Miller THUNDERBOLT AC/DC Owner's Manual

 June 1988 FORM: OM-316B
Effective With Serial No. JJ320735
MODEL
“THUNDERBOLT® AC/DC
OWNER’S MANUAL
Read and understand the entire contents of this manual, Miller Electric Mfg. Co.
with special emphasis on the safety material throughout the manual, A Milier Group Lid. Company
before installing, operating, or maintaining this equipment. This unit and PO. Box 1079
these instructions are for use only by persons trained and experienced in Appleton, WI 54912 USA
the safe operation of welding equipment. Do not allow untrained persons Tel. 414-734-9821
to install, operate, or maintain this unit. Contact your distributor if you
do not fully understand these instructions.
PRINTED IN U.S.A,
CONGRATULATIONS
You have selected one of the finest welding power sources manufactured. MILLER Electric arc
welding equipment is used throughout the world and has an established reputation for quality per-
formance and construction. -
You should enjoy many hours of welding with your Thunderbolt power source. We suggest that
you read this manual thoroughly in order to familiarize yourself with the capabilities of this equip-
ment.
Thank you for selecting MILLER.
MILLER Electric Mfg. Co.
LIMITED WARRANTY
4 EFFECTIVE: FEBRUARY 16, 1988
6 This warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY - Subject to the terms and condi-
tions hereof, Miller Electric Mfg. Co., Appleton, Wisconsin
warrants to its Distributor/Dealer that all new and unused
Equipment furnished by Miller is free from defect in workman-
ship and material as of the time and place of delivery by Miller.
No warranty is made by Miller with respect to engines, trade
accessories or other items manufactured by others. Such
engines, trade accessories and other items are sold subject to
the warranties of their respective manufacturers, if any . All
engines are warranted by their manufacturer for one year from
date of original purchase, except Tecumseh engines which
have a two year warranty.
Except as specified below, Miller's warranty does not apply
to components having normal useful life of less than one (1)
year, such as spot welder tips, relay and contactor points,
MILLERMATIC parts that come in contact with the welding
wire including nozzles and nozzle insulators where failure does
not result from defect in workmanship or material.
Miller shall be required to honor warranty claims on war-
ranted Equipment in the event of failure resulting from a defect
within the following periods from the date of delivery of Equip-
ment to the original user:
Arc welders, power sources, robots, and components . 1 year
1.
2. Loadbanks ............. iii, 1 year
3. Original main powerrectifiers ................. 3 years
(labor - 1 year only)
4. All welding guns, feeder/guns and torches . . . .. 90 days
5. All other Millermatic Feeders ................... 1 year
6. Replacement or repair parts, exclusive of labor .. 60 days
7. Batterie . 00 6 months
provided that Miller is notified in writing within thirty (30) days
of the date of such failure.
As a matter of general policy only, Miller may honor claims
submitted by the original user within the foregoing periods.
e Career 19 e * В or? J i eee? ен *
in the case of Miller's breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedies
therefore shall be, at Millers option (1) repair or (2) replacement
or, where authorized in writing by Miller in appropriate cases, (3)
the reasonable cost of repair or replacement at an authorized
Miller service station or (4) payment of or credit for the purchase
price (less reasonable depreciation based upon actual use) upon
retum of the goods at Customer's risk and expense. MILLER's
option of repair or replacement will be F.O.B., Factory, at
Appleton, Wisconsin, or F.O.B., at a MILLER authorized service
facility, therefore, no compensation for transportation costs of
any kind will be allowed. Upon receipt of notice of apparent
defect or failure, Miller shall instruct the claimant on the warranty
claim procedures to be followed.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA.
TION AS TO PERFORMANCE, AND ANY REMEDY FOR
BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW.
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX
CLUDED AND DISCLAIMED BY MILLER.
EXCEPT AS EXPRESSLY PROVIDED 8Y MILLER IN
WRITING, MILLER PRODUCTS ARE INTENDED FOR
ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED AND
EXPERIENCED IN THE USE AND MAINTENANCE OF
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR
CONSUMER USE. MILLER'S WARRANTIES DO NOT EXTEND
TO, AND NO RESELLER IS AUTHORIZED TO EXTEND
MILLER'S WARRANTIES TO, ANY CONSUMER.
Essense TABLE OF CONTENTS Emm ОАОННЛЕАСОАООАООААННАОАННАННя
Section No. Page No.
SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER
SOURCE -
1-1. introduction.............eeeeeeceeceeenuiro:arec ee eoceareca 1
1-2. General Precautions ...............ceecow._.eceerececdoredodececao 1
1-3. Arc Welding...............eooeoc.c.esre:eecorececereeeevar 4
1-4. Standards Booklet Index .............—...o.ee.ceeecerecedeece. 6
SECTION 2 - INTRODUCTION
2-1. General Information And Safety ...............e.oeeérececoreoo 7
2-2. Receiving-Handling ............_o_eeeeecorodioreceorerceceeo.. 7
2-3. Description ...........e _eeee0eorederreereea eeococoaore.. 7
SECTION 3 - INSTALLATION
3-1. Location... sea aa aa ea ee a de ee ad da a de ne da aa en 8
3 - 2. Weld Output Cable Preparations..................... 8
3 - 3. Electrical Input Connections ...............esesecueorererecec, 9
SECTION 4 - OPERATOR CONTROLS
4 - 1. Power Switch ..... cc iii iii eee eee 10
4-2. AC/DC Coarse Amperage Range Selection ..................... 10
4 - 3. Amperage Adjustment Control .............eeee.ercereocooe. 11
4 - 4. Volt-Ampere Curves..........eoweo._.eee.erecrrerecadoraocaaard 11
4 - 5. Очи1у Сус!е........................, Cree rie ea 11
SECTION 5 - SEQUENCE OF OPERATION |
5 - 1. Shielded Metal Arc (SMAW) Welding ..... onearearereerrecooa 11
5-2. Shutting Down ...........wo_..ee0co.evecororooorever. sa ae» 12
SECTION 6 - MAINTENANCE & TROUBLSHOOTING
6-1. Transformer........10200 0024 aa ee sa a aa wa ae a ae a ae aa a nana à 13
6-2. Movable Shunt.............o occecererzer:ererecirercacaroaoo 13
6 - 3. Fan Motor ...........eo_._eovvcceroecdorecrore irene recaroaaa 13
6 - 4. Anti-Noise Block Adjustment ................... iii. 13
6 - 5. Troubleshooting Chart...............ooee.ecoreredereorea de 14
SECTION 7 - PRINCIPLES OF SHIELDED METAL ARC WELDING
7 - 1. General.............o_onrrevrccsccrorror ar aceaeaiedaararen nao 17
7-2. Striking The Arc-Running Beads ...........ñ.eeee_eeonresararono. 17
7-3. Weaving droco Tenor en 18
7-4. ButtJoints............eo_xonccocerrecoreacrarerrenrerecóocva, 19
7-5. Tee And Lap Joints..........._eoecrecdorecvereororerevcevero 20
7-6. Welding Vertically, Horizontally, And Overhead...............cw.. 21
7-7. Conclusion............ o mrrceereenvoceroreneoccocareraoraraa 23
mSECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCEm
1-1. INTRODUCTION - We learn by experience.
Learning safety through personal experience, like a
child touching a hot stove is harmful, wasteful, and un-
wise. Let the experience of others teach you.
Safe practices developed from experience in the use of
welding and cutting are -described in this manual.
Research, development, and field experience have
evolved reliable equipment and safe installation, opera-
tion, and servicing practices. Accidents occur when
equipment is improperly used or maintained. The
reason for the safe practices may not always be given.
Some are based on common sense, others may require
technical volumes to explain. It is wiser to follow the
rules,
Read and understand these safe practices before at-
tempting to install, operate, or service the equipment.
Comply with these procedures as applicable to the par-
ticular equipment used and their instruction manuals,
for personal safety and for the safety of others.
Failure to observe these safe practices may cause
serious injury or death. When safety becomes a habit,
the equipment can be used with confidence.
. These safe practices are divided into two Sections:
1 - General Precautions, common to arc welding and
cutting; and 2 - Arc Welding (and Cutting) (only).
Reference standards: Published Standards on safety are
also available for additional and more complete pro-
cedures than those given in this manual. They are listed
in the Standards Index in this manual. ANSI Z49.1 is
the most complete.
The National Electrical Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements also provide a basis for equip-
ment installation, use, and service.
1-2. GENERAL PRECAUTIONS
Different arc welding processes, electrode alloys,
and fluxes can produce different fumes, gases,
and radiation levels. in addition to the information
in this manual, be sure to consult flux and elec-
trode manufacturers for specific technical data
and precautionary measures concerning their
material.
A. Burn Prevention
Wear protective clothing - gauntlet gloves designed for
use in welding, hat, and high safety-toe shoes. Button
shirt collar and pocket flaps, and wear cuffless trousers
to avoid entry of sparks and slag.
Wear helmet with safety goggles or glasses with side
shields underneath, appropriate filter lenses or plates
(protected by clear cover glass). This is a MUST for
welding or cutting, (and chipping) to protect the eyes
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
Avoid oily or greasy clothing. A spark may ignite them.
Hot metal such as electrode stubs and workpieces
should never be handled without gloves.
Medical first aid and eye treatment. First aid facilities
and a qualified first aid person should be available for
each shift unless medical facilities are close by for im-
mediate treatment of flash burns of the eyes and skin
burns.
Ear plugs should be worn when working on overhead or
in a confined space. A hard hat should be worn when
others work overhead.
Flammable hair preparations should not be used by per-
sons intending to weld or cut.
B. Toxic Fume Prevention
Severe discomfort, illness or death can result from
fumes, vapors, heat, or oxygen enrichment or depletion
that welding (or cutting) may produce. Prevent them
with adequate ventilation as described in ANS| Stan-
dard 249.1 listed 1 in Standards index. NEVER ventilate
with oxygen.
Lead -, cadmium -, zinc -, mercury -, and beryllium -
bearing and similar materials, when welded (or cut) may
produce harmful concentrations of toxic fumes. Ade-
quate local exhaust ventilation must be used, or each
person in the area as well as the operator must wear an
air-supplied respirator. For beryllium, both must be us-
ed.
Metals coated with or containing materials that emit
toxic fumes should not be heated uniess coating is
removed from the work surface, the area is well ven-
tilated, or the operator wears an air-supplied respirator.
Work in a confined space only while it is being ven-
tilated and, if necessary, while wearing an air-supplied
respirator.
Gas leaks in a confined space should be avoided.
Leaked gas in large quantities can change oxygen con-
centration dangerously. Do not bring gas cylinders into
a confined space.
Leaving confined space, shut OFF gas supply at source
to prevent possible accumulation of gases in the space
if downstream valves have been accidently opened or
left open. Check to be sure that the space is safe before
re-entering it.
Vapors from chlorinated solvents can be decomposed
by the heat of the arc (or flame) to form PHOSGENE, a
OM-316 Page 1
highly toxic gas, and other lung and eye irritating pro-
ducts. The ultraviolet (radiant) energy of the arc can
also decompose trichloroethylene and per-
chloroethylene vapors to form phosgene. DO NOT
WELD or cut where solvent vapors can be drawn into
the welding or cutting atmosphere or where the radiant
energy can penetrate to atmospheres containing even
minute amounts of trichloroethylene or per-
chloroethylene.
C. Fire and Explosion Prevention
Causes of fire and explosion are: combustibles reached
by the arc, flame, flying sparks, hot slag or heated
material; misuse of compressed gases and cylinders;
and short circuits.
BE AWARE THAT flying sparks or falling slag can pass
through cracks, along pipes, through windows or
doors, and through wall or floor openings, out of sight
of the goggled operator, Sparks and slag can fly 35 feet.
To prevent fires and explosion:
Keep equipment clean and operable, free of oil, grease,
and (in electrical parts) of metallic particles that can
cause short circuits.
If combustibles are in area, do NOT weld or cut. Move
the work if practicable, to an area free of combustibles.
Avoid paint spray rooms, dip tanks, storage areas, ven-
tilators. If the work cannot be moved, move com-
bustibles at least 35 feet away out of reach of sparks
and heat; or protect against ignition with suitable and
snug-fitting, fire-resistant covers or shields.
Walls touching combustibles on opposite sides should
not be welded on (or cut). Walls, ceilings, and floor near
work should be protected by heat-resistant covers or
shields.
Fire watcher must be standing by with suitable fire ex-
tinguishing equipment during and for some time after
welding or cutting if:
a. appreciable combustibles (including building
construction) are within 35 feet
b. appreciable combustibles are further than 3b
feet but can be ignited by sparks
c. openings (concealed or visible) in floors or
walls within 35 feet may expose com-
bustibles to sparks
d. combustibles adjacent to walls, ceilings,
rcofs, or metal partitions can be ignited by
radiant or conducted heat.
Hot work permit should be obtained before operation to
ensure supervisor's approval that adequate precautions
have been taken.
After work is done, check that area is free of sparks,
glowing embers, and flames.
An empty container that held combustibles, or that can
produce flammable or toxic: vapors when heated, must
OM-316 Page 2
never be welded on or cut, unless container has first
been cleaned as described in AWS Standard A6.0,
listed 7 in Standards index. -
This includes: a thorough steam or caustic cleaning (or
a solvent or water washing, depending on the com-
bustible's solubility) followed by purging and inerting
with nitrogen or carbon dioxide, and using protective
equipment as recommended in A6.0. Waterfilling just
below working level may substitute for inerting.
A container with unknown contents should be cleaned
(see paragraph above). Do NOT depend on sense of
smell or sight to determine if it is safe to weld or cut.
Hollow castings or containers must be vented before
welding or cutting. They can explode.
Explosive atmospheres. Never weld or cut where the air
may contain flammable dust, gas, or liquid vapors (such
as gasoline).
D. Compressed Gas Equipment
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-1, SAFE
HANDLING OF COMPRESSED GASES IN
CYLINDERS, listed 11 in Standards index.
1. Pressure Regulators
Regulator relief valve is designed to protect only the
regulator from overpressure; it is not intended to
protect any downstream equipment. Provide such
protection with one or more relief devices.
Never connect a regulator to a cylinder containing
gas other than that for which the regulator was
designed.
Remove faulty regulator from service immediately
for repair (first close cylinder valve). The following
symptoms indicate a faulty regulator:
Leaks - if gas leaks externally.
Excessive Creep - if delivery pressure continues to
rise with downstream valve closed.
Faulty Gauge - if gauge pointer does not move off
stop pin when pressurized, nor returns to stop pin
after pressure release.
Repair. Do NOT attempt repair. Send faulty
regulators for repair to manufacturer's designated
repair center, where special techniques and tools
are used by trained personnel.
2. Cylinders
Cylinders must be handled carefully to prevent
leaks and damage to their walls, valves, or safety
devices:
Avoid electrical circuit contact with cylinders in-
cluding third rails, electrical wires, or welding cir-
cuits. They can produce short circuit arcs that may
lead to a serious accident. (See 1-3C.)
ICC or DOT marking must be on each cylinder. It is
an assurance of safety when the cylinder is properly
handled.
Identifying gas content. Use only cylinders with
name of gas marked on them; do not rely on color to
identify gas content. Notify supplier if unmarked.
NEVER DEFACE or alter name, number, or other
markings on a cylinder. It is illegal and hazardous.
Empties: Keep valves closed, replace caps securely;
mark MT; keep them separate from FULLS and
return promptly.
Prohibited use. Never use a cylinder or its contents for
other than its intended use, NEVER as a support or
roller.
Locate or secure cylinders so they cannot be knocked
over.
Passageways and work areas. Keep cylinders clear of
areas where they may be struck.
Transporting cylinders. With a crane, use a secure sup-
port such as a platform or cradle. Do NOT lift cylinders
off the ground by their valves or caps, or by chains,
slings, or magnets.
Do NOT expose cylinders to excessive heat, sparks,
slag, and flame, etc. that may cause rupture. Do not
allow contents to exceed 130°F. Cool with water spray
where such exposure exists.
Protect cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when moving cylinders.
Stuck valve. Do NOT use a hammer or wrench to open
a cylinder valve that can not be opened by hand. Notify
your supplier.
Mixing gases. Never try to mix any gases in a cylinder.
Never refill any cylinder.
Cylinder fittings should never be modified or exchang-
ed.
3. Hose
Prohibited use. Never use hose other than that designed
for the specified gas. A general hose identification rule
is: red for fuel gas, green for oxygen, and black for inert
gases.
Use ferrules or clamps designed for the hose (not or-
dinary wire or other substitute) as a binding to connect
hoses to fittings.
No copper tubing splices. Use only standard brass fit-
tings to splice hose.
Avoid long runs to prevent kinks and abuse. Suspend
hose off ground to keep it from being run over, stepped
on, or otherwise damaged.
Coil excess hose to prevent kinks and tangles.
Protect hose from damage by sharp edges, and by
sparks, slag, and open flame.
Examine hose regularly for leaks, wear, and loose con-
nections. Immerse pressured hose in water; bubbles in-
dicate leaks.
Repair leaky or worn hose by cutting area out and splic-
ing (1-2D3). Do NOT use tape.
4. Proper Connections
Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing
outlet away from people and sources of ignition. Wipe
with a clean lintless cloth.
Match regulator to cylinder. Before connecting, check
that the regulator label and cylinder marking agree, and
that the regulator inlet and cylinder outlet match.
NEVER CONNECT a regulator designed for a particular
gas or gases to a cylinder containing any other gas.
Tighten connections. When assembling threaded con-
nections, clean and smooth seats where necessary.
Tighten. If connection leaks, disassemble, clean, and
retighten using properly fitting wrench.
Adapters. Use a CGA adapter (available from your sup-
plier) between cylinder and regulator, if one is required.
Use two wrenches to tighten adapter marked RIGHT
and LEFT HAND threads.
Regulator outlet (or hose) connections may be iden-
tified by right hand threads for oxygen and left hand
threads (with grooved hex on nut or shank) for fuel gas.
5. Pressurizing Steps:
Drain regulator of residual gas through suitable vent
before opening cylinder (or manifold valve) by turning
adjusting screw in (clockwise). Draining prevents ex-
cessive compression heat at high pressure seat by
allowing seat to open on pressurization. Leave adjusting
screw engaged slightly on single-stage regulators.
Stand to side of regulator while opening cylinder valve.
Open cylinder valve slowly so that regulator pressure in-
creases siowly. When gauge is pressurized (gauge
reaches regulator maximum) leave cylinder valve in
following position: For oxygen, and inert gases, open
fully to seal stem against possible leak. For fuel gas,
open to less than one turn to permit quick emergency
shutoff.
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on
regulators.
Check for leaks on first pressurization and regularly
there-after. Brush with soap solution (capful of Ivory
OM-316 Page 3
Liquid* or equivalent per gallon of water). Bubbles in-
dicate leak. Clean off soapy water after test; dried soap
is combustible.
E. User Responsibilities
Remove leaky or defective equipment from service im-
mediately for repair. See User Responsibility statement
in equipment manual.
F. Leaving Equipment Unattended
Close gas supply at source and drain gas.
G. Rope Staging-Support
Rope staging-support should not be used for welding or
cutting operation; rope may burn.
1-3. ARC WELDING - Comply with precautions in
1-1, 1-2, and this section. Arc Welding, properly done,
is a safe process, but a careless operator invites trouble.
The equipment carries high currents at significant
voltages. The arc is very bright and hot. Sparks fly,
fumes rise, ultraviolet and infrared energy radiates,
weldments are hot, and compressed gases may be us-
ed. The wise operator avoids unnecessary risks and pro-
tects himself and others from accidents. Precautions
are described here and in standards referenced in index.
A. Burn Protection
Comply with precautions in 1-2.
The welding arc is intense and visibly bright. Its radia-
tion can damage eyes, penetrate lightweight clothing,
reflect from light-colored surfaces, and burn the skin
and eyes. Skin burns resemble acute sunburn, those
from gas-shielded arcs are more severe and painful.
DON'T GET BURNED; COMPLY WITH PRECAU-
TIONS.
1. Protective Clothing
Wear long-sleeve clothing (particularly for gas-shielded
arc) in addition to gloves, hat, and shoes (1-2A). As
necessary, use additional protective clothing such as
leather jacket or sleeves, flame-proof apron, and fire-
resistant leggings. Avoid outergarments of untreated
cotton.
Bare skin protection. Wear dark, substantial clothing.
Button collar to protect chest and neck and button
pockets to prevent entry of sparks.
2. Eye and Head Protection
Protect eyes from exposure to arc. NEVER look at an
electric arc without protection.
Welding helmet or shield containing a filter plate shade
no. 12 or denser must be used when welding. Place
over face before striking arc.
*Trademark of Proctor 6 Gamble.
OM-316 Page 4
Protect filter plate with a clear cover plate.
Cracked or broken helmet or shield should NOT be
worn; radiation can pass through to cause burns.
Cracked, broken, or loose filter plates must be replaced
IMMEDIATELY. Replace clear cover plate when
broken, pitted, or spattered.
Flash goggles with side shields MUST be worn under
the helmet to give some protection to the eyes should
the helmet not be lowered over the face before an arc is
struck. Looking at an arc momentarily with unprotected
eyes (particularly a high intensity gas-shielded arc) can
cause a retinal burn that may leave a permanent dark
area in the field of vision.
3. Protection of Nearby Persannel
Enclosed welding area. For production welding, a
separate room or enclosed bay is best. In open areas,
surround the operation with low-reflective, non-
combustible screens or panels. Allow for free air circula-
tion, particularly at floor level.
Viewing the weld. Provide face shields for all persons
who will be looking directly at the weld.
Others working in area. See that all persons are wearing
flash goggles.
Before starting to weld, make sure that screen flaps or
bay doors are closed.
B. Toxic Fume Prevention
Comply with precautions in 1-2B.
Generator engine exhaust must be vented to the outside
air. Carbon monoxide can kill.
C. Fire and Explosion Prevention
Comply with precautions in 1-2C.
Equipment's rated capacity. Do not overload arc
welding equipment. It may overheat cables and cause a
fire.
Loose cable connections may overheat or flash and
cause a fire.
Never strike an arc on a cylinder or other pressure
vessel. It creates a brittle area that can cause a violent
rupture or lead to such a rupture later under rough
handling.
D. Compressed Gas Equipment
Comply with precautions in 1-2D.
E. Shock Prevention
Exposed hot conductors or other bare metal in the
welding circuit, or in ungrounded, electrically-HOT
equipment can fatally shock a person whose body
becomes a conductor. DO NOT STAND, SIT, LIE,
LEAN ON, OR TOUCH a wet surface when welding,
without suitable protection.
To protect against shock: .
Keep body and clothing dry. Never work in damp area
without adequate insulation against electrical shock.
Stay on a dry duckboard, or rubber mat when damp-
ness or sweat can not be avoided. Sweat, sea water, or
moisture between body and an electrically HOT
part - or grounded metal - reduces the body surface
electrical resistance, enabling dangerous and possibly
lethal currents to flow through the body.
1. Grounding the Equipment
When arc welding equipment is grounded according to
the National Electrical Code, and the work is grounded
according to ANSI 249.1 “Safety In Welding And Cut-
ting,” a voltage may exist between the electrode and
any conducting object. Examples of conducting objects
include, but are not limited to, buildings, electrical
tools, work benches, welding power source cases,
workpieces, etc. Never touch the electrode and any
metal object unless the welding power source is
off.
When installing, connect the frames of each unit such
as welding power source, control, work table, and
water circulator to the building ground. Conductors
must be adequate to carry ground currents safely.
Equipment made electrically HOT by stray current may
shock, possibly fatally. Do NOT GROUND to electrical
conduit, or to a pipe carrying ANY gas or a flammable li-
quid such as oil or fuel.
Three-phase connection. Check phase requirements of
equipment before installing. If only 3-phase power is
available, connect single-phase equipment to only two
wires of the 3-phase line. Do NOT connect the equip-
ment ground lead to the third (live) wire, or the equip-
ment will become electrically HOT - a dangerous condi-
tion that can shock, possibly fatally.
Before welding, check ground for continuity. Be sure
conductors are touching bare metal of equipment
frames at connections.
if a line cord with a ground lead is provided with the
equipment for connection to a switchbox, connect the
ground lead to the grounded switchbox. If a three-
prong plug is added for connection to a grounded
mating receptacle, the ground lead must be connected
to the ground prong only. If the line cord comes with a
three-prong plug, connect to a grounded mating recep-
tacle. Never remove the ground prong from a plug, or
use a plug with a broken off ground prong.
2. Electrode Holders
Fully insulated electrode holders should be used. Do
NOT use holders with protruding screws.
3. Connectors
Fully insulated lock-type connectors should be used to
join welding cable lengths.
4. Cables
Frequently inspect cables for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn
- or damaged insulation to avoid possibly - lethal shock
from bared cable. Cables with damaged areas may be
taped to give resistance equivalent to original cable.
Keep cable dry, free of oil and grease, and protected
from hot metal and sparks.
5. Terminals And Other Exposed Parts
Terminals and other exposed parts of electrical units
should have insulating covers secured before operation.
6. Electrode
a. Equipment with output on/off control (con-
tactor)
Welding power sources for use with the gas
metal arc welding (GMAW), gas tungsten
arc welding (GTAW) and similar processes
normally are equipped with devices that per-
mit on-off control of the welding power out-
put. When so equipped the electrode wire
becomes electrically HOT when the power
source switch is ON and the welding gun
switch is closed. Never touch the electrode
wire or any conducting object in contact
with the electrode circuit unless the welding
power source is off.
b. Equipment without output on/off control
(no contactor)
Welding power sources used with shielded
metal arc welding (SMAW) and similar pro-
cesses may not be equipped with welding
power output on-off control devices. With
such equipment the electrode is electrically
HOT when the power switch is turned ON.
Never touch the electrode unless the
welding power source is off.
7. Safety Devices
Safety devices such as interlocks and circuit breakers
should not be disconnected or shunted out.
Before installation, inspection, or service, of equip-
ment, shut OFF all power and remove line fuses (or lock
ОМ-316 Раде 5
or red-tag switches) to prevent accidental turning ON of
power. Disconnect all cables from welding power
source, and pull alt 115 volts line-cord plugs.
Do not open power circuit or change polarity while
welding. If, in an emergency, it must be disconnected,
guard against shock burns, or flash from switch arcing.
Leaving equipment unattended. Always shut OFF and
disconnect all power to equipment.
Power disconnect switch must be available near the
welding power source.
F. Protection For Wearers Of Electronic Life
Support Devices (Pacemakers)
Magnetic fields from high currents can affect
pacemaker operation. Persons wearing electronic life
support equipment (pacemaker) should consult with
their doctor before going near arc welding, gouging, or
spot welding operations,
1-4. STANDARDS BOOKLET INDEX
For more information, refer to the following standards
or their latest revisions and comply as applicable:
1. ANSI Standard 749.1, SAFETY IN WELDING
AND CUTTING obtainable from the American
Welding Society, 550 Le Jeune Rd, Р.О. Вох
351040, Miami, FL 33135.
2. NIOSH, SAFETY AND HEALTH IN ARC
WELDING AND GAS WELDING AND CUTTING
obtainable from the Superintendent of
Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
3. OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the U.S. Govern-
ment Printing Office, Washington, D.C. 20402.
4. ANSI Standard 287.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
5. ANSI Standard Z41.1, STANDARD FOR MEN'S
SAFETY-TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
OM-316 Page 6
10.
11.
12.
13.
14.
15.
ANSI Standard 249.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO-
CESSES obtainable from the American National
Standards Institute, 1430 Broadway, New York,
NY 10018.
AWS Standard A6.0, WELDING AND CUT-
TING CONTAINERS WHICH HAVE HELD COM-
BUSTIBLES obtainable from the American
Welding Society, 550 Le Jeune Rd.
Р.О. Box 351040, Miami FL 33135.
NFPA Standard 51, OXYGEN - FUEL GAS
SYSTEMS FOR WELDING AND CUTTING ob-
tainable from the National Fire Protection
Association, 470 Atlantic Avenue, Boston, MA
02210.
NFPA Standard 70-1978, NATIONAL ELEC-
TRICAL CODE obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
NFPA Standard 51B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS obtainable
from the Compressed Gas Association, 500 Fifth
Avenue, New York, NY 10036.
CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the
Canadian Standards Association, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada: M9W 1R3.
NWSA booklet, WELDING SAFETY
BIBLIOGRAPHY obtainable from the National
Welding Supply Association, 1900 Arch Street,
Philadelphia, PA 19103.
American Welding Society Standard AWSF4.1
“Recommended Safe Practices for the Prepara-
tion for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances’,
obtainable from the American Welding Society,
550 Le Jeune Rd. P.O. Box 351040, Miami, FL. 33135.
ANSI Standard Z88.2 ‘Practice for Respiratory
Protection’’ obtainable from the American Na-
tional Standards Institute, 1430 Broadway, New
York, NY 10018.
A SECTION 2 - INTRODUCTION. IA EEE
Input At Rated
Max. Load Output 80 Hertz
Welding Current Current Output Circuit Approx.
Volta Am 9 At Weight
Ranges Amperes at 25 Voits a = Overall 9
Model AC HIGH | AC LOW DC 20% Duty Cycle | AC DC | 230V | 380V | 460V | 575V | kw Dimensions Net Ship
Without 230 Meight - 21-1/2 in,
P.F. Correction Amperas 45.6 | 27.5 | 22.7 | 18.2 | 72 (548 mm)
AC Width - 12-1/2 in. 1 114 Iba, | 119 Iba.
40-230 | 30-150 | 20-150 150 80 | 72 (318 mm) (62 kg) | (64 kg)
With 7 Amperes 39.6 à 23.9 | 19.7 | 15.7 | 7.2 Depth - 14 in.
P.F. Correction DC {368 mm)
NOTE: “The power factor correcting capacitors supplied in this product contain no PCB's. The dielectric material is an OSHA Class It! B fluid having a flash point of 440°F,
(227% C.). Each individual capacitor is protected by an internal UL recognized pressure sensitive disconnact and an internal fuse.”
Figure 2-1. Specifications
2-1. GENERAL INFORMATION AND SAFETY
A. General
Information presented in this manual and on various
labels, tags, and plates provided on this unit pertains to
equipment design, installation, operation, maintenance
and troubleshooting which should be read, understood
and followed for the safe and effective use of this equip-
ment.
The nameplate of this unit uses international symbols
for labeling front panel controls. The symbols also ap-
pear at the appropriate section in the text.
B. Safety
The installation, operation, maintenance, and
troubleshooting of arc welding equipment requires
practices and procedures which ensure personal safety
and the safety of others. Therefore, this equipment is to
be installed, operated and maintained only by qualified
persons in accordance with this manual and all ap-
plicable codes such as, but not limited to, those listed at
the end of Section 1 - Safety Rules For Operation Of
Arc Welding Power Source.
Safety instructions specifically pertaining to this unit ap-
pear throughout this manual highlighted by the signal
words ДЕЙ and which identify
different levels of hazard.
statements include installation, operating,
and maintenance procedures or practices which if not
carefully followed could result in serious personal injury
or loss of life.
statements include installation, operating
and maintenance procedures or practices which if not
carefully followed could result in minor personal injury
or damage to this equipment.
A third signal word, TXT IF DIE, highlights instruc-
tions which need special emphasis to obtain the most
efficient operation of this equipment.
2-2. RECEIVING-HANDLING - Prior to installing
this equipment, clean all packing material from around
the unit and carefully inspect for any damage that may
have occurred during shipment. Any claims for loss or
damage that may have occurred in transit must be filed
by the purchaser with the carrier. A copy of the bill
of lading will be furnished by the manufacturer on re-
quest if occasion to file claim arises.
When requesting information concerning this equip-
ment, it is essential that Model Description and Style
Number of the equipment be supplied.
2-3. DESCRIPTION - This unit is a constant current
ac/dc arc welding power source with single-phase elec-
trical input. It is designed for Shielded Metal Arc
Welding (SMAW).
Rated output is 230 amperes ac, 1560 amperes dc at 25
volts, 20% duty cycle.
ОМ-316 Раде 7
Ese SECTION 3 - INSTALLATION A
A
a Z *19-1/2 in.
(495 mm)
D
Ls A
XZ
3174 in, aoe in.
317 mm) ( mm
Зи — TB-087 026
*Add 2 in. (51 mm)
for handie
Figure 3-1. Dimensional Drawing
СИЕ ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
. Disconnect input power plug or conductors from
1. Keep cables as short as possible and place cables
close together. Excessive cable length adds
resistance which may reduce output or cause
overloading of the unit.
2. Select adequate size welding cable for the an-
ticipated maximum weld current. Use total
length of welding cable in the circuit to deter-
mine cable size. For example: If the electrode
holder cable is 75 feet (23 m) long and the work
cable is 25 feet (7.6 m) long, select the size cable
recommended in Table 3-1 for 100 ft (31 m).
3. Do not use damaged or frayed cables.
4. Install electrode holder to cable following
manufacturer's instructions. An insulated elec-
trode holder must be used to ensure operator
safety.
5. Install a correct size lug onto one end of work
cable, and instal! work clamp to cable.
6. Install jack plugs onto cables as instructed in
Subsection B.
Table 3-1. Welding Cable Size
3-1.
deenergized supply line BEFORE moving unit.
LOCATION
RESTRICTED AIR FLOW causes
overheating and possible damage to internal
parts.
e Maintain at least 18 inches (457 mm) of
unrestricted space on all sides of unit.
e Do not place any filtering device over the intake air
passages of this welding power source. |
Warranty is void if any type of filtering device is used.
The service life and efficiency of this unit are reduced
when the unit is subjected to high levels of dust, dirt,
moisture, corrosive vapors, and extreme heat.
3-2. WELD OUTPUT CABLE PREPARATIONS
(> OUTPUT
To obtain the full rated output from this unit, it is
necessary to select, install, and maintain proper welding
cables. Failure to comply in any of these areas may
result in less than satisfactory welding performance.
A. Welding Cables
If welding cables were not ordered with this unit, the
steps listed should be followed to ensure the best
welding performance:
OM-316 Page 8
WELDING *TOTAL LENGTH OF CABLE ( COPPER! IN WELD CIRCUIT
AMPERESI “50 100 150 200 250 300 350 400
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 2 2 1 - 1/0 2/0 3/0 4/0 4/0
250 1 1 1/0 2/0 3/0 4/0 4/0 2-2/0
A-002 624
NOTE: ‘А. 50 FEET OR LESS.
“8. CABLE SIZE IS BASED ON DIRECT CURRENT (DC),
60% DUTY CYCLE AND EITHER A 4 VOLTS OR LESS
DROP OR A CURRENT DENSITY OF NOT OVER 300
CIRCULAR MILS PER AMP.
*C. WELD CABLE INSULATION WITH A VOLTAGE
RATING TO WITHSTANO THE OPEN-CIRCUIT VOLT-
AGE (OCV) OF THE WELDING POWER SOURCE MUST
BE USED. WHILE MOST WELDING POWER SOURCES
HAVE AN OPEN-CIRCUIT VOLTAGE OF LESS THAN
100 VOLTS, SOME WELDING POWER SOURCES OF
SPECIAL DESIGN MAY HAVE HIGHER OPEN CIRCUIT
VOLTAGE.
B. Jack Plug installation
The red and black jack plugs are supplied to provide cor-
rect connections to the weld output receptacles. Con-
nect the red jack plug to the Electrode Holder cable and
the black jack plug to the Work clamp cable as follows:
1. Remove 1 inch (25.4 mm) of insulation from one
end of welding cable.
2. Clamp cable in a vise with the uninsulated end
extending upward out of vise approximately
1-3/4 inches (44.5 mm).
3. Place steel tie wire (item A) approximately 1/4
inch (6.4 mm) from end of insulation.
4. Make a half turn around the cable bringing
looped ends of tie wire together.
D
98
E АА)
ТА-901 024-4
5. Inserta 3/8 inch (9.5 mm) diameter rod through
looped ends of tie wire.
6. Twist tie wire (B) until entire tie wire is twisted
and is tight around insulation of cable.
7. Clip off looped ends of tie wire.
8. Bend the twisted tie wire over and along the side
(C) of uninsulated portion of cable.
9. Wrap the strip of copper foil tightly around unin-
sulated end of cable and twisted tie wire (D).
10. Push the jack plug onto cable over copper foil
(E).
11. Insert the 1/4-20 setscrews into the center and
bottom holes in jack plug and tighten (E).
12. Remove cabie from vise and insert jack plug into
insulating sleeve. Slide insulating sleeve over
jack plug and cable until hole in insulating sleeve
lines up with remaining hole in jack plug (F).
13. Insert the 8-32 self-tapping screw (F) through
hole in insulating sleeve into jack plug and
tighten.
3-3. ELECTRICAL INPUT CONNECTIONS
€ ) meu
A. Electrical Input Requirements
This welding power source is designed to be operated
from single-phase, 60 Hertz, ac input power which has
a voltage rating that corresponds with one of the elec-
trical input voltages shown on the nameplate. Consult
the local electric utility if there is any question about the
type of electrical system available at the installation site
or how proper connections to the welding power source
are to be made.
B. Input Conductor Connections
ELECTRIC SHOCK can kill.
e /nstall a fusible line disconnect switch in the input
circuit to the welding power source.
This provides a safe and convenient means to complete-
ly remove all electrical power from the welding power
source whenever it is necessary to inspect or service the
unit.
e Employ “lockout/tagging procedures” on input
line before making input connections to the
welding power source.
Lockout/tagging procedures consist of removing plug
from receptacle, padlocking line disconnect switch in
open position, removing fuses from fuse box, or red-
tagging circuit breaker or other disconnecting device.
Table 3-2 provides guidelines for selecting the proper
size input conductors and line fuses. The input conduc-
tors should be covered with an insulating material that
meets local electrical standards.
Table 3 - 2. Input Conductor And Fuse Size
Input Conductor Size AWG*
Model 230V | 380V | 460V | 575V
wl 10 | 12 | 14 | 14
WO PEC E (12) | (14) | (14) | (14)
12 12 14 14
WIPFC | (12) | (14) | (14) | (14)
Fuse Size In Amperes
Model 230V | 380V | 460V | 575V
W/O PFC** 90 25 45 35
W/PFC 80 | 25 | 45 30
*Input conductor sizes are based on National Electrical
Code specifications for allowable ampacities of insulated
copper conductors, having a temperature rating of 75°C,
with not more than three conductors in a raceway or cable.
Numbers in ( } are equipment ground conductor sizes.
**PFC = Power Factory Correction
C. Wall Receptacle And Power Cable (Figure
3-3)
All models are ordinarily equipped with a three-
conductor power cable. Models requiring 230 volts in-
put are equipped with a three-prong polarized plug and
wall receptacle. The wall receptacle should be installed
in a convenient location by a competent electrician. The
~ wall receptacle should be installed with the grounding
terminal at the top. This would allow the power cable to
hang downward without undue bending or twisting.
Models having an electrical input voltage above 250
volts have power cables with 3 conductors. The black
and white conductors must be connected to the line ter-
minals and the green conductor to a proper ground. Use
a grounding method that is acceptable to the locai elec-
trical inspection authority.
ELITE ELECTRIC SHOCK can Kill.
Do not connect an input (white or black) conduc-
tor to the ground terminal,
® Do not connect the ground (green) conductor to
an input line terminal.
OM-316 Page 9
Ground Line Disconnect
Conductor Switch
Ground Lead
Terminai
Line Terminal
L2
0
ву ны Receptacle
ТА-901 858-2А
Line Terminal
L1
Figure 3-3. Input Conductor Connections
— SECTION 4 - OPERATOR CONTROLS TES
Amperage Adjustment Control
Amperage Indicator
Scale ay >
Power Switch
Electrode 40-230
Receptacle
A
Electrode 30-150 —
Receptacle
Work Receptacle
Positive
Receptacle Negative
Receptacle
TB-087 026
Figure 4-1. Operator Controls
4-1. POWER SWITCH (Figure 4-1)
owen LY | on
О or
Placing the POWER switch in the ON position energizes
the welding power source, making the unit operational.
Placing the POWER switch in the OFF position shuts
the unit down.
RILLGLNIDISE ELECTRIC SHOCK can kill.
e Do not touch live electrical parts.
® Disconnect input power and employ
“lockout/tagging procedures’ before internally
inspecting or servicing.
OM-316 Page 10
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.
4-2. AC/DC COARSE AMPERAGE RANGE
SELECTION (Figure 4-1)
EIZLLIDISE ELECTRIC SHOCK can kill; ARCING
can burn skin or damage electrical connections.
e Do not touch live electrical parts.
e Fnsure that the unit is completely shut down
before making any weld output connections.
® Do not change position of the welding cable jack
plugs while welding.
e Be sure that jack plugs are secure in correct recep-
tacles before welding.
Three ac receptacles, labeled ELECTRODE 30-150 and
40-230, and WORK provide selection of low amperage
(30-150 amperes) and high amperage (40-230 amperes)
ranges for ac output. Two dc receptacles, labeled
POSITIVE and NEGATIVE provide selection of a single
range for dc output. Insert the electrode cable jack plug
into the appropriate ELECTRODE receptacle and the
work cable jack plug into the WORK receptacle for ac
output.
For welding applications requiring less
than 150 amperes, use the ELECTRODE 30-150
amperage range rather than the ELECTRODE 40-230
amperage range since better arc characteristics are ob-
tained due to higher open-circuit voltage.
For dc reverse polarity output, connect the electrode
cable to the POSITIVE receptacle and the work cable to
the NEGATIVE receptacle. For dc straight polarity, con-
nect the electrode cable to the NEGATIVE receptacle
and the work cable to the POSITIVE receptacle.
4-3. AMPERAGE ADJUSTMENT CONTROL
(Figure 4-1)
The Amperage Adjustment control provides fine
amperage adjustment within the range selected.
Rotating the control clockwise increases amperage out-
put.
The AMPERAGE indicator scale displays the amperage
selected by the Amperage Adjustment control. The in-
dicator scale is calibrated for the dc range and for the
high and low ac ranges.
4-4, VOLT-AMPERE CURVES (Figure 4-2) - The
volt-ampere curves show the voltage and amperage
80
70 Fr
o
o
y
А = Low Range
B = High Range
A C VOLTS
© me uu
o © o
E y
Dz
“2
O.
Т
А
o
1
| | 1 1 à
o 50 100 150 200 250 300
AC AMPERES B-001 944
190
90 |
80
DC VOLTS
0 50 100 150 200 250 300
DC AMPERES
8-086 728
Figure 4-2. Volt-Ampere Curves
Voltage and amperage adjustment within each range is
provided by the Amperage Adjustment Control.
output capabilities of the welding power source at the
minimum and maximum of each amperage range.
With the use of the voltage-ampere curves it is possible
to determine the load voltage at the minimum and max-
imum settings of the Amperage Adjustment Control.
Curves of other settings will fall between the minimum
and maximum curves shown,
4-5. DUTY CYCLE (Figure 4-3) - The duty cycle of
the welding power source is the percentage of a ten
minute period that a welding power source can be
operated at a given output current setting without caus-
ing overheating and damage to the unit. This welding
power source is rated at 20 percent duty cycle. This
means the welding power source can be operated at
rated load welding current for two minutes out of every
ten. If the welding current is decreased, the duty cycle
will increase. Figure 4-3 enables the operator to deter-
mine the output of the welding power source at various
duty cycles.
EXCEEDING DUTY CYCLE RATINGS
will damage the welding power source.
® Do not exceed duty cycle indicated on duty cycle
chart,
~ RATED OUTPUT
300
250
200 |
9 |
e 180 | >
—
> > NN |
< |} mx
© | >
2 100 1 < АС
a | ь <
„=
WJ | N
= 7
| N DC
|
60
10 15 20 30 40 50 60 70 80 90 100
% DUTY CYCLE |
В-086 727
Figure 4-3. Duty Cycle Chart
Ts SECTION 5 - SEQUENCE OF OPERATION mum E Te Ds
ELECTRIC SHOCK can kill; MOVING
PARTS can cause serious injury; IMPROPER AIR
FLOW AND EXPOSURE TO ENVIRONMENT can
damage internal parts.
e Do not touch live electrical parts.
e Keep clear of pinch points.
® 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.
e Ventilate to keep from breathing fumes and gases.
© /f ventilation is inadequate, use approved
breathing apparatus.
WELDING WIRE can cause puncture wounds.
e Do not point gun toward any part of the body, any
conductive surface, or other personnel.
HOT METAL, SPATTER, AND SLAG can cause fire
and burns,
e Watch for fire.
e Have a fire extinguisher nearby, and know how to
use it.
© Allow work and equipment to cool before handl-
ing.
OM-316 Page 11
MAGNETIC FIELDS FROM HIGH CURRENTS can
affect pacemaker operation.
e Wearers should consult with 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 infor-
mation.
5-1. SHIELDED METAL ARC (SMAW) WELDING
{Figure 5-1)
DC Reverse
Polarity Connections
Shown
Positive
Receptacle —
Negative
Receptacle
TB-087 025
Work
Receptacie > «
Electrode 30-150
Receptacie ~~
TB-087 024
AC Output
Figure 5 - 1. Shielded Metal Arc Welding Connec-
tions
1. Make electrical input connections as instructed
in Section 3.
2. Make ac/dc coarse amperage range selection as
instructed in Section 4-2.
3. Rotate the Amperage Adjustment control to the
desired amperage.
4. Connect the work clamp to the item to be weld-
ed.
5, Place the desired electrode into the Electrode
Holder (see Figure 5-1).
OM-316 Page 12
5-2. SHUTTING DOWN
1.
Place the POWER switch in the ON position.
Commence welding.
Readjust the Amperage Adjustment control if
necessary. The Amperage Adjustment control
may be adjusted while welding.
Break the arc.
2. Place the POWER switch in the OFF postion.
ELECTRODE
POSITION
ALL
DEEP
ALL
DEEP
MIN. PREP, ROUGH,
HIGH SPATTER
ALL
LOW
GENERAL
7014
ALL
MED
SMOOTH, EASY,
FAST
7018
ALL
LOW
LOW HYDROGEN,
STRONG
7024
FLAT
HORIZ.
FILLET
LOW
SMOOTH, EASY,
FASTER
Ni-CI
EP
ALL
LOW
CAST IRON
308L
EP
vr
ALL
LOW
STAINLESS
*EP =ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
AMPERES
MIN
6010
6011
3/32
1/8
5/32
3/16
50A
100A
150A
200A
MAX
6013
1/16
5/64
3/32
1/8
5/32
3/16
7014
3/32
1/8
5/32
7018
3/32
1/8
5/32
7024
3/32
1/8
5/32
Ni-CI
3/32
1/8
5/32
3/16
308L
3/32
1/8
5/32
la
Figure 5-2. Electrode Guide & Amperage Ranges
Charts
mms SECTION 6 - MAINTENANCE & TROUBLESHOOTING uuu maes
Every six months inspect the labels on
the 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 all
precautionary labels.
6-1. TRANSFORMER
HZ ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
® Shut down unit and disconnect input power
employing “lockout/tagging procedures” before
inspecting, maintaining, or servicing.
Lockout/tagging procedures consist of removing plug
from receptacle, padlocking line disconnect switch in
open position, removing fuses from fuse box, or shut-
ting off and red-tagging circuit breaker or other discon-
necting device.
Every six months blow out dust and dirt from around
the transformer using dry compressed air of 80 psi
(651.6 kPa) or less. If dirty or dusty conditions are pre-
sent, blow out the transformer every month.
We YVAN MR Warranty is void if unit failure is due
to accumulation of dirt in components.
6-2. MOVABLE SHUNT (Figure 6-1)
RILCGIIDICE ELECTRIC SHOCK can Kill.
e Do not touch live electrical parts.
e Shut down unit and disconnect input power
employing “lockout/tagging procedures” before
inspecting, maintaining, or servicing.
Lockout/tagging procedures consist of removing plug
from receptacle, padlocking line disconnect switch in
open position, removing fuses from fuse box, or shut-
ting off and red-tagging circuit breaker or other discon-
necting device.
Lubricate the shaft and sliding areas of the shunt ap-
proximately once a year. Apply a light coat of high
temperature grease, taking care to avoid getting grease
on any electrical components of the welding power
source.
6-3. FAN MOTOR
ELECTRIC SHOCK can kill.
e Do not touch live electrical parts.
® Shut down unit and disconnect input power
employing “lockout/tagging procedures” before
inspecting, maintaining, or servicing.
Lockout/tagging procedures consist of removing plug
from receptacle, padlocking line disconnect switch in
open position, removing fuses from fuse box, or shut-
ting off and red-tagging circuit breaker or other discon-
necting device. |
All models are equipped with an exhaust fan and rely on
forced draft for adequate cooling. Every six months
blow out dust and dirt from the fan motor using dry
compressed air of 80 psi or less. If dirty or dusty condi-
tions are present, clean the unit every month. The fan
motor bearings require no periodic maintenance.
WILY W-N\\'AM Warranty is void if unit failure is due
to accumulation of dirt in components.
6-4. ANTI-NOISE BLOCK ADJUSTMENT (Figure
6-1)
EZLN ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
® Shut down unit and disconnect input power
employing “lockout/tagging procedures’ before
inspecting, maintaining, or servicing.
Lockout/tagging procedures consist of removing plug
from receptacle, padlocking line disconnect switch in
open position, removing fuses from fuse box, or shut-
ting off and red-tagging circuit breaker or other discon-
necting device.
Warranty is void if the unit is operated with any portion
of the outer enclosure removed.
This adjustment is provided to compensate for vibration
noises should they arise. This adjustment eliminates
vibration noises by applying pressure against the
movable shunt.
If it becomes necessary to perform an anti-noise block
adjustment, proceed as follows:
1. Remove the locking pin from the Amperage Ad-
justment control handle (pry up; slide out).
2. Remove the Amperage Adjustment control han-
die from shaft (slide off upward).
3. Remove screws, and lift wrapper off from unit.
4, Place Amperage Adjustment control handle back
on shaft. (Handle needs to be in place to rotate
the shaft when cleaning and lubricating the
shunt.)
5. Slide locking pin into Amperage Adjustment
control handle, and snap locking pin forward to
lock it in place.
Clean and lubricate the shunt before
performing the following adjustment. (See Section
6-2).
6. Locate the adjustment screws, and loosen lock-
ing nuts on each screw.
7. Use a screwdriver to tighten adjustment screws
1/4 turn.
8. Tighten locking nuts on screws.
9. Remove Amperage Adjustment control handle:
install and secure wrapper; reinstall Amperage
Adjustment control handle. Energize unit and
check for shunt noise.
OM-316 Page 13
10. If shunt noise is still present, repeat procedure,
turning adjustment screws in 1/4 turn in-
crements until the noise stops.
Do not overtighten shunt. OQOver-
tightening the shunt can produce a hard cranking situa-
tion when the Amperage Adjustment control is rotated.
If vibration noise cannot be eliminated without over
tightening the shunt, call a serviceperson.
Amperage Adjustment
Control Handle
Wrapper
Screws
* Adjustment Screws
‘Locking Nuts
TD-062 395
*Items have a quantity
of 4 each
Figure 6-1. Location Of Anti-Noise Block Adjust-
ment Screws
6-5. TROUBLESHOOTING CHART
KALI ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
® Shut down unit and disconnect input power
employing “lockout/tagging procedures’ before
inspecting, maintaining, or servicing.
Lockout/tagging procedures consist of removing plug
from receptacle, padlocking line disconnect switch in
open position, removing fuses from fuse box, or shut-
ting off and red-tagging circuit breaker or other discon-
necting device.
MOVING PARTS can cause serious injury.
® Keep clear of moving parts.
HOT SURFACES can cause severe burns.
® Allow cooling period before servicing.
Troubleshooting to be performed only by qualified per-
sons.
It is assumed that the unit was properly installed accor-
ding to Section 3 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 chart is designed to diagnose and provide
remedies for some of the troubles that may develop in
this welding power source.
Use this chart in conjuntion with the circuit diagram
while performing troubleshooting procedures. If the
trouble is not remedied after performing these pro-
cedures, the nearest Factory Authorized Service Sta-
tion should be contacted. In all cases of equipment
malfunction, the manufacturer's recommendations
should be strictly followed.
TROUBLE
PROBABLE CAUSE
REMEDY
No weld ouput; fan does | No input power.
not run,
Be sure Line Disconnect switch is in the On posi-
tion.
breaker.
Open line fuse or circuit
Check line fuses and replace if open. Reset circuit
breaker.
POWER switch $1.
Replace S1.
Fan does not run; weld out-
put available.
Fan blade obstruction.
Remove obstruction and check fan blade. If fan
blade does not move freely, replace fan motor.
Fan motor FM.
Replace FM.
Arc hard to start; erratic.
Using wrong ELECTRODE
The ELECTRODE 30-150 receptacle will provide
receptacle. better arc starting for some electrodes. Tty both
ELECTRODE receptacles.
Arc erratic, with excessive | Damp electrode. Use dry, properly stored electrodes.
spatter.
Arc length too iong.
Shorten arc length.
Amperage setting too high.
Reduce amperage (see Nameplate).
OM-316 Page 14
TROUBLE
PROBABLE CAUSE
REMEDY
Electrode freezing to work.
Damp electrode.
Use dry, properly stored electrodes.
Arc length too short.
Increase arc length.
Amperage setting too low.
Increase amperage (see Nameplate).
Narrow,
high-crowned
weld bead. -
Travel speed too fast.
Reduce travel speed.
Amperage setting too low.
Increase amperage (see Nameplate).
Weld metal burns through
base metal.
Amperage setting too high.
Reduce amperage (see Nameplate).
Travel speed too slow.
Increase travel speed.
Weld metal doesn’t
1 penetrate base metal.
Arc length too long.
Shorten arc length.
Travel speed too fast.
Reduce travel speed.
Amperage setting too low.
Increase amperage (see Nameplate).
Poor joint design.
Redesign joint,
Poor fusion of weld metal
with base metal.
Surface contaminants in
the joint area.
Thoroughly clean joint area.
Incorrect electrode angie.
Use correct electrode angle.
Incorrect electrode size.
Use correct electrode size for base material
thickness {see Nameplate).
Poor joint design.
Redesign joint.
Arc length too long.
Shorten arc length.
Travel speed too fast.
Reduce travel speed.
Amperage setting too low.
Increase amperage (see Nameplate).
Slag trapped in weld.
Poor bead placement.
Center electrode in joint.
Incorrect electrode angle.
Use correct electrode angle.
Arc length too long.
Shorten arc length.
Travel speed too fast.
Reduce travel speed.
Amperage setting too low.
Increase amperage (see Nameplate).
Gas pockets or voids on the
surface or inside a welding
bead.
Arc length too long.
Shorten arc length.
Amperage setting too high.
Reduce amperage (see Nameplate).
Gas trapped in weld bead.
Travel speed irregular.
Maintain smooth even travel speed.
OM-316 Page 15
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Figure 6 - 2. Circuit Diagram For 230 Volts Models
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DIAGRAM APPLICABLE FOR
VOLTAGES ABOVE 230 VOLTS
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Figure 6 - 3. Circuit Diagram For Models Above 230 Volts
OM-316 Page 16
— SECTION 7 - PRINCIPLES OF SHIELDED METAL ARC WELDING ————
1-1. GENERAL - Shielded Metal Arc Welding with a
transformer welding machine depends upon the fun-
damental fact that when one side of the secondary
welding circuit is attached to a piece of steel and the
other side of the circuit is connected to an electrode, an
arc will be established when the electrode touches the
steel. If the arc is properly controlled, the metal from the
electrode will pass through the arc and be deposited on
the steel. When the electrode is moved along the steel
at the correct speed, the metal will deposit a uniform
layer called a bead. The electrodes used in welding are
carefully manufactured to produce strong, sound
welds. They consist of a core of steel wire, usually call-
ed mild since it contains a low (0.10-0.14) percentage
of carbon. Around this core is applied a special coating
which assists in creating the arc and at the same time
protects the molten steel as it transfers across the arc.
In order to utilize these principles in Shielded Metal Arc
Welding, some means of controlling the power is essen-
tial. The power in a welding circuit is determined by the
voltage and current. The arc voltage is governed by the
arc length and the electrode diameter. Therefore, the
practical measure of the power or heat is in terms of the
current, measured in amperes. A small electrode re-
quires less current than a large one. To simplify opera-
tions, the scale on the front of the welding machine is
marked off for the various current values.
The exact current required for a job depends upon the
size of the pieces to be welded and the position of
welding. Generally a lower current will be sufficient for
welding on a small part than would be necessary to
weld on a large piece of the same thickness. Similarly,
with a given size of electrode, a lower current should be
used on thin metals than on the thicker sections. Most
manufacturers of electrodes have ampere recommenda-
tion charts available.
Table 7-1. Current Requirements For Mild Steel
Electrodes
CURRENT REQUIREMENTS
FOR MILD STEEL
ELECTRODES
Electrode Amperage
Diameter Min. Max.
5/64 20 50
3/32 40 80
1/8 65 125
5/32 90 160
3/16 120 180
BUTT FILLET
Figure 7-1. Flat Position Welds
While it is always easier to weld on work in the flat posi-
tion, as shown in Figure 7-1, occasionally, it is
necessary to weld in a horizontal vertical or overhead
position as shown in Figures 7-2, 7-3, and 7-4, respec-
tively. Generally, under these conditions it is helpful te
reduce the current from the value used on welding in
the flat position.
=
BUTT FILLET
Figure 7-3. Vertical Position Welds
a= Cg
Figure 7-4. Overhead Position Welds
7-2. STRIKING THE ARC-RUNNING BEADS - In
learning to weld there are certain fundamental steps
which must be mastered before one can attempt to
weld on actual work. Prior to striking an arc, insert the
electrode in the holder, as shown in Figure 7-5. To
strike an arc, Figure 7-6 illustrates what is commonly
known as the “scratch start technique.” In this method
the striking end of the electrode is dragged across the
work in a manner much the same as striking a match.
When the electrode touches the work, the welding cur-
rent starts. If held in this position, the electrode would
“freeze” or weld itself to the work. To overcome this,
the electrode should be slightly withdrawn from the
work immediately after contact has been made. The
distance that the electrode is withdrawn is small and
depends upon the diameter of the electrode; this
distance is known as the arc length. If in striking an arc,
the electrode freezes, it may be freed by a quick twist of
the wrist.
Figure 7-5. Electrode Insertion
OM-316 Page 17
ARC
ESTABLISHED
Figure 7-6. Arc Initiation - Scratch Start Technique
Another method of establishing the arc is known as the
“tapping method’ as shown in Figure 7-7. The elec-
trode is brought straight down on the work and im-
mediately after contact, is withdrawn to the proper arc
length.
ARC
ESTABLISHED
Figure 7-7. Arc Initiation - Tapping Technique
Practice striking the arc using both methods. Generally
the scratch method is preferred for ac welding.
Determination of the correct arc length is difficult since
there is no ready means of measuring it. As a
preliminary guide, use about 1/16" arc lengthon 1/16"
and 3/32" electrode; for 1/8" and 5/32" electrodes
use about 1/8" arc length. As skill is acquired, the
sound of the arc will be a good guide. A short arc with
correct current will give a sharp, crackling sound.
A portion of the electrode coating forms a protective
coating called slag over the deposited weld metal. To
examine the weld, remove the slag from the weld with a
chipping hammer.
Once the knack of establishing and holding an arc has
been learned, the next step is learning to run a good
weld bead. In the beginning it is best to run beads of
weld metal on flat plates using a full electrode. Practice
moving from left to right and from right to left. The elec-
trode should be held less than perpendicular to the
work, tilting it in the direction of travel. The correct
position is shown in Figure 7-8. |
TO 16°
ELECTRODE
Cll All hd Lh LL ld LOL L
SIRECTION _
h OF WELDING —
BASE METAL
Figure 7-8. Electrode Position
A proper weld bead is illustrated in Figure 7-9. This
shows a cross-section through the bead and identifies
the various terms used in describing a weld. To produce
these results it is necessary to hold a short arc, travel at
OM-316 Page 18
a uniform speed, and feed the electrode downward at a
constant rate as it melts.
FINE SPATTER
7
. CRATER
FINE SPATTER
BEAD
BUILD UP CRATER
1/16” PENETRATION
NO OVERLAP
— aA 8
BEAD WELD
NO OVERLAY |
1/16 PENETRATION
GOOD
Figure 7-9. Proper Weld Bead
Probably the first attempts in the practice will fall short
of the results shown, Too long an arc will be held or the
travel speed will vary from slow to fast and the welds
will look as illustrated in Figure 7-10 showing a cross
section through a poor weld bead. In addition, the weld
will probably be spongy (porous) and of low strength.
LARGE SPATTER DEPOSITS
SLIGHT
CRATER
SPATTER
SLIGHT CRATER
-—
TACA nc > |
BEAD ROUGH- on 3
NOT UNIFORM NO PENETRATION 3
BAD OVERLAP
OVERLAP
; в
+
+ + +
{NO PENETRATION
Figure 7-10. Poor Weld Bead
Continue practicing until uniform beads as shown in
Figure 7-9 can be produced. A good method of practic-
ing is to deposit a series of beads, one next to the other
until the plate is covered. The slag must be thoroughly
removed between each pass. Then deposit another
series of beads at right angles to the first, thus binding
up the plate to a greater thickness.
7-3. WEAVING - When it is necessary to cover a
wider area in one pass of the electrode. a method
known as weaving is employed. in this the electrode is
moved or oscillated from side to side in a set pattern. In.
order to be sure of uniform deposits, it is necessary to
use a definite pattern such as those illustrated in Figure
7-11. While weaving is helpful, particularly when
building up metal, it should be limited to weaves not ex-
ceeding 2-1/2 times the diameter of the electrode.
or (cc
DIRECTION OF WELDING
ON
DIRECTION OF WELDING
DIRECTION OF WELDING
Figure 7-11. Weave Patterns
7-4. BUTT JOINTS - Up to this point the discussion
has covered only the deposit of beads on flat plate.
Such operations are helpful in building up worn parts or
applying hardfacing materials. The next step is learning
to weld two pieces of metal together. For this purpose,
other types of welds are illustrated in Figure 7-12.
REINFORCEMENT REINFORCEMENT
OF WELD OF WELD
>
E
Square groove weld
Single “V” groove weld
REINFORCEMENT
OF WELD
REINFORCEMENT
OF WELD
Double 'V” groove weld
Figure 7-12. Butt Joint Welds
In making weld beads previously described, it was pro-
bably noted that depositing weld metal on one side of
the plate, caused it to “curl” up towards the weld; this
is called distortion and will almost always be found
when heat is applied locally to a metal plate. Similarly in
making a butt weld, distortion will cause the edges of
the plate to draw together ahead of the electrode travel.
This is caused by the contraction of the deposited weld
metal on cooling. This may be overcome by spreading
the edges of the joint apart on a taper of about 1/8" per
foot.
Another procedure to avoid metal movement caused by
weld heat is to make short welds, tying the two pieces
together at spaced intervals. This is known as tack
welding and holds the metal in position for welding.
In making welds in a butt joint, preparation of the edges
“may be necessary to insure good results. In Shielded
Metal Arc Welding it is a common practice to weld thin
materials up to 3/16” thick without any special prepara-
tion using the square groove butt joint. For thickness of
3/16” and over, either the single or double “V” groove
is employed. Generally the single ““V'' groove will be
satisfactory on thicknesses up to 3/4”, regardless of
thickness, where one can work on the weld from one
side only.
One method for beveling steel for ‘“V’’ groove welding is
by means: of using an oxyacetylene cutting torch. The
work may be done with a hand guided torch or special
oxyacetylene cutting machine. However, in performing
this cutting, a scale will develop on the plates. This
must be removed by grinding or chipping before
welding as it is likely to become entrapped in the weld
bead and produce an unsound weld. Where ox-
yacetylene cutting equipment is not available, grinding
will probably be the best means of preparing bevels.
The ahgles of these bevels should be about 30 degrees
and the bottom edge may be left square for a distance
of about 1/16”. See Figure 7-13.
a 30°
~
‚№
v
y BOTTOM OF PLATE
Figure 7-13. Single Bevel
Practice making butt welds starting on thin material
about 1/8” thick (avoid very thin material, around
1/16” thick, in the beginning as this requires a fair
degree of skill). Separate the squared edges of the 1/8"
material about 1/16” and make a butt weld all the way
through with a 1/8" electrode. Probably the first at-
tempt will either fail to penetrate the sheet or burn
through it. Keep trying, adjusting the current within the
recommended range; also vary the electrode travel
speed to give the desired weld. Having mastered 1/8"
thick metal, proceed to similar exercise on 1/4" thick
metal. This time, however, deposit a bead on each side
of the joint and try to fuse one to the other. Since the
weld from one side is in effect an 1/8" thickness, no
bevel is needed.
Next make a single “V” groove on 1/4” plate beveled
30 degrees. Start with a 1/8” electrode at the bottom
of the groove and finish over that with a 5/32" elec-
trode. Be sure to penetrate about 1/32" beyond the
bottom of the “V” (called the root). When skill has been
acquired on the 1/4” material, proceed to 3/8” and
then to 1/2” thick metal. On these, particularly the
1/2", also make the double “V” groove butt joints.
Generally speaking, it will be necessary to deposit a
bead or layer for each 1/8” thickness. On the heavier
plates, weaving the top layers may be necessary to fill
the groove completely.
When making practice butt welds it is wise to check the
results occasionally. Where elaborate testing equipment
is not available, this may be done with a hammer and
vise.
(07 VW L,VB Caution should be observed in handling
welded pieces of metal, since weld heat absorbed by
the metal is intense and can cause serious burns.
Grip a short, welded piece with the weld just above the
jaws of the vise. Hammer it in a direction that tends to
OM-316 Page 19
open the bottom, root side of the weld, in the manner
shown in Figure 7-14. A good weld will not break under
this test, but will bend over. If the weld breaks, examine
it to determine the cause. If there are a large number of
holes (the weld looks spongy) it is porous. This is pro-
bably due to holding too long an arc. If there are bits of
slag in the weld perhaps the arc was too short or the
electrode was manipulated incorrectly thus permitting
molten slag from the electrode coating to be trapped.
This is quite likely to happen on a “V” joint made in
several layers and calls for thorough cleaning between
layers. Perhaps on breaking it will be found that the
original surface of the bevel is still evident. That means
that it was not melted and the cause is quite likely to be
found in too fast a travel speed or insufficient heat.
STRIKE
MT HERE
2" to 3"
+
Figure 7-14. Weld Test
7-5. TEE AND LAP JOINTS - The other basic type
of weld, the fillet weld, is used for making tee and lap
joints. For this type of welding, no special preparation,
- other than squared edges, is necessary. Typical welded
tee and lap joints are pictured in Figures 7-15 and 7-16
respectively.
Figure 7-16. Lap Joint
Considering the tee joint first, it will be seen immediate-
ly that the position of the pieces requires a different
method of electrode manipulation than for a butt weld.
The method of holding the electrode for butt welds will
not be satisfactory.
To deposit a single pass fillet weld, hold the electrode as
shown in Figure 7-17. This will provide fusion into the
OM-318 Page 20
corner and a fillet, the sides of which will be approx-
imately equal. For maximum strength a fillet weld
should be deposited on each side of the upright section.
When a heavier fillet is needed, deposit a second layer
as indicated in Figure 7-18, using any of the weaving
patterns shown in Figure 7-19.
ARC SHORT AND MOVED AT DEFINITE
RATE OF SPEED-NO OSCILLATION
45° OR LESS
Figure 7-17. Tee Joint Fillet Weld
INVERTED
"U” WEAVE
CIRCULA
WEAVE
Figure 7-19. Tee Joint Fillet Weld Weave Patterns
The lap joint, while involving the same fundamental
weld type as the fillet, has metal distributed differently
and therefore requires still another technique. The
details of the application are given in Figure 7-20, for a
single pass weld. For a two pass weld, Figure 7-21 pro-
vides the details.
{
30° OR LESS +”
Figure 7-20. Lap Joint Fillet Weld
Figure 7-21. Multi-Layer Deposit Lay Joint
7-6. WELDING VERTICALLY, HORIZONTALLY
AND OVERHEAD - The importance of welding in the
flat position, whenever possible, cannot be stressed too
strongly. The quality of the weld is better, the operation
easier and faster. However, occasions will arise when it
is necessary to work on parts in a position in which
welds must be deposited horizontally, vertically and
overhead. It must be realized at the very beginning that
welding in these positions is difficult and will require
constant practice to develop skill.
As in the case of welding in the flat position, it is best to
start practicing by first running: weld beads in the
various positions. Then as proficiency is gained on
thése operations, practice may be continued on butt
and fillet welds (tee and lap joints) in these positions.
One of the first facts to be noted when welding in these
positions is that the force of gravity tends to cause the
“molten metal to drip (fail) down. The technique used,
therefore, must be acquired to overcome this. Start by
making horizontal weld beads on plates inclined at 45
degrees as shown in Figure 7-22. When this has been
mastered so that uniform beads can be made con-
sistently, practice on welding vertically may be started.
Again begin with an easy operation such as running
beads vertically on plates set at 45 degrees. (See Figure
7-23).
RIGHT TO LEFT
a A a TOTO TIE
CEI ET O AY LL
—— —
LEFT TO RIGHT
45°
Plate
Figure 7-23. Vertical Weld Beads - Inclined Plate
To progress with this practice it is necessary now to
move the plates into vertical position. The details of
horizontal weld beads are given in Figure 7-24.
VERTICAL PLATE
90°
DIRECTION OF WELDING
TILT 15° TOWARD |
DIRECTION ОР 5
WELDING
Figure 7-24. Horizontal Weld Beads - Vertical Plate
Welding vertically may be performed either by welding .
upward or starting from the top and welding down. It is
generally conceded that working upward is easier and
therefore, weld beads in this manner should be practic-
ed. A method for making weave weld beads is il-'
lustrated in Figure 7-25.
Since single weld beads are of limited value, weaving *
weld beads must be practiced on butt welds in the ver-
tical and horizontal positions.
/
— 4/27 b—
o WHIPPING UP > ©
2 o 2
> 90 MOTION o
+ — Y Es
. 1
i gil WEAVE BEAD >
= WI -
asili | 1/2 = An
Figure 7-25. Weave Pattern - Vertical Plate
Figure 7-26 provides information suitable for single pass
vertical butt weld or the first pass of a multiple layer
deposit. Two methods of depositing the subsequent
layers are given in Figure 7-27.
ARROWS SHOW LIFTING
UP OF ELECTRODE AND
RETURN TO CRATER
„< A]
| AQ
N a
wad
их ; wm
= =
==. ii.
и” о
<< «Е
Y) = o
©
Q
Figure 7-26. Single Pass Vertical Butt Weld
OM-316 Раде 21
o
-1st PASS 9.
= ~~ A <>
че - > = O .
= zz > ‘25 (
Z Y LAYER = (7 7 | 5 ad
№7 ‚ в = 2:08
3 - Ow AES
Hesitate with - | 9% uw > En
slight up and = 2 3 de O |
down motion 4 нет -
Tp De o = 90° ~~.
Shorten arc © $ +
at arrow- <> | OQ Figure 7-30. Fillet Weld - Vertical Tee Joint
heads when = » 3rd 2
| at center _ LAYER For fillet welds on tee and lap joints the technique is
of weld shown in Figure 7-30. When depositing a multilayer
fillet weld, the same method would be used to deposit
the first layer on both lap and tee joints. For depositing
Hesitate at
sides with subsequent layers on tee joints two means are used and
sight up and are shown in Figure 7-31. For additional layers on lap
2 fore + joints a somewhat similar weave may be seen in Figure
7-32.
q = —
Ke) » = “oa
> © SHOWS E —
os SHOWS WEAVING I _ WEAVING 2 9
| 59 MOTION 32 MOTION XD (OS
Ш > 59 15
© og ow
a FE < =
|= ag
as O
Figure 7-27. Multi-Layer Deposit Vertical Butt
Weld
For horizontal welds details are shown in Figures 7-28 Figure 7-31
and 7-29. Note that a strip of metal is shown at the foot 9
of the weld. This is known as the backing strip. Its use
permits securing a sound root pass without great dif-
ficulty. In use, the beveled plate edges should be
centered on the backing strip and the strip tack welded
to the plates on the reverse side.
. Multi-Layer Depost - Tee Joint
WEAVING
TECHNIQUE J
DIRECTION
OF WELDING
DIRECTION
OF WELDING
Tilt 16° in
Direction
of Travel
Figure 7-28. Root Pass
DIRECTION
OF WELDING, +
Figure 7-32. Multi-Layer Deposit - Lap Joint
Welding in the overhead position is the final problem to
master. Again proceed through the steps of making
weld beads, the making of butt welds and finally the
making of fillet welds. For overhead welding, the elec-
trode position, Figure 7-33, will prove helpful. When
weaving is necessary, the pattern in Figure 7-34 may be
used. The technique for overhead butt welds is il-
lustrated in Figure 7-35; this covers single pass welds or
the first pass of multilayer welds. Subsequent beads
may be deposited as shown in Figure 7-36. For
depositing single layer fillets or the first layer of multiple
fillets in the overhead position the technique in Figure
7-37 should be employed. The sequence for depositing
beads on a muitilayer fillet weld is provided in Figure
« DIRECTION ; 7-38. Note that single beads are recommended and for
OF WELDING that reason use the same technique shown in Figure
- 7-37. Again the technique for fillet welds may be
Figure 7-29. Multi-Layer Deposit - Horizontal Butt employed for welding lap joints
Weld
OM-316 Page 22
——
DIRECTION ;
OF WELDING, 15°
0
DIRECTION OF WELDING
Figure 7-33. Electrode Figure 7-34. Weave
Position - Overhead Pattern - Overhead
Weld _ Weld
Figure 7-35. Overhead Butt Weld - Root Pass
1st PASS
2ndPASS — f 3rd PASS
1 [< 71
MET DZ —- AI 2nd LAYER |
T
By / A
Figure 7-36. Multi-Layer Deposit - Overhead Butt
Weld
VERTICAL PLATE
>
a
Figure 7-37. Overhead Weld Tee Joint - Single
Pass
— 1/2” P—
Figure 7-38. Multi-Layer Deposit - Overhead Tee
Joint
7-7. CONCLUSION - It may be appreciated that no
printed instruction can impart to the beginner all the skill
necessary for successful welding. Personal instruction
by an experienced welding operator is the best means
for accomplishing this end. Therefore, an effort should
be made to secure some facility for instruction and prac-
tice under competent supervision. In any event the
beginner should at least secure the benefit of criticism
of finished welds by a qualified welding operator.
OM-316 Page 23
Item Dia.
Part
№. Mkgs. No. Description - Quantity
Figure A Main Assembly
1 Z 086 759 STABILIZER ............eeereeoncaroreroaeeorrerevereecanrenreneov ave
2 086 950 BUS BAR, 13-5/8 inchesig ....................... WERE KERN ..
3 086 740 BUS BAR, 30 inches lg ............ñooecceccrcosorvorecocrnecorereroae,
4 C1 059 417 CAPACITOR, paper oil 30 uf 460 volts (PFC modelsonly) ..........
11
OM-316 Page 1
‘ og
ho.
TC-087 027-A
Figure A - Main Assembiy
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure A Main Assembly (Cont'd.)
5 088 372 CASE SECTION, base/front/rear.................... uN eonerocococrenco 1
6 51 090 328 SWITCH, toggle 2PST 40 amp 600 voltsac.............__.eeeeeoreceoo 1
7 024 103 BLANK, snap in-nylon 3/4 mtg hole .................e—eeoorenceciocedoa 2
8 088 299 CONNECTOR, clamp-cable 1-1/8 mtg hole (for 115/230 volts units) ......... 1
8 111 443 BUSHING, strain relief 7/8 mtg hole (for 200/230 volt unit) ................ 1
8 010 325 BUSHING, strain relief 3/4 x .840 mtg hole (units over 230 volts) ............ 1
9 023 898 CORD SET, power 230 volts 10 ga 3C 6 ft Ig (for 115/230 volt units) ......... 1
9 088 297 CORD SET, power 300 volts 12 ga 3C 6 ft Ig (for 200/230 volt units) ......... 1
9 088 298 CORD, power 600 volts 14 ga 3C 6 ft 1g (unitsover230 volts) ............... 1
10 039 778 RECEPTACLE, straight 2P3W 50 amp 250 volts .............ceco ecoococeeéoeono 1
11 009 433 HANDLE, current control ..............e.eocrceoccocoorererdececercenia 1
12 082 272 WRAPPER... ee ee ee à 1
13 009 926 PIN, handle ......................—..—........e........0aadarerecoocercaroen 1
14 T1 117 668 TRANSFORMER & SHUNT (230 volts w/o PFC) (Fig B Pg3)............... 1
14 T1 117 664 TRANSFORMER & SHUNT (230 volts w/PFC) (FigBPg3) ................ 1
14 T1 117 678 TRANSFORMER & SHUNT (380 volts w/o PFC) (Fig B Pg 3)............... 1
14 T1 117 681 TRANSFORMER & SHUNT (380 volts w/PFC) (FigBPg3) ................ 1
14 T1 117 677 TRANSFORMER & SHUNT (460 volts w/PFC E w/o PFC) (Fig B Pg 3) ...... 1
14 T1 117 673 TRANSFORMER & SHUNT (575 volts w/PFC) (FigBPg3) ................ 1
15 010 142 CLAMP, 5/16 clamp dia ...............e.eecconcoracorrerderarecenenooa 1
16 088 060 RECTIFIER, silicon diode (consisting of) ..............._..eececereeveerene. 1
17 C45 031689 . CAPACITOR, ceramic 0.01 uf 500 volts de ............._._eeeeececcorecao 2
18 D3,4 087999 .DIODE, 85 amp 300 volts RP .................—...céeseeneda0aasooreneaao 2
19 083 147 . GROMMET, screw size 8-10 .............. .eooereeooaaaaordecreorcdarao 2
20 R1,VR1 044 482 . SUPPRESSOR ..................2000d00dcarcarercoearerrorcacenreonnoao 1
21 086 949 BUS BAR, 10-7/8 incheslg ..................eee.eeocedacero recono. 1
22 005 656 BLADE, fan 6 in 4 wing 30 deg ..............e.c_oeeewewcceovcorecrddesorcaoa 1
23 FM 008 825 MOTOR, 240 volts 60/50 3000 RPM. .................... PS 1
24 103 947 TUBING, steel 5/16 x 17 ga wall x 15/16 ..............ee_ecxcorerorec en. 1
25 088 061 RECTIFIER, silicon diode (consisting of) ................_.—e.eesec00adrao. 1
26 2,3 031689 .CAPACITOR, ceramic 0.01 uf 500 volts dc ................._.eoeoeece... 2
27 D1,2 087998 .DIODE, 85 amp 300 volts SP .................ee_eoceecacaooreorecorenoo 2
083 147 .GROMMET, screw size 8-10 ..............—w_eocccoocrecuoccoreriarrenaoa 2
28 NAM EPLATE (order by model and stylenumber).......................... 1
29 — 039608 PLUG, jack-red (consisting of) ................e._ee2eomerecaorerererem. 1
29 039 901 PLUG, jack-black (consisting of). ...............___ec_ecoresoovcercoreaacana 1
30 019 833 .STRIP, copper 0.010 x2-1/2x3/4...............—eo_revcaorsodaaroernveo 1
31 010 521 .WIRE, tie............eo_recodareaocroracoroaaorecoradovancaroreonarao 1
32 602 178 . SCREW, set-socket hd 1/4-20 x 3/8 Cerne eee etree era ae à 2
33 101219 .PLUG, jack ...............—.o2e0eco0ves0neaadarecdoronoarerareorecanooncra, 1
34 602 814 .INSULATOR, redor...............—.0_r ecxcarcareocecoorenonenvenac0a. 1
34 026 978 .INSULATOR, black ..............eos-recooroooccorecrecacecar. eee 1
35 602 160 . SCREW, self 1арр!па-#ИП51ег Па 8-32 х 1/4 ............................. 1
36 057 608 RECEPTACLE, jack plug-yellow (consistingof) ................. cit. 3
36 039 801 RECEPTACLE, jack plug-black (consisting of) ...............__eeececese. 1
36 039 800 RECEPTACLE, jack plug-red (consisting of) .................eceeecececeeoeo 1
37 072 334 .RECEPTACLE E NUT, yellow or ............c_oorerccorereoaccarecoaaer. 1
37 091 542 . RECEPTACLE € NUT, black or ............eeoconcccarace dec eesrcarva, 1
37 091 541 .RECEPTACLE € NUT, red ..............eoececeneocnodscarecreooeaonven. 1
38 010 291 .WASHER, flat-nylafil 5/8 1D x 1/4 OD x 1/8 .............eocececreccocoveno 1
39 604 668. NUT, self-locking hex 1/2-20 ............_eezeeeeecororrdoreoreaieare, 2
40 605 787 .WASHER, lock-internal tooth 1/2 .............e_.eereeevveccorereneeno. 1
41 601 881 .NUT, hex-jam 1/2-20................eeereneorococorarecorecacareroa, 1
42 059 712 CLIP, cable ..........._.c_ee_eerecorecieecoreceanreraciranerermerecara 1
43 017 125 CLAMP, mtg-capacitor (PFC models only) ................ec_eeeereeroreoo 2
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-316 Page 2
Replace Coils at Factory or Factory Authorized Service Station
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure B Transformer & Shunt (Fig A Pg 2 Item 14)
1 080 522 BLOCK, anti-noise-shunt .............._..eew_r_eoerccorodoaciciaadeverdo 4
2 604 992 NUT, hex double chamfer 5/16-18...............—.—eooercecerec0ceoo0edod0m. 4
3 080 425 SCREW, set - headless 5/16-18 x 1-1/2...............ec0es00 0000000 4
4 112 569 INSULATION, coil-secondary .............—..eoocw.eexecsoeccorcceracoceaaoa | 2
5 SEC 112 488 COIL, secondary ................ee._e.ereodoareaoaranaaooa0renoneoao0 1
6 119 962 SHUNT, transformer (Fig B1 Pg4)..................e00000000000aco ee 1
7 PRI 112 498 COIL, pri (230 volts w/o PFC) ................6nece 000.00. ee. 1
7 PRI 112 492 COIL, pri (230 volts w/PFC).............o...eecccccserecere cerro ene. 1
7 PRI 112 497 COIL, pri (380 volts w/o PFC) ....................0000. 000 .ercoree 1
7 PRI 112 493 COIL, pri (380 volts w/PEC).....................erarecoeereecreacocaa 1
7 PRI 112 496 COIL, pri (460 volts w/PFC E w/o PFC) .............. e. eeesecrseea, 1
7 PRI 112 495 COIL, pri (575 volts w/o PFC) ................ e... reneceesecederida 1
7 PRI 112 491 COIL, pri(B75 volts W/PFC) . «ove eee eee ee sei 1
8 112 573 INSULATION, coil-primary ................... erecerecedecoria, 2
9 605 129 SCREW, cap-hex hd 1/4-20 X 7 ................ e anna aa anna 1
10 602 241 WASHER, flat-SAE 1/4 ..................00¿0%d222000000 00. e eceori 2
11 020 300 WEDGE, rear-removable ...............ñ.cweeeceeree0renoeo0ericer es ia, 2
12 020 301 GUIDE, wedge-rear..................eooeexrecde0nuee0aaeeaaecoeeaoa, 1
13 089 800 NUT, self locking-hex 1/4-20 ....................002d0d< 000 nana aa 1
13
Figure B - Transformer & Shunt
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-316 Page 3
Item Part
No. No. Description Quantity
Figure B1 119 962 Shunt, Transformer (Fig B Pg 3 Item 6)
+081 821 SCREW, self-tapping fillister hd 8-11 x 1/2 ..............eom_ceesoreorocven.
601 860 NUT, hex 8-32 ..............eo_ecoeeecxcécsevarrraecirocacocarecareocararcaca
009 428 SCREW, lead-shunt .............._..o.eeecec_.reovecorev0, eee
021 100 NUT, lead-screw .............—.._ceeeecreosocreroordao PP
602 087 SCREW, round-hd 8-32 x 1-1/4 ..............ec_ecooce0nsadcorecareone ree
036 356 BLOCK, shunt ...............e_wooneccecarocareoconooccarecasareaneca o
024 869 COLLAR, set-w/screws (consisting of) ..............e.meeceerececveccov
602 176 . SCREW, set-socket hd 1/4-20 x 3/16 ..............ec-eecorerococrec¡nren.
024 612 COLLAR «oii iii tt ite it ten teste it sete eee,
10 010 929 WASHER, flat-spring 3/8... cco i err ea
11 010 653 BEARING, thrust 3/8 ID x 3/4 OD x1/16 ketene ene
12 020 284 WEDGE, coil. ................coxess0svecoorarored.acarverecarrcanrecvorao
13 119 963 TUBING, 17/32 ID x7/8 OD X 1/2 ............e..eco0ss0vrecawrirerredreer.
14 +009 312 INDICATOR ...................2002s.s00raciocenoacvnsenranreavoredxrere
N
| - |
~ — | - 4
~ A
' | NN —
, 4
O
№
14
pa
UN
O O Y OO WN
— — — o med od №) A NI N) — — DN) wa
12
11 8 18.082 387 A
10 9
Figure B1 - Shunt
+ These items not included with shunt.
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-316 Page 4
OPTIONAL
ACCESSORIES
No. 11 Running Gear
Stock No. 040 874
Two solid rubber tired wheels and
handle,
1-TWA Welding Accessories Stock
No. 040 604 includes: 15 feet
(4.57 meters) No. 4 electrode
cable.
10 feet (3.04 meters) No. 4
work cable with work clamp.
Heavy duty electrode holder.
High grade welding helmet.
AT-10 Carbon Arc Torch
Stock No. 040 229
increase the value of your electric
welder with this easy to use
Carbon Arc Torch. With the
MILLER Carbon Arc Torch it is
now possible to weld and braze
metals that ordinarily are
considered weldable only by the
oxy-acetylene method. It is
especially adaptable to brazing,
soldering, pre-heating and hard
surfacing.