD1. Contact nearest Factory Authorized Service Station.
See Section 7-5, and contact nearest Factory
Authorized Service Station.
Replace HD1. Contact nearest Factory Authorized Service Station.
Circuit Board PC1.
See Section 7-5, and contact nearest Factory
Authorized Service Station.
Erratic weld output.
Circuit Board PC1.
See Section 7-5, and contact nearest Factory
Authorized Service Station.
No AC BALANCE control.
AC BALANCE control R13.
Check and replace R13.
Circuit Board PC1.
See Section 7-5, and contact nearest Factory
Authorized Service Station.
No control of weld output.
AMPERAGE
CONTROL Place S1 in the PANEL position if no remote conswitch S11 position.
trol is used. Place S11 in the REMOTE 14 position, and be sure a remote control is connected
to the REMOTE CONTACTOR AND CURRENT
CONTROL receptacle RC2 (see Sections 4-3
and 5-3).
AMPERAGE
control R1.
ADJUSTMENT Check and replace R1.
Circuit Board PC1.
See Section 7-5, and contact nearest Factory
Authorized Service Station.
OM-350 Page 25
Table 7-3. Troubleshooting (Continued)
TROUBLE
PROBABLE CAUSE
No high frequency and no gas Circuit Board PC2.
flow.
Circuit Breaker CB1.
REMEDY
See Section 7-5, and contact nearest Factory
Authorized Service Station.
Correct overhead and reset CB1 (see Section
7-2).
Tungsten electrode oxidizing Loose gas fittings on regulator Check and tighten all gas fittings.
and not remaining bright after or gas line. This will siphon oxyconclusion of weld.
gen into the weld zone.
Insufficient gas flow.
Increase gas flow setting.
Drafts blowing gas shield away Shield weld zone from drafts.
from tungsten.
Dirty filter rod or material.
Use clean filter rod or material.
Gas shutting off too quickly af- Increase time setting of POSTFLOW TIME conter end of weld.
trol (see Section 5-9).
HIGH FREQUENCY switch S3 Place S3 in START or CONTINUOUS position.
position.
Lack of high frequency; difficul- Use of tungsten larger than rec- Use proper size tungsten for welding application
ty in establishing an arc.
ommended for welding amper- (see Table 7-2).
age.
Dissipation of high frequency Be sure that electrode holder cable is not close
from electrode holder lead.
to any grounded metal.
Weld cable leakage.
Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace necessary parts.
Improper spark gap.
Check spark gaps G and adjust if necessary
(see Section 7-4).
HIGH FREQUENCY INTENSI- Increase setting of R20 (see Section 5-8).
TY control R20 setting.
Wandering arc - poor control of Use of tungsten considerably Use proper size tungsten (see Table 7-2).
direction of arc.
larger than recommended.
Improperly prepared tungsten. Prepare tungsten as instructed in Section 7-3.
Fan inoperative.
Fan blade obstructions.
Check for and remove fan blade obstructions.
Fan motor (FM) leads open or Check for and correct open or shorted FM leads.
shorted.
Fan motor (FM).
OM-350 Page 26
Check and replace FM.
SECTION 8 − ELECTRICAL DIAGRAMS
Diagram 8-1. Circuit Diagram For Welding Power Source
OM-350 Page 27
Circuit Diagram No. SD-137 500
OM-350 Page 28
Diagram 8-2. Wiring Diagram For Welding Power Source
OM-350 Page 29
Wiring Diagram No. SD-139 066
OM-350 Page 30
SECTION 9 − CERTIFICATION FOR HIGH FREQUENCY ARC WELDING EQUIPMENT
9-1.
GENERAL
The following information is necessary to make a proper
installation of the high-frequency arc welding equipment
described in this instruction manual. In order to comply
with Part 18 of the Rules and Regulations of the Federal
Communications Commission (FCC), the certificate in
the front of this manual must be filled in completely and
signed after the unit has been correctly installed. The
certificate must be kept WITH THE EQUIPMENT AT
ALL TIMES to comply with the regulation. The manufacturer of the equipment covered herein has conducted
approved field tests and certifies that the radiation can
be expected to be within the legal limits if the correct installation procedures, as outlined, are followed. The importance of a correct installation cannot be overemphasized since case histories of interference due to highfrequency stabilized arc welding equipment have shown
that in most cases, an inadequate installation was at
fault. In the event that interference with authorized FCC
services occurs, the user is required to take suitable
steps to clear the situation. The Factory Service Department personnel will assist the user by supplying technical information.
Instead of complying with the installation requirements
and the certification of each individual installation, the
user may elect to certify the entire plant by having a
qualified engineer make a plant radiation survey. In such
cases, these instructions could serve as a guide in minimizing interference that might be caused by the highfrequency arc welding equipment.
Many processes and applications of processes require
open-circuit voltages sufficient to jump from the electrode to the work without making direct contact. The
maximum open-circuit voltage (OCV) of a welding
power source is not sufficient for this. In the Submerged
Arc Welding (SAW) process, granules of flux often get
between the electrode and the workpiece making starting of the arc difficult at normal open-circuit voltages. A
higher voltage is also required to start and maintain a
stable arc in processes like the Gas Tungsten Arc Welding (GTAW) process. In these cases it will take several
thousand volts to cause an electrical spark to jump this
gap between the electrode and the work, creating an initial path of ionization that the arc current can follow
without the hazards that would be present at power frequency.
In order to provide these higher voltages, it is common
practice to superimpose a high open-circuit voltage on
the output of a welding power source by using high-frequency techniques. The high-frequency voltage can be
a source of interference and will be discussed in this
section.
9-2.
DEFINITIONS
A. High-Frequency Assisted Arc Welding Power
Sources
In the arc welding process, high frequency may be used
for initiating an arc or stabilizing the arc once it is struck,
or for both functions.
The energy from the high-frequency source must flow to
the welding electrode via a good quality, low impedance,
and well insulated connecting cable.
B. Welding Circuit
The welding circuit consists of all attachments connected to the welding terminals.
C. Welding Terminals
Welding terminals are the terminals which provide welding power and high-frequency energy to the arc.
D. Electrode Terminal
The electrode terminal is the terminal to which the electrode cable or welding torch is connected.
E. Welding Torch
A device used in the Gas Tungsten Arc Welding (GTAW)
process to control the position of the electrode, to transfer current to the arc, and to direct the flow of shielding
gas.
F.
Work Terminal
The work terminal is the terminal to which the welding
workpiece is connected.
G. Welding Zone
The welding zone is the space within 50 ft. (15 m) in all
directions from the midpoint between the power source
and the welding arc (see Figure 9-6).
H. Bonding
Bonding refers to connecting metallic objects together
to cause the objects to be at the same potential regardless of any current flow between them (see Figures 9-3
and 9-4).
I.
Grounding (Earthing)
Depending on the practices within jurisdictions, one of
these terms is commonly used to indicate the connection, or bonding, of parts of the apparatus to the
earth.The terms may be used interchangeably.
J. Receiver
A receiver is any device normally used for receiving
electromagnetic energy and converting it to useful communications purposes.
K. Conduction
Conduction is the transmission of high-frequency energy via an electrical conductor or conducting medium.
OM-350 Page 31
L. High Frequency
9-4.
High frequency is radio frequency energy, either continuous or pulsed, used to start or stabilize a welding arc.
Locate the high-frequency power source as close to the
welding process as possible. Also consider the nearness of a suitable ground connection when selecting a
site for the installation of the power source. Ideally, the
high-frequency power source should be located in an
area where there is a limited amount of miscellaneous
wiring (lighting, power, telephone, communications, and
other unshielded conductors) located within the welding
zone. Ungrounded, metallic conductors in the welding
zone can act as antennas which will pick up, conduct, or
reradiate the high-frequency energy transmitted by the
welding circuit. All miscellaneous wiring in the welding
zone should be enclosed in grounded, rigid metallic conduit, copper braid, or some other material having an
equivalent shielding efficiency, and grounded at 50 ft.
(15 m) intervals (see Figure 9-1).
M. High-Frequency Assisted Arc Welding
High-frequency assisted arc welding refers to any of the
arc welding processes requiring high frequency.
N. Interference
Interference is the unwanted and problematic reception
of high-frequency energy.
O. Radiation
Radiation is the transmission of high-frequency energy
through space.
9-3.
HIGH-FREQUENCY RADIATION
LOCATION
Shielded Wire
Installations using high frequency, either as an integral
part of the power source or as an accessory unit, will
produce some high-frequency radiation. Such radiation,
if the signal strength is sufficient at the receiving device,
can cause an inconvenience or disruption of communications or can cause malfunction in sensitive electronic
controls and systems. The four major causes of highfrequency radiation are as follows:
Ground At 50ft.
(15 m) Intervals
A. Direct Radiation From The Power Source Or
High-Frequency Accessory Unit
Direct radiation is that radiation emanating directly from
the power source or accessory unit. Radiation from the
power line and welding power source accessories is not
considered to be direct radiation from the power source
or accessory unit.
B. Direct Radiation From The Welding Circuit
Any attachment to the output terminals of the high-frequency source is capable of acting as an antenna and
radiating high-frequency energy. Attachments include
weld cables, torches, worktables, etc. Since direct radiation from the welding circuit is the major source of radiation, it is important to keep attachments to a minimum.
C. Conduction And Radiation From The Power
Line
Most power lines are capable of conducting high-frequency energy which may cause interference directly or
by reradiation from these power lines. Normally such radiation is small when compared to that caused by radiation from the weld cables.
D. Reradiation
Radiation from the welding circuit can be picked up by
ungrounded metal objects or unshielded wiring in the
immediate vicinity, conducted some distance, and
reradiated. This can be a troublesome source of interference.
OM-350 Page 32
Electrode
Holder
50 ft.
(15 m)
Work Clamp
High-Frequency
Welding
Power Source
Ground
S-0017
Keep all unshielded and ungrounded
wires out of the welding zone.
Figure 9-1. Requirements To Minimize Reradiation Pickup In The Vicinity Of The Welding Zone
9-5.
GENERAL INSTALLATION PROCEDURES
A. Weld Cables
Keep the weld cables as short as possible and do not
exceed 25 ft. (8 m) in length. Position the cables as
close together and as close to the floor or ground plane
as possible.
If the welding operation must be carried out at a point
farther than 25 ft. (8 m) from the welding power source,
use a portable high-frequency source and locate the
portable unit within 25 ft. (8 m) of the welding electrode.
B. High-Frequency Assisted Arc Welding Power
Sources
When the high-frequency assisted arc welding power
source is in operation, all service doors and covers must
be closed, securely fastened, and adequately bonded to
ensure good contact around the entire perimeter of the
opening. Except for changes and adjustments allowed
by the manufacturer, the high-frequency assisted arc
welding power source should not be modified.
High-Frequency
Welding Power Source
Place leads on floor or on boards
and keep 3/4 in. (19 mm)
to 1 in. (25 mm) apart.
Electrode
Holder
Electrical
Input
Supply
Work Clamp
S-0018
Ground
Figure 9-2. General Rules For Welding Leads
However, when the high-frequency power source is installed within a metal building, precautions must be
taken to be sure that the building is properly bonded and
grounded (earthed). This can be accomplished by placing several good electrical ground rods around the periphery of the building. During the construction of a new
building of any type having metal in the structure, be
sure that all the reinforcing and structural steel is
bonded together (as by welding each piece of metal to
all other adjacent pieces). For metal buildings, adjacent
metal panels should be bolted or welded together at frequent intervals.All windows and doorways should be
covered with grounded copper screen or galvanized
hardware cloth of not more than 1/4 in. (6.4 mm) mesh.
E. Shielding Of Miscellaneous Wiring In The Welding Zone
C. Grounding (Earthing) The Weld Cables
Be sure that the enclosure of the high-frequency power
source is firmly grounded to the WORK terminal. If the
high-frequency power source is not labeled as being internally high-frequency grounded, then this ground
must be made by grounding the enclosure to the WORK
terminal with No. 12 AWG gauge or smaller wire. Connect the ground wire to a driven ground rod or to a water
pipe which enters the earth within 10 ft. (3 m) of the highfrequency power source.
D. Metal Buildings
Installation of a high-frequency power source within a
suitably bonded and grounded (earthed) metal building
can be an effective means of reducing high-frequency
radiation. Wherever possible, install high-frequency
power sources in such places.
Ungrounded, metallic conductors in the welding zone
can act as antennas which will pick up, conduct, and/or
reradiate the high-frequency energy transmitted by the
welding circuit located within or near the welding zone.
This means that all ungrounded water pipes must be
grounded, and that all lighting, power, telephone, communications, and other conductors within the welding
zone must be enclosed in grounded, rigid metallic conduit, copper braid, or some other material having an
equivalent shielding capability (spirally wound, flexible,
metallic conduit is not suitable). Shielding of the miscellaneous wiring in the welding zone must be grounded at
50 ft. (15 m) intervals. Excellent low resistance electrical
connections must be maintained between conduit sections (see Figure 9-4).
Copper Strap
Grounded
Copper Screens
Driven
Ground
Rod
S-0020
Metal Building
Panels
Grounding Wire
Metal Panels
F.
Metal Panels
S-0019
Bonding Of Metal Panels
Figure 9-3. Grounding And Bonding
Panels Of Metal Building
Figure 9-4. Bonding Method For Poor Conductors
Power Service
The high-frequency power source should be connected
to the line input power supply as instructed in this manual. If the unit is equipped with a power cord, the supply
conductors serving the high-frequency power source
should be completely enclosed in solid metallic conduit,
or in equivalent shielding, up to the point of connection
with the power cord. The solid, metallic conduit, or
equivalent shielding, should extend the entire distance
from the power entrance location in the building to the
high-frequency power source. Shielding should be electrically continuous throughout its length and should be
connected so that good electrical contact is provided between the shield and the high-frequency power source.
OM-350 Page 33
Line Input
Power Supply
a. Have all unshielded power, lighting, and communication wires within the welding zone
placed in grounded shields or relocated outside
the welding zone.
High-Frequency
Welding Power Source
50 ft. (15 m)
b. Ground all large metallic objects, long guy
wires, or support wires within the welding zone.
Solid Metallic Conduit
c. Be sure that there are no external power or telephone wires, which may be off the immediate
premises, within the welding zone.
Ground
Line Fuse And Switch Box
Or Receptacle
High-Frequency
Welding Power
Source
S-0021
Figure 9-5. Installation Of High-Frequency
Stabilized Arc Welding Power Source
9-6.
GUIDELINES FOR INSTALLATION OF HIGHFREQUENCY ASSISTED ARC WELDING
POWER SOURCES
1.
Locate the equipment so that the ground wire of
the high-frequency power source can be kept as
short as possible.
2.
Shield the line input power leads up to the point of
connection with the enclosure of the high-frequency power source as specified by the manufacture’s requirements (see Section 9-5F).
3.
Be sure that there is good electrical contact made
at the enclosure of the high-frequency welding
power source, through the conduit, and back to
the service box. Be sure that the conduit system
is continuous to a point at least 50 ft. (15 m) from
the equipment, and that the conduit system is
one complete run within the high-frequency zone.
If rigid, metallic conduit is not used, be sure that
the shielding used has equivalent shielding efficiency. Copper sleeving, lead covered cable, or
the equivalent, is satisfactory. Spirally wound,
flexible, metallic conduit is not suitable.
Center Point
Electrode
Holder
S-0022
Figure 9-6. Welding Zone
10.
Use driven ground rods which enter the ground
10 ft. (3 m) or less from the ground connection, or
cold water pipes, as the ground for the high-frequency welding power source.
11.
Be sure that all ground connections are clean and
tight.
12.
If the high-frequency welding power source is operated within a metal building, be sure that the
building is properly grounded.
9-7.
INSTALLATION GUIDELINES CHECKLIST
All items may not be necessary or practical for each installation. Complete the necessary items to eliminate interference with authorized FCC services.
4.
Keep WORK and ELECTRODE cables as short
and straight as possible.
5.
Keep weld cables to a maximum length of 25 ft. (8
m).
1.
Is equipment properly located?
(See Sections 9-4, 9-5D, 9-5E, 9-6.1, and 9-6.9.)
6.
Keep weld cables as close together and as close
to the ground plane as possible.
2.
Are ac input power connections properly made?
(See Sections 9-5B, 9-6.2, and 9-6.3.)
7.
Adjust spark gap setting to the minimum setting
given in this manual.
3.
8.
Secure all service and access doors before operating.
Are weld cables and equipment properly installed?
(See Sections 9-5A, 9-6.4, 9-6.5, and 9-6.6.)
4.
9.
Visualize the welding zone as a sphere with a 50
ft. (15 m) radius centered on a point between the
power source and the electrode holder (see Figure 9-6), and proceed as follows:
Are ground connections properly made?
(See Sections 9-5C, 9-6.1, 9-6.6, 9-6.11, and
9-6.12.)
5.
Is equipment properly set up and adjusted?
(See Sections 9-6.7 and 9-6.8.)
OM-350 Page 34
SECTION 10 − PARTS LIST
1
2
3
4
5
Fig 10-2
6
15
14
Fig 10-3
7
8
13
12
10
11
Fig 10-6 & 10-7 Fig 10-5
10
9
Fig 10-4
SD-127 627
Figure 10-1. Main Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-1. Main Assembly
... 1
... 1
... 2
... 3
... 4
... 5
... 6
... 7
... 7
... 8
... 9
. . 10
. . 11
. . 12
. . 13
. . . . . . . . . . . . . . 039 244
. . . . . . . . . . . . . ♦052 302
. . . . . . . . . . . . . . 109 035
. . . . . . . . . . . . . . 026 627
. . HA1,HD1 . . 059 641
. . . . . . . . . . . . . . 135 361
. . . . . . . . . . . . . . Fig 10-2
. . . . TE1 . . . . . 059 241
. . . . TE1 . . . . . 059 095
. . . . C1,3 . . . . . 112 557
. . . . . . . . . . . . . . Fig 10-4
. . . . . . . . . . . . . ♦025 141
. . . . . C2 . . . . ♦114 610
. . . . . . . . . . . . . . 108 323
. . . . . . . . . . . . . . Fig 10-6
& 10-7
. . 14 . . . . C16 . . . . . 009 062
. . 15 . . . . . . . . . . . . . +039 248
..
..
..
..
..
..
..
..
..
..
..
..
..
..
COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COVER, top w/programmer mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, warning electric shock can kill etc. . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKET, lifting eye cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENSOR, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TERMINAL ASSEMBLY, pri dual voltage (Fig 10-3) . . . . . . . . . . . . . . . . . .
TERMINAL ASSEMBLY, pri triple voltage (Fig 10-3) . . . . . . . . . . . . . . . . . .
CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REACTOR & TRANSFORMER, pwr main . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, polyp MF 30uf 480VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HF PANEL, (Fig 10-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
2
1
2
4
1
. . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CAPACITOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
♦OPTIONAL
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-350 Page 35
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-2. Panel, Rear w/Components (Fig 10-1 Item 6)
...
...
...
...
...
1
2
3
4
5
. . . . FM . . . . .
..............
..............
..............
. . . . R10 . . . . .
032 605
020 729
032 606
059 068
097 459
..
..
..
..
..
MOTOR, cap perm SP 1/4 hp 235VAC 1625RPM . . . . . . . . . . . . . . . . . . . .
CHAMBER, plenum 18in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLADE, fan 18 in 3wg 22deg .500 bore CW . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, WW fxd 375W 20 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
4
2
3
3
4
2
1
5
1
6
1
5
SD-127 630
Figure 10-2. Panel, Rear w/Components
Item
No.
Part
No.
SA-128 152
Figure 10-3. Terminal Assembly, Pri
Description
Figure 10-3. Terminal Assembly, Pri (Fig 10-1 Item 7)
...
...
...
...
...
...
1
2
3
4
5
6
. . . . . . . 601 838
. . . . . . . 602 221
. . . . . . . 010 910
. . . . . . . 059 050
. . . . . . . 038 804
. . . . . . . 038 898
...
...
...
...
...
...
Quantity
059 241
NUT, brs hex .375-16 jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, lock stl intl tooth .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, flat stl SAE .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TERMINAL BOARD, pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STUD, brs .375-16 x 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LINK, terminal connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 . . . . 22
6 ...... 8
6 ...... 8
1 ...... 1
6 ...... 8
2 ...... 2
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-350 Page 36
059 095
Replace Coils At Factory Or Factory Authorized Service Station
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-4. Reactor & Transformer, Power Main ( Fig 10-1 Item 9)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
4
4
5
6
5
6
5
6
7
8
9
. . . . . Z1 . . . . . . 059 113
. . . . . . . . . . . . . . 059 101
. . . . . . . . . . . . . . 059 102
. . . . . T1 . . . . . 145 269
. . . . . T1 . . . . . 145 268
. . . . . T1 . . . . . 145 267
. . . . . . . . . . . . . . 139 540
. . . . . . . . . . . . . . 139 541
. . . . . . . . . . . . . . 139 542
. . . . . . . . . . . . . . 139 543
. . . . . . . . . . . . . . 139 544
. . . . . . . . . . . . . . 139 545
. . . . . . . . . . . . . . 135 508
. . . . . . . . . . . . . . . 022 113
. . . . . . . . . . . . . . 000 194
. . REACTOR, square wave (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . COIL, reactor square wave RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . COIL, reactor square wave LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, (230/460) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, (200(208)/230/460) (consisting of) . . . . . . . . . . . . . . . . .
. . TRANSFORMER, (230/460/575) (consisting of) . . . . . . . . . . . . . . . . . . . . .
. . . . COIL, pri/sec LH (230/460) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . COIL, pri/sec RH (230/460) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . COIL, pri/sec LH (200(208)/230/460) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . COIL, pri/sec RH (200(208)/230/460) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . COIL, pri/sec LH (230/460/575) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . COIL, pri/sec RH (230/460/575) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAR, mtg transformer/reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAR, stl HR .250 x 1.000 x 5.875 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAR, stl HR .375 x 2.000 x 29.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
TC-006 611-A
Figure 10-4. Reactor & Transformer, Power Main
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-350 Page 37
Item
No.
Dia.
Mkgs.
Part
No.
Description
108 323
... 1
... 2
... 3
... 4
... 5
... 6
... 7
... 8
... 9
. . 10
. . 11
. . 12
. . 13
. . 14
. . 15
. . 16
. . 17
. . 18
. . 19
. . 20
. . 21
. . . . . . . . . . . . . . 010 885
. . . . . . . . . . . . . . 603 737
. . . . . . . . . . . . . . 010 910
. . . . . . . . . . . . . . 016 601
. . . . . . . . . . . . . . 038 887
. . . . . . . . . . . . . . 601 838
. . . . . . . . . . . . . . 602 243
. . . . . T4 . . . . . 033 373
. . . . . T3 . . . . . 074 398
. . . . R11 . . . . . 083 784
. . . . . . . . . . . . . . 088 487
. . . . . . . . . . . . . . 081 282
. . . . . . . . . . . . . . 007 532
. . . . C13 . . . . . 059 887
. . . . . . . . . . . . . . 602 042
. . . . C14 . . . . . 096 761
. . . . . . . . . . . . . . . 111 181
. . . . . . . . . . . . . . 020 623
. . . . . . . . . . . . . . 020 622
. . . . . G . . . . . . *020 603
. . . . . . . . . . . . . . 095 621
Quantity
Figure 10-5. HF Panel (Fig 10-1 Item 12)
. . STRIP, conductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, mach brs rdh .375-16 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, flat stl SAE .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MOUNTING BOARD, component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, brs hex .375-16 jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, flat stl std .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COIL, coupling air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, high voltage 115V pri 3600V sec 30MA . . . . . . . . . . . .
. . RESISTOR, WW fxd 100W 10 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, HF (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . STRIP, mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CLAMP, capacitor 1.000dia clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CAPACITOR, ployp MF 10uf 220V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, mach brs rdh 10-32 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, mica .002uf 10000V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINK, connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPARK GAP ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOLDER, points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . POINT, spark gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BASE, spark gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
2
2
1
2
5
4
1
1
1
1
1
4
2
1
2
1
1
4
4
1
7
5
1
2
3
6
6
4
8
21
9
18 20
19
1
10
17
16 15 5
12
13 11
14
Figure 10-5. HF Panel
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-350 Page 38
SC-127 635
OM-350 Page 39
32
1
31
2
4
5
6
30
7
7
29
9
11
28
12 13
27
14
Figure 10-6. Panel, Front (Lower Section) w/Components
3
8
10
10
15
26
16
23
17
26
18
22
25
24
23
22
21
20
19
SC-127 629
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-6. Panel, Front (Lower Section) w/Components
(Figure 10-1 Item 13)
. . . 1 . . . . . . . . . . . . . . 003 045
. . . 2 . . . . . . . . . . . . . . 009 835
. . . 3 . . . . . . . . . . . . . . 039 273
. . . 4 . . . . . . . . . . . . . . 039 685
. . . 5 . . . . . . . . . . . . . . 602 358
. . . 6 . . . . . . . . . . . . . . 052 467
. . . 7 . . . . . . . . . . . . . . 010 855
. . . 8 . . . . . . . . . . . . . . 130 171
. . . 9 . . . . C15 . . . . . 136 736
. . 10 . . . . . . . . . . . . . . 039 047
. . 11 . . . . . . . . . . . . . . 601 879
. . 12 . . . . . . . . . . . . . . 039 044
. . 13 . . . . . . . . . . . . . . 601 880
. . 14 . . . . . . . . . . . . . . 039 049
. . 15 . . . . . . . . . . . . . . 601 976
. . 16 . . . . R20 . . . . . 605 828
. . 17 . . . . C24 . . . . . 144 298
. . 18 . . . . C20 . . . . . 144 296
. . 18 . . . . C21 . . . . . 144 297
. . 18 . . . . C25 . . . . . 144 295
. . 19 . . . . RC2 . . . . . 143 976
. . . . . . . . . . . . . . . . . . . 079 534
. . . . . . . . . . . . . . . . . . . 134 734
. . . . . . . . . . . . . . . . . . . 134 731
. . . . . . . . . . . . . . . . . . . 079 739
. . 20 . . . . RC1 . . . . . 604 176
. . . . . . . . . . . . . . . . . . . 073 690
. . 21 . . . . . C4 . . . . . 135 664
. . 22 . . . . . . . . . . . . . . 010 296
. . 23 . GS1,WS1 . ♦003 538
. . 24 . . . . . R9 . . . . . 030 761
. . 25 . . . . . C6 . . . . . 028 294
. . 26 . . . . . . . . . . . . . ♦010 295
. . 27 . . . . . . . . . . . . . . 605 670
. . 28 . . . . CB1 . . . . . 093 995
. . 29 . . . . . . . . . . . . . . 097 922
. . 30 . . . . . . . . . . . . . +003 043
. . 31 . . . . . . . . . . . . . . 078 034
. . . . . . . . . . . . . . . . . . . 070 371
. . 32 . . . . . . . . . . . . . . 134 327
. . PANEL, front louvered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SWITCH, w/leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . PLUG, 5 pin MS-3106A-16S-8P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CLAMP, cable AN-3057-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FASTENER, scr knrl hd No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . DOOR, access HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RETAINER, screw No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CAPACITOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . TERMINAL, pwr output red (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . NUT, stl hex full fnsh .500-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . BUS BAR, term bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . NUT, stl hex jam .500-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . TERMINAL BOARD, red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . SCREW, cap stl hex hd .500-13 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RHEOSTAT, WW 50W 1.5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RECEPTACLE w/TERMINALS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . TERMINAL, female 1skt 18-14 wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . HOUSING, term plug 14cont Amp 213571-2
. . TERMINAL, male 1 pin 18-14 wire Amp 213603-1
. . CLAMP, cable strain relief sz 17 Amp 206322-2
. . RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CAP, P & S 5266DF
. . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FITTING, hose brs elb M 1/4NPT x .625-18RH . . . . . . . . . . . . . . . . . . . . . . 2
. . VALVE, 115VAC 2 way 1/4 IPS port 1/8 orf . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . RESISTOR, C 1W 10 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CAPACITOR, ploye met film 1uf 250VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FITTING,pipe brs elb M 1/4NPT x .625-18LH . . . . . . . . . . . . . . . . . . . . . . . 2
. . NUT, speed 12-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . . . . . 1
. . KNOB, pointer .875dia x .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . DOOR, access front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FASTENER, screw sltd hd .736 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . BLANK, snap-in nyl 1.093/1.125 mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦WS1 and fittings are now optional parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-350 Page 40
OM-350 Page 41
39
40
38
41
1
Fig 10-8
37
36
2
3
35
4
5
4
6
33
7
32
8
11
30
12
31 Fig 10-13
12
29
14
15
16
28
18
19
Fig 10-14
17
Figure 10-7. Panel, Front (Upper Section) w/Components
34
4
9 10
Fig 10-12
Fig 10-12
13
20
21
22
23
23
24
23
27
25
SD-127 628
23
26
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-7. Panel, Front (Upper Section) w/Components
(Fig 10-1 Item 13)
. . . 1 . . . . S5,7 . . . . . 059 081 . . SWITCH, polarity/selector (Fig 10-8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front (Fig 10-6 Item 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . S4 . . . . . . 011 622 . . SWITCH, tgl 3PDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . S10-12 . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 5 . . . . . S3 . . . . . . 011 610 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . R1 . . . . . 072 462 . . POTENTIOMETER, w/shaft lock (consisting of) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 072 590 . . . . LOCK, shaft pot .375-32 x .250dia shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . R14 . . . . . 035 897 . . POTENTIOMETER, C sltd sft 1/T 2W 1000 ohm . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . ♦Fig 10-12 . . SPOT TIMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . R13 . . . . . 030 109 . . POTENTIOMETER, C sltd sft 1/T 2W 5000 ohm . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . R15 . . . . . 028 769 . . POTENTIOMETER, C sltd sft 1/T 2W 750K ohm . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . ♦Fig 10-12 . . PRE-FLOW TIMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . 106 556 . . BAFFLE, panel front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . . . . . . . . . . 059 152 . . PANEL, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . CR2 . . . . . 000 174 . . RELAY, encl 24VAC 3PDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . SN1 . . . . . . 110 079 . . SNUBBER, poly MF .5uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . CR1 . . . . . 052 251 . . RELAY, volt sense 100V DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 16 . . . . . 2T . . . . . 038 081 . . BLOCK, term 30A 4P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . T2 . . . . . 035 759 . . TRANSFORMER, control mintr 115/36VCT . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 18 . . . . C23 . . . . . 139 204 . . CAPACITOR, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 19 . . . FC1,2 . . . . . 110 142 . . PULSE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 20 . . . . . 1T . . . . . 038 833 . . BLOCK, term 20A 13P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 21 . . . . . . . . . . . . . . 107 794 . . ENCLOSURE, circuit card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 22 . . . PLG20 . . . 039 347 . . TERMINAL, hdr 17skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 003 168 . . TERMINAL, frict fem mintr 20-18 wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
. . 23 . . . . . . . . . . . . . . 035 506 . . GUIDE, circuit card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 24 . . . PLG3 . . . . 039 358 . . TERMINAL, hdr 35skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 003 168 . . TERMINAL, frict fem mintr 20-18 wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
. . 25 . . . . . . . . . . . . . . 000 020 . . PANEL, encl circuit card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 26 . . . . PC1 . . . . . . 110 459 . . CIRCUIT CARD, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 27 . . . . PC2 . . . . . 052 790 . . CIRCUIT CARD, HF & post-flow timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 28 . . . . SR1 . . . . . . 119 939 . . RECTIFIER, SCR main (Fig 10-14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 29 . . . . . . . . . . . . . . 007 097 . . TUBING, stl .500 OD x .060 x 1.437 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 30 . . . . . . . . . . . . . Fig 10-13 . . PULSER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 31 . . . . . S1 . . . . . 059 518 . . CIRCUIT BREAKER, 2P 225A 600VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 32 . . . . . . . . . . . . . . 080 309 . . CIRCUIT CARD, meter calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 33 . . . . . A . . . . . . 059 494 . . METER, amp ac/dc 0-750 scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 34 . . . . . V . . . . . . 004 189 . . METER, volt ac/dc 0-100 scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 35 . . . . PL1 . . . . . 027 645 . . LIGHT, indicator 125VAC red lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 36 . . . . . . . . . . . . . ♦097 922 . . KNOB, pointer .875dia x .250 ID (included w/item 11) . . . . . . . . . . . . . . . . 1
. . 37 . . . . . . . . . . . . . . 097 922 . . KNOB, pointer .875dia x .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 38 . . . . . . . . . . . . . ♦097 922 . . KNOB, pointer .875dia x .250 ID (included w/item 8) . . . . . . . . . . . . . . . . . 1
. . 39 . . . . . . . . . . . . . . 019 603 . . KNOB, ball 1.250 OD w/.250-20 fthrd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 40 . . . . . . . . . . . . . . 097 926 . . KNOB, pointer 2.375dia x .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 41 . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . 1
♦OPTIONAL
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-350 Page 42
Item
No.
Dia.
Mkgs.
Part
No.
Description
059 081
... 1
... 2
... 3
... 4
... 5
... 6
... 7
... 8
... 9
. . 10
. . 11
. . 12
. . 13
. . 14
. . . . . . . . . . . . . . 048 314
. . . . . S5 . . . . . 059 084
. . . . . . . . . . . . . . 025 181
. . . . . . . . . . . . . . 104 935
. . . . . . . . . . . . . . 020 484
. . . . . S5 . . . . . 059 083
. . . . . . . . . . . . . . 003 230
. . . . . . . . . . . . . ♦021 193
. . . . . . . . . . . . . . 010 086
. . . . . S7 . . . . . 059 082
. . . . . . . . . . . . . . 004 696
. . . . . . . . . . . ♦♦004 267
. . . . . . . . . . . ♦♦080 346
. . . . . . . . . . . . . . 080 348
Quantity
Figure 10-8. Switch, Range/Polarity/Selector (Fig 10-7 Item 1)
..
..
..
..
..
..
..
..
..
..
..
..
..
..
STUD, stl .250-20 x 9.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTACT BOARD ASSEMBLY, switch selector ac/dc (Fig 10-9) . . . . . .
TUBING, stl .625 OD x 12ga x .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, mtg switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TUBING, stl .625 OD x 12ga x .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTACT BOARD ASSEMBLY, switch selector ac/dc (Fig 10-10) . . . . .
TUBING, stl .625 OD x 12ga x 2.625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GUIDE, contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPACER, polarity switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTACTOR BOARD ASSEMBLY, switch polarity (Fig 10-11) . . . . . . . .
BRACKET, mtg switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LINK, jumper switch (ac/dc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LINK, jumper switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1
6
2
2
1
2
2
2
1
2
1
1
1
1
Fig 10-9
2
3
4
5
3
Fig 10-10
6
7
8
9
4
Fig 10-11
10
5
14
3
4
13
12
11
SC-127 634
Figure 10-8. Switch, Range/Polarity/Selector
♦Item part of 059 082 polarity switch contact board assembly.
♦♦Items are not part of 059 081 parts list.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-350 Page 43
Item
No.
Part
No.
Description
Figure 10-9. Contact Board Assembly, Switch Selector AC/DC
(Fig 10-8 Item 2)
059 084
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
1 . . . . . 604 318
2 . . . . . 070 318
3 . . . . . 103 632
4 . . . . . 039 257
5 . . . . . . 011 645
6 . . . . . . 011 074
7 . . . . . . 011 953
8 . . . . . . 011 075
9 . . . . . 103 633
10 . . . . . 011 950
11 . . . . . . 011 948
12 . . . . . 011 951
13 . . . . 070 317
14 . . . . . 011 645
15 . . . . . 011 075
16 . . . . . 011 953
17 . . . . . 011 074
18 . . . . 103 632
19 . . . . 020 484
20 . . . . 024 694
21 . . . . 103 634
Quantity
. . NUT, stl slflkg hex hvy .250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTACT BOARD, movable switch (consisting of) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . PLATE, switch tgl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONTACT ASSEMBLY, movable switch (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . . . SPRING, pressure contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . CONTACT, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . SPRING, pressure contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUS BAR, shorting switch polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTACT, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GUIDE, contact movable switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTACT, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTACT BOARD ASSEMBLY, movable switch (consisting of) . . . . . . . . . . . . .
. . . . CONTACT ASSEMBLY, movable switch (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . . . SPRING, pressure contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . CONTACT, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . SPRING, pressure contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . PLATE, switch tgl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TUBING, stl .625 OD x 12ga x .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BEARING, polarity switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MOUNTING BOARD, component polarity switch . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
2
1
2
1
2
2
4
2
1
1
1
2
1
1
1
2
1
2
3
Includes
Item 4
5
6
7
8
9
10
11
1
12 Includes
Item 18
13
15
14
16
17
4
20
19
11
21
11
9
10
20
18
SA-127 633
Figure 10-9. Contact Board Assembly, Switch Selector AC/DC
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-350 Page 44
Item
No.
Part
No.
Description
Figure 10-10. Contact Board Assembly, Switch Selector AC/DC
(Fig 10-8 Item 6)
059 083
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
1 . . . . . 604 318
2 . . . . . 070 318
3 . . . . . 039 257
4 . . . . . . 011 645
5 . . . . . . 011 075
6 . . . . . . 011 074
7 . . . . . . 011 953
8 . . . . . 103 632
9 . . . . . . 011 951
10 . . . . . 011 950
11 . . . . . . 011 948
12 . . . . 070 317
13 . . . . . 011 645
14 . . . . . 011 075
15 . . . . . 011 953
16 . . . . . 011 074
17 . . . . 103 632
18 . . . . 020 484
19 . . . . 024 694
20 . . . . 103 634
Quantity
. . NUT, stl slflkg hex hvy .250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTACT BOARD, movable switch (consisting of) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONTACT ASSEMBLY, movable switch (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . . . SPRING, pressure contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . SPRING, pressure contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . CONTACT, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . · PLATE, switch tgl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTACT, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTACT, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GUIDE, contact movable switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTACT BOARD ASSEMBLY, movable switch (consisting of) . . . . . . . . . . . . .
. . . . CONTACT ASSEMBLY, movable switch (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . . . SPRING, pressure contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . CONTACT, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . SPRING, pressure contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . PLATE, switch tgl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TUBING, stl .625 OD x 12ga x .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BEARING, polarity switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MOUNTING BOARD, component polarity switch . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
1
1
2
1
4
4
4
1
2
1
2
1
1
1
2
1
2
4
8
Includes 6
Item 5
7
5
Includes
Item 3
9
10
11
1
10
9
Includes
Item 17
14
12
13
15
16
3
19
11
20
19
11
17
18
SA-127 632
Figure 10-10. Contact Board Assembly, Switch Selector AC/DC
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-350 Page 45
Item
No.
Part
No.
Description
059 082
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
1 . . . . . 020 484
2 . . . . . 070 317
3 . . . . . . 011 645
4 . . . . . . 011 075
5 . . . . . . . 011 07
6 . . . . . . 011 953
7 . . . . . 103 632
8 . . . . . 103 633
9 . . . . . 103 634
10 . . . . . 011 948
11 . . . . . 070 316
12 . . . . . 011 645
13 . . . . . 011 075
14 . . . . . 011 953
15 . . . . . 011 074
16 . . . . 010 805
17 . . . . 103 632
18 . . . . 604 318
19 . . . . 024 694
Quantity
Figure 10-11. Contact Board Assembly, Switch Polarity (Fig 10-8 Item 10)
. . TUBING, stl .625 OD x 12ga x .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTACT BOARD ASSEMBLY, movable switch (consisting of) . . . . . . . . . . . . .
. . . . CONTACT ASSEMBLY, movable switch (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . . . SPRING, pressure contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . SPRING, pressure contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . CONTACT, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . PLATE, switch tgl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUS BAR, shorting switch polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MOUNTING BOARD, component polarity switch . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GUIDE, contact movable switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTACT BOARD ASSEMBLY, movable switch (consisting of) . . . . . . . . . . . . .
. . . . CONTACT ASSEMBLY, movable switch (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . . . SPRING, pressure contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . CONTACT, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . SPRING, pressure contact switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . PLATE, switch tgl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, stl slflkg hex hvy .250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BEARING, polarity switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
2
1
4
1
2
1
2
1
2
1
1
1
1
2
2
3
Includes 5
Item 4
6
7
4
8
1
9
10
8
Includes
Item 16 & 17
13
11
12
14
15
19
18
19
8
17
10
16
SA-127 631
Figure 10-11. Contact Board Assembly, Switch Polarity
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-350 Page 46
Item
No.
Dia.
Mkgs.
Part
No.
Quantity
Model
Spot Preflow
Timer
Timer
Description
Figure 10-12. Spot Timer And Preflow Timer (Fig 10-7 Items 8 & 11)
. . . 1 . . . . S200 . . . . . 011 609
. . . 1 . . . . S200 . . . . . 011 611
. . . 2 . . . . . . . . . . . . . . 000 821
. . . 3 . . . . . . . . . . . . . . 106 625
. . . 4 . . . . PC3 . . . . . 006 797
. . . . . . . . PLG30 . . . 135 558
. . . . . . . . . . . . . . . . . . . 079 747
. . . 4 . . . . PC4 . . . . . 006 799
. . . . . . . . PLG40 . . . 135 558
. . . . . . . . . . . . . . . . . . . 079 747
. . . 5 . . . . R205 . . . . 028 769
. . . 5 . . . . R205 . . . . 005 577
. . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SWITCH, tgl DPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STRIP, mtg pot/pwb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . SPACER, nyl .250 OD x .140 ID x 1.000 lg . . . . . . . . . . . . . . . . . . . 4 . . . .
. . CIRCUIT CARD, spot timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . . . . . . 1
. . . . TERMINAL, contact hdr 24-18 wire . . . . . . . . . . . . . . . . . . . . . . . 7
. . CIRCUIT CARD, preflow timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . .
. . . . TERMINAL, contact hdr 24-18 wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . POTENTIOMETER, C stld sft 1/T 2W 750K ohm . . . . . . . . . . . . . 1
. . POTENTIOMETER, C stld sft 1/T 2W 200K ohm . . . . . . . . . . . . . . . . . . . .
1
2
1
1
4
1
1
7
1
3
4
5
SA-006 613-B
Figure 10-12. Spot Timer And Preflow Timer
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-350 Page 47
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-13. Pulser Control (Fig 10-7 Item 30)
... 1 ....................
. . . 2 . . . . . . R422 . . . . . . .
... 3 ....................
... 4 ....................
. . . . . . . . . . . PLG60 . . . . . . .
.........................
. . . . . . . . . . . PLG61 . . . . . . .
.........................
. . . 5 . . . . . . R420 . . . . . . .
. . . 6 . . . . . . R421 . . . . . . .
. . . 7 . . . . . . S400 . . . . . . .
003 513
035 897
106 625
072 810
135 558
079 747
135 560
079 747
004 186
030 109
011 609
. . STRIP, mtg controls/pwb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . POTENTIOMETER, C sltd sft 1/T 2W 1000 ohm . . . . . . . . . . . . . . .
. . SPACER, nyl .250 OD x .140 ID x 1.000 lg . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD, pulser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . . . . . . .
. . . . TERMINAL, contact hdr 24-18 wire . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . . . . . . .
. . . . TERMINAL, contact hdr 24-18 wire . . . . . . . . . . . . . . . . . . . . . . . . .
. . POTENTIOMETER, C sltd sft 1/T 2W 5000 ohm . . . . . . . . . . . . . . .
. . POTENTIOMETER, C sltd sft 1/T 2W 5000 ohm . . . . . . . . . . . . . . .
. . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1
1
4
1
1
7
1
9
1
1
1
4
2
1
5
6
7
SB-006 612-D
Figure 10-13. Pulser Control
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-350 Page 48
Item
No.
Dia.
Mkgs.
Part
No.
Description
119 939
...
...
...
...
...
...
...
1
2
3
4
5
6
7
. . . . . . . . . . . . . . 083 884
. . . . . . . . . . . . . . 059 075
. . . . . . . . . . . . . . 028 516
. . SCR1-4 . . . . 112 941
. . . . . . . . . . . . . . . 010 311
. C7-10,R3-6 . 044 468
. . . . . D1 . . . . . 023 178
Quantity
Figure 10-14. Rectifier, SCR Main (Fig 10-7 Item 28)
..
..
..
..
..
..
..
CLAMP, thyristor rectifier 4.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEAT SINK, rectifier snowflake 5.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PIN, spring CS .125 x .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THYRISTOR, SCR 700A 300V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, nyl .750 clamp dia x .500 wide . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPPRESSOR, .5uf 200V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIODE, rect 275A 300V RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
8
4
4
4
2
1
2
3
4
3
7
6
5
1
SC-127 636
Figure 10-14. Rectifier, SCR Main
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-350 Page 49
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