Miller KD368924 Owner's manual

Miller KD368924 Owner's manual
 - March 1993 Form: OM-351H
| er. Effective With Serial No. KD368924
OWNERS
MANUAL
330ST Aircrafter®
CC, AC/DC Welding Power Source
For SMAW And GTAW Welding
300 Amperes, 32 Volts AC/DC At 60% Duty Cycle
Single-Phase Input Power
Protection For Control Circuitry, 24 And 115 VAC, And Overheating
14-Pin Remote Receptacle
High Frequency Switch
E Read and follow these instructions and all | 7 ® Give this manual to the operator.
safety biocks carefully. N°
w Have oniy trained and qualified persons in-
stall, operate, or service this unit.’ B For help, call your distributor
a Call your distributor if you do not understand E or: MILLER ELECTRIC Mfg. Co., Р.О. Box
| the directions. — 1079, Appleton, WI 54912 414-734-9821
cover 8/92 - ST-110 867-F PRINTED IN USA
+
MILLER'S TRUE BLUE” LIMITED WARRANTY
Effective January 1, 1992
(Equipment with a serial number preface of “KC” or newer)
This limited warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY - Sukbjectto the terms and conditions below, MILLER Electric * Accessory Kits
Mfg. Co.. Appleton, Wisconsin, warrants to- its original retail purchaser that new * Replacement Parts
MILLER equipment sold after the effective date of this limited warranty is free of de-
fects in material and workmanship at the time it is shipped by MILLER. THIS WAR- , ™ о |
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES. EXPRESS OR MILLER'S True Blue Limited Warranty shal not apply to:
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FiT-
NESS. 1. ftems furnished by MILLER, but manutactured by others, such as engines or
trade accessories. These items are covered hy the manufacturer's warranty, if
Within the warranty periods listed below, MILLER will repair or replace any war- any.
ranted parts or components that fail due to such detects in material or workmanship.
which time MILLER will provide instructions on the warranty claim procedures to be and relays.
followed.
3, Equipment that has been modified by any party other than MILLER, or equip-
MILLER shall honor warranty claims on warranted equipment listed below in the ment that has been improperly installed, improperly operated or misused
event of such a failure within the warranty time periods. All warranty time periods based upon industry standards, or equipment which has not had reasonable
start on the date that the equipment was delivered to the original retail purchaser, and necessary maintenance. or equipment which has been used for operation
and are as follows: outside of the specifications for the equipment.
1. 5 Years Parts - 3 Years Labor MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER.
| CIAL/INDUSTAIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
* Original main power rectifiers THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
2. 3 Years — Parts and Labor . , . .
In the event of a warranty claim covered by this warranty, the exclusive remedies
* Transformer/Rectifier Power Sources shall be, at MILLER'S option: (1) repair; or (2) replacement; or, where authorized in
* Plasma Are Cutting Power Sources writing by MILLER in appropriate cases, (3) the reasonable cost of repair or replace-
. Semi-Automatic and Automatic Wire Feeders ment at an authorized MILLER service station: or (4) payment of or credit for the pur-
chase price {less reasonable depreciation based upon actual use) upon return of the
- Robots goods at customer's risk and expense. MILLER'S option of repair or replacement
4 2 Years — Parts and Labor willbe F O.B.. Factory at Appleton. Wisconsin, or F.O B. ata MILLER authorized ser-
vice facility as determined by MILLER Therefore no compensation or reimburses
* Engine Driven Welding Generators ment for transportation costs of any kind will be allowed.
(NOTE. Engines are warranted separately Dy the engine manufacturer.)
TG THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN
4. 1 Year — Parts and Labor ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE
* Motor Driven Guns LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL
* Process Contraliers DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CON- ‘
x Water Coolant Systems TRACT, TORT OR ANY OTHER LEGAL THEORY.
HF Units “ ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR-
© Grids RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY
© Spot Welders REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL
* Load Banks THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
+ SOX Transformers OPERATION OF LAW. CUSTOM OF TRADE OR COURSE Of DEALING. IN-
. CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
Running Gear/Trailers FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY ANO ALL EQUIPMENT
* Field Options FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
Te
(NOTE Field options are covered under True Blue for the remaining
warranty period of the product they are installed in, or for a minimum of Some states in the U.S.A. do not allow limitations of how long an implied warranty
one year — whichever is greater) lasts, or the exclusion of incidental, indirect, special or consequential damages, so
the above limitation or exclusion may not apply to you. This warranty provides spe-
5. 6 Months — Batteries cific legal rights, and other rights may be available, but may vary from state to state.
6. 90 Days — Parts and Labor In Canada, legislation in some provinces provides for certain additional warranties
* MIG Guns/TIG Torches or remedies other than as stated herein, and to the extent that they may not be
waived, the imitations and exclusions set out above may not apply. This Limited
* Plasma Cutting Torches Warranty provides specific legal rights, and other rights may be available, but may
+ Remote Controls vary from province to province.
e
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 distributor and/or equipment manufacturer's
Transportation Department.
When requesting information about this equipment, always provide Mode! Designation and Serial or Style Number.
Use the following spaces to record 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
miller 5/92
FEE E
A
ARC WELDING SAFETY PRECAUTIONS
Y WARNING A
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
ARC WELDING can be hazardous.
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
in welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
giectrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. incorrectly installed or improperly
grounded equipment is a hazard.
1. Do not touch live electricat parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating
mats or covers.
4. Disconnect input power or stop engine before installing or
servicing this equipment.
2
"ть
NOISE
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can damage
hearing.
1. Use approved ear plugs or ear muffs if noise level is high.
3, | FUMES AND GASES can be hazardous
| to your health.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. if inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator,
4, Read the Material Safety Data Sheets (MSDSs) and the
manufacturer's instruction for metals, consumables, coatings,
and cleaners.
AZ
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode or welding wire
to metal objects can cause sparks, overheating, or
fire.
1. Protect yourseif and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
Remove ail lammables within 35 ft {10.7 m} of the welding arc. If
this is not possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can
easily go through smail cracks and openings to adjacent areas.
Ea | FLYING SPARKS AND HOT METAL can
cause injury.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
5. Properly install and ground this equipment according to its
Owner's Manual and national, state, and local codes.
6. When making input connections, attach proper grounding
conductor first. ‘
7. Turn off ali equipment when not in use.
8. Do not use worn, damaged, undersized, or poorly spliced
cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical {earth) ground.
11. Do not touch electrode if in contact with the work or ground.
12. Use only well-maintained equipment. Repair or replace
damaged parts at once.
13. Wear a safety harness if working above floor level.
14. Keep ail panels and covers securely in place.
ARC RAYS
2. Wear a welding heimet fitted with a proper shade of filter (see
ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
3. Wear approved safety glasses. Side shields recommended.
4. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
5. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
6. Do notweld in locations near degreasing, cleaning, or spraying
operations. The heat and rays ofthe arc can react with vapors to
form highly toxic and irritating gases.
7. Do not weld on coated metals. such as galvanized, lead; or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead. or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
11. Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
1. Wear approved face shield or safety goggles. Side shields
recommended.
2. Wear proper body protection to protect skin.
srt 9/92
CYLINDERS can explode if damaged.
_| Shielding gas cylinders contain gas under high
“ | pressure. if damaged, a cylinder can explade. Since
“| gas cylinders are normally part of the welding
| process, be sure to treat them carefully,
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining
them to a stationary support or equipment cylinder rack to
prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical
circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shieiding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
6. Turn face away from valve outiet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinderis
in use ar connected for use.
8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
ENGINES can be hazardous.
ENGINE EXHAUST GASES can kill.
Engines produce harmíul exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
2. if used in a closed area, vent engine exhaust outside and
away from any building air intakes.
ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
2. Donot add fuel while smoking or if unit is near any sparks or
open flames.
3. Allow engine to cool before fueling. if possible, check and add
fuel to cold engine before beginning job.
4. . Do not overfill tank - allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before starting
engine,
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can
cut fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and
securely in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
4. To prevent accidentai starting during servicing, disconnect
negative (-) battery cable from battery.
5. Keephands, hair, loose clothing, and tools away from moving
parts,
6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
| burn eyes and skin.
Batteries contain acid and generate explosive
gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery
cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and —) on batteries.
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
The coolant in the radiator can be very hot and
under pressure.
1. Do not remove radiator cap when engine is hot. Allow engine
to cool.
2. Wear gloves and puta rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard 249.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Ameri-
can Welding Society Standard AWS F4.1, from American Welding So-
ciety, 550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Pro-
tection Association, Batterymarch Park, Quincy, MA 02269.
#rt 9/92
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis High-
way, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou-
levard, Rexdale, Ontario, Canada MSW 1R3.
Safe Practices For Occupation And Educational Eye And Face Frotec-
tion, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
MISE EN GARDE —
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES
ENFANTS S'APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU'ILS N'AIENT CONSULTE UN MEDECIN).
LE SOUDAGE À L'ARC est dangereux.
Le soudage, comme la plupart des activités industrielles, expose à certains risques. Le soudage n’est pas dangereux lorsqu‘on prend des
précautions. Les consignes de sécurité suivantes ne font que résumer l'information contenue dans les normes énumérées ci-après. Lisez et
respectez toutes ces normes.
SEULES DES PERSONNES QUALIFIÉES DOIVENT FAIRE DES TRAVAUX D'INSTALLATION, DE RÉPARATION, D'ENTRETIEN ET
D'ESSAI.
=
L’'ELECTROCUTION peut être mortelle.
Une décharge électrique peut vous tuer ou vous
brûler gravement. L'électrode et le circuit de soudage
sont sous tension au démarrage. Le circuit d'entrée et
les circuits internes des matériels sont aussi sous
tension dès la mise en marche. En soudage
1.
2.
automatique ou semi-automatique avec fil, ce dernier, le support de
roquette, le logement des galets d'entraînement et toutes les pièces
métalliques en contact avec le fil de soudage sont sous tension. Des
matériels mal installés ou mal mis à la terre sont dangereux.
Ne touchez pas a des pieces sous tension.
Portez des gants et des vêtements isolants, secs et non troués.
‚ Isoiez-vous de la tôle à souder et de la mise à la terre au moyen
de petits tapis isolants ou autres.
Déconnectez la prise d'entrée des matériels ou arrêtez leur
moteur avant de les installer ou d'en faire l'entretien.
© 00
10.
11.
12.
13.
Veillez à installer ces matériels et à les mettre à la terre selon le
manuel d’utilisation et les codes nationaux, provinciaux et
locaux applicables.
Arrêtez tous les matériels après utilisation.
N'utilisez pas de câbles usés, endommagés, mal épissés ou de
calibre trop petits.
N'enroulez pas de câbles autour de votre corps.
Mettez à la terre ta tôle à souder au moyen d'une bonne prise de
terre.
Ne touchez pas à l'électrode si vous êtes en contact avec le
circuit de soudage (terre).
N'utilisez que des matériels en bon état. Réparez ou remplacez
sur-le-champ les pièces endommagées.
Portez un harnais de sécurité si vous travaillez en hauteur.
Fermez solidement tous les panneaux et les capots.
1.
Le RAYONNEMENT DE L'ARC peut
brúler les yeux et la peau; le BRUIT peut
endommager l’ouie.
Portez un casque de soudeur avec écran filtrant de teinte
appropriée (consultez la norme ANSI Z49 indiquée ci-après),
pour vous protéger le visage et les yeux lorsque vous soudez ou
L'arc de soudage produit une chaleur et des rayons
ultraviolets intenses, susceptibles de brûler les yeux et la peau. Le
bruit causé par certains procédés peut endommager l’oufe.
que vous observez l'exécution d'une soudure.
Portez des lunettes de sécurité approuvées. Des écrans latéraux
sont recommandées.
Entourez l'aire de soudage de rideaux ou de cloisons de
protection contre les coups d'arc ou l'éblouissement; avertissez
les observateurs de ne pas regarder l'arc.
Portez des vêtements en tissus ignifuge durable (laine et cuir)
et des chaussures de sécurité.
Portez un casque antibruit ou des bouchons d'oreille approuvés
si le niveau de bruit est élevé.
Les VAPEURS ET LES FUMÉES sont
dangereuses pour fa santé.
Le soudage dégage des vapeurs et des fumées qu'il
est dangereux de respirer.
1. Écartez le visage pour éviter de respirer les
2.
3.
4.
fumées.
À l'intérieur, assurez-vous que l'aire de soudage est bien
ventilée ou que les fumées et les vapeurs sont aspirées à l'arc.
Sila ventilation est mauvaise, portez un respirateur à adduction
d'air approuvé.
Lisez les fiches signalétiques et les consignes du fabricant
relatives aux métaux, aux produits consummables, aux
revêtements et aux produits nettoyants.
Ne travaillez dans un espace confiné que s’il est bien ventilé;
sinon, portez un respirateur à adduction d'air. Les gaz protecteurs
de soudage peuvent déplacer l'oxygène de l'air et causer des
blessures ou la mort. Assurez-vous que l’air est propre à la
respiration.
Ne soudez pas à proximité d'opérations de dégraissage, de
nettoyage ou de pulvérisation. La chaleur et les rayons de l'arc
peuvent réagir avec des vapeurs et former des gaz hautement
toxiques et irritants.
Ne soudez pas de tôles galvanisées ou plaquées en plomb ou
en cadmium sans les avoir grattées à fond, car ces métaux, et
tout revêtement qui en contient, peuvent alors dégager des
fumées toxiques. Assurez-vous d'une bonne ventilation etportez
un respirateur à adéuction d'air si c’est nécessaire.
Le SOUDAGE peut causer un incendie
ou une expiosion.
L'arc produit des étincelles et des projections. Avec la
chaleur intense dégagée par la tôle et les matériels,
elles peuvent causer un incendie et des brûlures. Le
2.
3.
contact accidentel de l’électrode avec un objet
métallique peut provoquer des étincelles, un échauffement ou un
incendie. |
1. Protégez-vous, ainsi que les autres, contre les étincelles et !es
projections.
Ne soudez pas dans un endroit où des étincelles peuvent
atteindre des matériaux inflammables.
Enievez toutes les matières inflammables dans un rayon de
10,7 mêtres autour de l'arc, ou couvrez-les soigneusement avec
des bâches approuvées.
. Méfiez-vous des étincelles et des éclats brûlants, susceptibles
de pénétrer dans des aires adjacentes par de petites ouvertures
Qu fissures.
11.
Méfiez-vous des incendies et gardez un extincteur à portée de
la main.
N'oubliez pas qu'une soudure sur un plafond, un plancher, une
cloison ou une paroi peut en enflammer l'autre côté.
Ne soudez pas un récipient fermé, comme un réservoir ou un
tonneau.
Connectez le câble de soudage le pius près possible de la tôle
de soudage pour empêcher le courant de suivre un parcours
long et inconnu, et prévenir ainsi les risques d'électrocution et
d'incendie.
Ne faites pas dégeler des tuyaux avec un chalumeau.
. Videz votre carquois porte-électrodes ou coupez le fil au tube-
contact apres le soudage.
Portez des vétements protecteurs non huileux, tels des gants en
cuir, une chemise épaisse, un pantalon sans revers, des
chaussures montantes et un casque.
LES ETINCELLES ET LES
PROJECTIONS BRULANTES peuvent
causer des biessures.
Le piquage et le meulage produisent des éclats de
métal. En refroidissant, la soudure peut projeter du laitier.
1. Portez un écran facial ou des lunettes à coques approuvées.
Des écrans latéraux sont recommandés.
2. Portez des vêtements de protection individuelle appropriés.
Les BOUTEILLES endommagées peuvent
exploser.
Les bouteilles contiennent des gaz protecteurs sous
haute pression. Des bouteilles endommagées peuvent
exploser. Comme les bouteilles font normaiement
partie du procédé de soudage, traitez-les avec soin.
1. Les bouteilles doivent être protégées contre les sources de
chaleur intense, les chocs et les arcs de soudage.
2. Enchaînez verticalement les bouteilles à un support ou à UN
cadre fixe pour les empêcher de tomber ou d'être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de soudage.
MISE EN GARDE
4. Empéchez tout contact entre une bouteille et une électrode.
5. N'utilisez que des bouteilles de gaz protecteur, des détendeurs,
des flexibles et des raccords conçus pour chaque application
spécifique; ces matériels etles pièces connexes doivent être en
bon état.
6. Ne mettez pas le visage devant le robinet de bouteille en
l’'ouvrant.
7. Remettez le chapeau de bouteille après utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
comprimé et aux matériels connexes, ainsi que la publication
P-1 de la CGA, énumérées dans les normes ci-dessous.
Les MOTEURS peuvent être dangereux.
Les GAZ D’'ÉCHAPPEMENT DES MOTEURS
PEUVENT ÊTRE MORTELS.
Les moteurs produisent des gaz d'échappement
nocifs.
1. Utilisez des machines à l'extérieur dans des aires ouvertes et
bien ventilées.
2. Si vous utilisez des machines dans un endroit confiné, les
fumées d’échappement doivent être envoyées à l'extérieur, loin
des prises d'air du bâtiment.
Le CARBURANT peut causer un incendie ou
une explosion.
Le carburant est hautement inflammable.
1. Arrêtez le moteur avant de vérifier le niveau de
carburant ou de faire le plein.
Ne faites pas le plein en fumant ou proche d'une source
d'étincelles ou d'une flamme nue.
3. Sic'estpossible, laissez le moteur refroidir avant de faire le plein
de carburant ou d'en vérifier le niveau au début du soudage.
4. Ne faites pas le plein de carburant à ras bord : prévoyez de
l’espace pour son expansion.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout
carburant renversé avant de faire démarrer le moteur.
Des PIÈCES EN MOUVEMENT peuvent
causer des blessures.
Des pièces en mouvement, telles des ventilateurs,
des rotors et des courroies peuvent couper les doigts
et les mains, ou accrocher des vêtements amples.
. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs sont bien fermés.
2, Avant d'installer ou de connecter un système, arrêtez-en le
moteur.
3. Seules des personnes qualifiées doivent démonter des
protecteurs ou des capots pour faire l'entretien ou le dépannage
nécessaire.
4. Pourempêcher un démarrage accidentel d'un système pendant
l'entretien, débranchez le câble d'accumulateur a la borne
négative.
5. N'approchez pas les mains ou les cheveux de pièces en
mouvement; elles peuvent aussi accrocher des vêtements
amples et des outils.
6. Réinstallez les capots ou les protecteurs et fermez les portes
après des travaux d'entretien et avant de faire démarrer le
moteur.
Des ÉTINCELLES peuvent FAIRE EXPLOSER
UN ACCUMULATEUR: L'ELECTROLYTED'UN
ACCUMULATEUR peut brûler la peau et les
yeux.
Les accumulateurs contiennent de l'électrolyte et
dégagent des vapeurs explosives.
1. Portez toujours un écran facial en travaillant sur
WP
=
un accumulateur.
2. Arrétez le moteur avant de connecter ou de déconnecter des
cábles d'accumulateur.
3. N'utilisez que des outils anti-étincelies pour travailler sur un
accumulateur.
4. N'utilisez pas unposte de soudage pour charger un accumulateur
ou connecter provisoirement un véhicule.
5. Utilisez ia polarité correcte (+ et -) de l'accumulateur.
La VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT BRÛLANT SOUS
PRESSION peuvent brûler la peau et les
yeux.
Le liquide de refroidissement d'un radiateur peut être
brûlant et sous pression.
1. N'ôtez pas le bouchon de radiateur tant que ie moteur n'a pas
refroidi.
2. Mettez des gants et posez un torchon sur le bouchon pour l'ôter.
3. Laissez la pression s'échapper avant d'ôter complètement le
bouchon.
PRINCIPALES NORMES DE SÉCURITÉ
Safety in Welding and Cutting, norme ANSI Z49.1, American Welding
Society, 550, NW. LeJeune Rd., Miami FL 33128.
f n Ith , OSHA 29 CFR 1910, Superintendent
of Documents, U.S. Government Printing Office, Washington D.C.
20402,
R men fe Practi he P r Weldin
ing of Conta ThatHave Held Hazar nçes, norme
AWS F4.1, American Welding Society, 550, N.W. LeJeune Rd.,
. Miami FL 33128.
National Electrical Code, norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
sr1f 9/91
Safe Handling of Compressed Gases in Cylinders, document P-1,
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, Va 22202.
in Weidin ng, norme CSA W117.2, Asso-
ciation canadienne de normalisation, Standards Sales, 176 Rexdale
Boulevard, Rexdale, Ontario, Canada MSW 1R3.
Sate Practices for Occupation and Educational Eve and Face Protec-
tion, norme ANSIZ87.1, American National Standards Institute, 1430
Broadway, New York, NY 10018.
ing and Welding Pr , norme 518 NFPA, National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
TABLE OF CONTENTS
="
SECTION 1 — SAFETY INFORMATION 1121021001 LA La a da a a aa ALL 1
SECTION 2 —- SPECIFICATIONS
2-1. Volt-Ampere Curves .... AAA a 4 A da a a ea a aa PS 2
2-2. Duty Cycle ......221 0004411 AA VAL 4 AAA A 4 AAA a a A A A A a a a a a Ne 2
SECTION 3 - INSTALLATION
3-1. Typical Process Connections... .... e anar onaroniam 3
3-2. Selecting A Location And Moving Welding Power Source .............. oon... .. 3
3-3. Selecting And Preparing Weld Qutput Cables ............. ii... 4
3-4. Lower Front Panel . .... 2... eeoieraaadarnanderancoreecrenda, 5
3-5. Connecting To Weld Qutput Terminals . .......... iia. 5
3-6. Remote 14 Receptacie Information And Connections ............. 00... 6
3-7. 115 Volts AC Duplex Receptacie ............ iii. 6
3-8. Shielding Gas Connections .......... aa aaanernenaco. 7
3-9. Connecting Input Power . . . 100101 aa VA de da a a AA LL LL LL LA LL 8
SECTION 4 - OPERATION ......12121112 LL LL A LA NA a da a LA Ra La 10
SECTION 5 - MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance Aa AA LL A aa aa 18
5-2. Overload Protection ...... AL AA A A a a a ea AL a a aa Le 18
5-3. Adjusting Spark Gaps ........10 00211 A A4 a 4 4 4 a ea 4 a de A aa a de a La aan 19
5-4. Setting Preflow Function For Spot Weld Timer Option 0.0.2... 20
5-5. Troubleshooting ...... rerecrecrerecereeuononenma eee 21
SECTION 6 —- ELECTRICAL DIAGRAMS . . ess, 23
SECTION 7 — HIGH FREQUENCY edd 26
SECTION 8 - TUNGSTEN ELECTRODE
8-1. Selecting Tungsten Electrode . .. ea ananaoa oa 28
8-2. Preparing Tungsten RR 29
SECTION 9 — PARTS LIST
Figure 9-1. Main Assembly 222202001002 L LL AA A a Aa a a a a a A A Aa 30
Figure 9-2. Panel, Front w/Components ... A a ea aa a a a a a a a Aa aa LL LL 32
Figure 9-3. Switch, Push Button . LL... RR a 34
Figure 9-4. Terminal Assembly, Primary ............... LL A A ee a ea A a A 4 a a a a ee 34
Figure 9-5. Panel, Rear w/ComponentsS . La La .... 35
Figure 9-6. HF Panel .. RER a a a a ae a a ae 36
Optional Equipment LA 4 A A 4 4 4 4 A 4 4 4 4 a 4 A A 4e a a a aa aa ae 38
OM-351H - 3/93
SECTION 1 — SAFETY INFORMATION
möd1.1 8/92
E Read all safety messages throughout this manual.
B Obey all safety messages to avoid injury.
№ Learn the meaning of WARNING and CAUTION.
1 Safety Alert Symbol
2 Signal Word
WARNING means possible death
or serious injury can happen.
CAUTION means possible minor
ELECTRIC SHOCK can kill.“ injury or equipment damage can
* Co not touch live electrical parts. | * Keep away from moving parts. happen.
* Disconnect input power before 4 а « Keep all panels and covers closed 3 Statement Of Hazard And
я
installing or servicing. when operating. Result
/ 4 Safety Instructions To Avoid
5 Hazard
5 Hazard Symbol (if Available)
= Len 6 Safety Banner
| READ SAFETY BLOCKS at start of
6 & WARNING 7 we af | Section 3-1 before proceeding. Read safety blocks for each sym-
—— bol shown.
7 NOTE
7 NOTE (7 Turn OFF switch when using high frequency. Special instructions for best oper-
ation — not related to safety.
Figure 1-1. Safety Information
SECTION 2 — SPECIFICATIONS
Table 2-1. Welding Power Source
Specification Description
Type Of Output Direct Current/Constant Current (DC/CC) Or Alternating Current/Constant Current (AC/CC)
Rated Weld Output 300 Amperes, 32 Volts At 60% Duty Cycle (See Section 2-2)
Type Of Input Power Single-Phase; 200, 230, 460, Or 575 Volts AC; 60 Hz
input Amperes At Rated Output 106 A At 200 Y, 92 A At 230 Y, 46 A At 460 Y, 36.8 A At 575 V
KVA/KW Used At Rated Output 21.2 kVA/16 KW
Max. Open-Circuit Voltage 80 Y, AC Or DC Mode
Welding Processes | Gas Tungsten Arc (GTAW) And Shielded Metal Arc (SMAW) Welding
Overall Dimensions See Figure 3-3
Weight Net: 750 Ib (340 kg): Ship: 775 Ib (351 kg)
Options See Rear Cover
Welding Ranges AC GTAW AC SMAW DC GTAW DC SMAW
5-55 A 5-50 A 5-60 A 5-45 A
20-280 A 20-265 A 20-280 A 18-235 A
50-450 A 40-420 A 45-450 A 35-370 À
OM-351 Page 1
2-1. Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities
of the welding power source.
Curves of other settings fail be-
tween the curves shown.
A. DC Mode B. AC Mode
100 100
90 90 +
80 80
70 70
© wm 60
5 60 =
> 50 © 50
Q 40 Г
5 40 Q .
30 | so | e -
20 20 | RANGE
10 on 10 |] LOW RANGE
0 | | | | | 0 | | | !
0 100 200 300 400 500 600 0 100 200 300 400 500 600
DC AMPERES AC AMPERES
ssb1.1 10/91 - $8-108 001-A / S6-107 982-A
Figure 2-1. Volt-Ampere Curves
2-2. Duty Cycle
4 CAUTION
EXCEEDING DUTY CYCLE RATINGS will damage unit.
* Do not exceed indicated duty cycles.
warn7.1 2/92
RATED OUTPUT
400
350
250
WELD AMPERES
50 80
2 DUTY CYCLE
70 80 80 0
Duty cycle is how long the unit can
operate within a ten minute period
without causing overheating or
damage.
This unit is rated at 60% duty cycle
allowing welding 6 minutes out of
every 10 minutes at rated load. If
the weiding amperes decrease, the
duty cycle increases.
sbt.2 2/92 — 5B-000 768-A
Figure 2-2. Duty Cycle Chart
OM-351 Page 2
SECTION 3 — INSTALLATION
4 WARNING
(E HIGH-FREQUENCY RADIATION can interfere with radionavigation, safety services, computers,
>) /) and communications equipment.
s Have only qualified person familiar with electronic equipment perform this installation.
* Read and follow entire Section 7 for proper location and installation requirements for high-frequency equipment before
installing unit.
3-1. Typical Process Connections
SMAW GTAW
. Welding «= Welding —
Power Source Power Source
Work
1
With HF Off
; Work
With HF On ———
Figure 3-1. Typical Process Connections
3-2. Selecting A Location And Moving Welding Power Source
Á WARNING
- e ELECTRIC SHOCK can kill. FUMES can be hazardous; LACK OF
e Do not touch live electrical parts. i FRESH AIR AND PROPER
e Disconnect input power conductors from VENTILATION can be harmful.
deenergized supply line BEFORE moving welding ® Do not breathe weiding fumes.
power source.
- = e Place unit only where there is a good fresh air
FIRE OR EXPLOSION can result from supply and proper ventilation.
placing unit on, over, or near
combustible surfaces.
# Do not locate unit on, over, or near combustible
surfaces.
® Do not install unit near flammables.
BLOCKED AIRFLOW causes
overheating and possible damage to
unit.
® Do not block or fiiter airflow.
Warranty is void if any type of filter is used. swarn11.1 2/92
FALLING EQUIPMENT can cause
serious personal injury and equipment
damage.
s Uselifting eyetolift unit only, NOT running gear, gas
cylinders, or any other accessories.
e Use equipment of adequate capacity to lift the unit.
1 18 in (460 mm) Open Space
On Front And Rear For Good
Airflow
2 Rating Label
3 Lifting Eye
Use lifting eye to move unit.
4 Lifting Forks
If using lifting forks, extend forks
out opposite side of unit.
Locate unit near correct input pow-
er supply.
ST-159 638
Figure 3-2. Location and Movement Of Welding Power Source
OM-351 Page 3
E > | F = K Inches | Millimeters
D > li с _ / H A | 33-34 857
y В | 22-1/4 565
TT N y С | 35-34 908
D 2-1/4 57
| Е 1-1/2 38
Front | J Е | 32-3/4 832
G 32 813
H 1-1/8 29
J 20 508
TH — P K 7/16 11
ST-158 639-A
Figure 3-3. Overall Dimensions And Base Mounting Hole Layout
3-3. Selecting And Preparing Weld Output Cables
1 Weld Output Cable
Determine total cable length in
weld circuit and maximum welding
amperes. Use Table 3-1 to select
proper cable size.
Use shortest cables possible.
Do not use damaged cables.
2 Terminal Lug
Use lugs of proper amperage ca-
pacity and hole size for connecting
— to work clamp or electrode holder,
and weld output terminals.
3 Insulated Electrode Holder
4 GTAW Torch
Install according to manufacturer's
Tools Needed: — For Example
5 Total Cable instructions.
II Length In Weld 5 Work Clamp
Circuit = 20 ft {6 m)
Install onto work cable.
10 ft (3 m)
—
sb6.5* 11/92 - 5-0752
Figure 3-4. Selecting And Preparing Weld Output Cables
Table 3-1. Weld Cable Size*
Total Cable (Copper) Length In Weld Circuit Not Exceeding
1 200 ft 50 ft 300 ft 350 ft 4
100 ft (30 m) Or Less (5 m) (60 m) 70 m) (90 т) | (195 т) | (1 20 т
in 10T % 60 Thru 100°
Amperes | Duty Cycle | Duty Cycle. 10 Thru 100% Duty Cycle
100 4 4 4 —3 2 1 1/0 1/0
150 3 3 2 i 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
“Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of not more than 300 circular mils per ampere. 5-0007-C
OM-351 Page 4
3-4. Lower Front Panel
1 Access Door
Loosen screw and open access
door.
ЕЕ ЕЕ == === == ===
===> rs 2 Bar
bar.
3 Gas Out Connection
Gas In Connection
Work Weld Output Terminal
Electrode Weld Output
High Frequency Intensity
Control (Figure 4-11)
8 High Frequency Spark Gaps
{Section 5-3)
Close access door after making
connections.
~ ло
Tools Needed:
= Fo
Ret. ST-158 640
Figure 3-5. Lower Front Panel
3-5. Connecting To Weld Output Terminals
Á WARNING
— e, | ELECTRIC SHOCK can kilt
MM = e Do not touch live electrical parts. |
e Turn Of welding power source, and disconnect input power before making any weld output connections.
swarniz.1 2/97
1 Work Weld Output Terminal
For both GTAW and SMAW weld-
ing, connect one end of work cable
to Work weld output terminal and
remaining end to warkpiece.
2 Electrode Weld Output Termi-
nal
For GTAW welding, connect torch
connector or cable to Electrode
weld output terminal. Be sure torch
connector does not touch access
door when closed.
For SMAW welding, connect elec-
WORK ELECTRODE trode hoider cable to Electrode
= A weld output terminal.
° e | Weld output polarity is determined
by position of the Output Selector
switch (see Figure 4-4).
Close access door.
Tools Needed:
mat 3/4in
Figure 3-6. Weld Output Connections
OM-351 Page 5
3-6. Remote 14 Receptacle Information And Connections
AQ O
во Xo ol
© © № Onl] AMPERAGE
OUTPUT
{CONTACTOR])
Socket Information:
Remote Contactor
A 24 volts ac.
Remote 14 Receptacle RC1
Keyway
WN =
Plug
4 Threaded Collar
To connect to this receptacle, align
keyway, insert plug, and tighten
threaded collar.
8 Contact closure to pin A completes 24 voits ac con-
tactor control circuit. Protected by circuit breaker
CB1.
Remote Amperage/Voltage Control
C Command reference; +10 volts dc.
D Control circuit common.
E Input command signal {potentiometer wiper or 0 to
+10 volts dc).
The remaining sockets are not used.
sb7.1 8/92 — Ref. ST-130 230-B / Ref. S-0004-A / S-0750
Figure 3-7. Remote 14 Connections
3-7.
115 Volts AC Duplex Receptacle
er —
15V 15A "VAC
1 115 Volts AC Duplex Recep-
tacte
This welding power source sup-
plies up to 15 amperes of 115 volts
ac power.
The duplex receptacle is protected
from overload by circuit breaker
CB2 (see Section 5-2B).
Ref. ST-120 923-B
Figure 3-8. Connecting To 115 Volts AC Duplex Receptacle
OM-351 Page 6
3-8. Shielding Gas Connections
A WARNING
CYLINDERS can explode if damaged.
* Keep cylinders away from welding and other |;
electrical circuits. :
e Never touch cylinder with welding electrode.
* Always secure cylinder to running gear, wall, or
other stationary support. | warn4.1 9/91
BUILDUP OF SHIELDING GAS can harm
health or kill.
¢ Shut off shielding gas supply when not in use.
Obtain gas cylinder and chain to
running gear, wall, or other station-
ary support so cylinder cannot fail
and break off valve.
1 Cap
2 Cylinder Valve
QUTPUT
(CONTACTOR)
Remove cap, stand to side of
valve, and open vaive slightly. Gas
flow blows dust and dirt from vaive.
Close valve.
3 Cylinder
4 Regulator/-lIowmeter
Connect
Remote Device Install so face is vertical.
5 Gas Hose Connection
Fitting has 5/8-18 right-hand
threads.
6 Flow Adjust
Typical flow rate is 20 cfh (cubic
G To Torch feet per hour). Check wire man-
To Use
Gas Vaive
ufacturers recommended flow
rate.
7 СО» Adapter
8 O-Ring
4 Install adapter with O-ring between
regulator/flowmeter and CO, cylin-
9 der.
9 Gas In Fitting
10 Gas Out Fitting
2
The Gas In and Gas Out fittings
have 5/8-18 right hand threads.
Obtain proper size, type, and
length hose and make connections
a as follows:
3 Connect hose from shielding gas
supply regulator/flowmeter to Gas
In fitting.
Connect shielding gas hose from
torch to Gas Qut fitting.
Close access door.
IN-GAS-OUT
Argon Gas !
2
+ — |) 3
Tools Needed: 7 8
I———€ 1-1/8, 5/8 in ° ;
CO, Gas ssb3.1* 12/92 — ST-158 697-A / Ret. ST-130 230-В
Figure 3-9. Typical Regulator/Flowmeter Installation
OM-351 Page 7
3-9. Connecting Input Power
E services,
equipment perform this installation.
| A WARNING
HIGH-FREQUENCY RADIATION can
interfere with radionavigation, safety
computers,
a) |) communications equipment.
* Have only qualified person familiar with electronic
and
* Read and follow entire Section 7 for proper location
and installation requirements for high-frequency
equipment before installing unit.
J
ELECTRIC SHOCK can kill.
* Do not touch live electrical parts.
* Turn Off welding power source, and disconnect
input power before inspecting or installing.
e Have only qualified persons install unit.
e |nstallation must meet National Electrical Code and
ali other codes.
A. Positioning Jumper Links
\
\ 200 VOLTS 230 VOLTS 460 VOLTS
ao 0&3 o Gad o o ofldoo
L L L E L L
© © © © © O
5-083 566-A
{ —
230 VOLTS 460 VOLTS 575 VOLTS
OL OL OL OL
5-010 587-B
Tools Needed:
Ie 3/8in
COX 3/8 in
Jumper links allow operation on dif-
ferent input voltages and are facto-
ry set for the highest input voltage.
Check input voltage available at
site.
Remove side panel to check jump-
er links.
1 Input Voltage Label — Only
One ls On Unit
Look at jumper links and compare
Ink position with unit label.
2 Input Terminal Board
3 Input Voltage Jumper Links
Move links to match input voltage.
For example, use 230 voits posi-
tion when 230 velts input power is
available.
Reinstall side panel or go on to
Figure 3-11.
+
ssb5.1* 2/92 — Ref. ST-158 637-À
OM-351 Page 8
Fiqure 3-10. Input Voitage Jumper Links Location
B. Connecting Input Power
Have only qualified persons make
this installation.
Remove side panel.
1 Line Disconnect Switch Of
Proper Rating
2 Input Conductors
3 Grounding Conductor
Select size and length using
Table 3-2. Conductor rating must
comply with national, state, and lo-
cal electrical codes. Use lugs of
proper amperage capacity and cor-
rect hole size.
4 Strain Relief Connector
Insert conductors through strain
relief.
5 Input Terminal Board
6 Line Terminals
7 Ground Terminal
Connect input conductors to line
terminals and grounding conductor
to ground terminal.
Install and connect input condue-
tors and grounding conductor in
conduit or equivalent to deener-
gized line disconnect switch.
Be sure grounding conductor goes
to an earth ground.
Reinstall side panel.
8 Line Fuses
Select fuses or circuit breakers us-
ing Table 3-2. Install into deener-
gized line disconnect switch.
Tools Needed:
le 0
3/8, 7/16, 1/2 in
5562.4 11/92 - ST-158 637-A
Figure 3-11. Input Power Connections
Table 3-2. Electrical Service Requirements*
Input Voltage 200 230 460 575
input Amperes At Rated Output 106 92 46 37
Circuit Breaker Size Range In Amperes' 159 thru 212 138 thru 184 69 thru 92 55 thru 74
Fuse Size In Amperes? 150 150 70 60
Input Conductor Size In AWG/Kemil® 4 4 8 10
Maximum Input Conductor Length In Feet (Meters)* 104 (32) 137 (42) 237 (72) 247 (75)
Grounding Conductor Size In AWG/Kcemil5 6 6 8 10
WwW M —-
hn
These values are calculated from the 1990 edition of the National Electrical Code (NEC).
Circuit breaker range is 150% to not more than 200% of rated input amperage of the welding power source (Article 630-12(a) of NEC).
Standard fuse size is that closest to 150% of rated input amperage of the welding power source (Article 630-12(a) of NEC).
Input conductar size is for insulated copper wire with 75°C rating with not more than three single current-carrying conductors in a cable or raceway
(Table 310-16 of NEC).
Maximum length is to prevent more than a 3% voltage drop between service entrance and input terminals of the welding power source (Articles
210-19(a) and 215-2{b) of NEC).
The grounding conductor shall be colored or identified as specified in the NEC. Grounding conductor size for.copper wire is not required to be larger
than input conductor (Article 250-85 of NEC). $-0092-D
OM-351 Page 9
A WARNING
SECTION 4 — OPERATION
ELECTRIC SHOCK can kill.
e Always wear dry insulating gloves.
¢ Insulate yourself from work and ground.
e Do not touch live electrical parts.
* Keep all panels and covers securely in place.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
e Wear welding helmet with correct shade of filter.
* Wear correct eye, ear, and body protection.
FUMES AND GASES can be hazardous
to your health.
e Keep your head out of the fumes.
® Ventilate area, or use breathing device.
+ Read Material Safety Data Sheets (MSDSs) and
manufacturers instructions for material used.
MOVING PARTS can cause injury.
* Keep away from moving parts.
e Keep all doors, panels, covers, and guards closed
and securely in place.
WELDING can cause fire or explosion.
® Do not weld near flammable material.
Watch for fire; keep extinguisher nearby.
Do not locate unit over combustible surfaces.
Do not weld on closed containers.
Allow work and equipment to cool before handling.
MAGNETIC FIELDS FROM HIGH CUR-
RENTS can affect pacemaker operation.
® Pacemaker wearers keep away.
e Wearers should consult their doctor before going
near arc welding, gouging, or spot welding opera-
tions.
See Safety Precautions at beginning of manual for ba-
sic welding safety information. swarn8.4 10/91
15
—
14
— 14
13
К
— —
11
1 Amperage Adjustment Con-
trol
Amperage Control Switch
Spot Time Control
Spot Time Switch
Power On Push Button
Power Off Push Button
Pilot Light
Qutput Selector Switch
Circuit Breaker CB1 (Section
5-28)
Output (Contactor) Control
Switch
Range Selector Switeh
D 0 “4 BH A E © N
11
12
13
High Frequency Switch
115 Volts AC Duplex Recep-
tacle (Section 3-7)
Circuit Breaker CB2 (Section
8 5-28)
15 Remote 14 Receptacle RC1
{Section 3-6)
16 Postflow Time Control
17
18
Start Amperage Switch
Start Amperage Control
Ref ST-159 640
OM-351 Page 10
Figure 4-1. Controls
Insulating Gloves
2 Safety Glasses With Side
Shields
3 Welding Helmet
Wear dry insulating gloves, safety
glasses with side shields, and a
welding helmet with a correct
shade of filter (see ANSI 249.1).
sb3.1 10/91
Figure 4-2. Safety Equipment
1 Work Clamp
Tools Needed: Use wire brush or sandpaper to
clean metal at weld joint area. Use
———— chipping hammer to remove slag
after welding.
Connect work ciamp to a clean,
paint-free location on workpiece,
as close to weld area as possible.
shd. 1 5/92
Figure 4-3. Work Clamp
ELECTRIC SHOCK can kill. ARCING can damage switch.
— * DonotuseAC output in damp areas, ıf movement is e Do not change Output Selector switch or Range
чл confined, or if there is a danger of falling. Selector switch position white welding.
e Use AC output ONLY if required for the welding Arcing inside switch can damage contacts, causing
process. switch to fail.
e !fAC output is required, use remote output control.
® Read Safety Precautions at beginning of this
manual. warn6.3 4/92 / warn5.1* 9/91
1 Output Selector Switch
4 ELECTRODE (+) К NN Use switch to select weld output.
POSITIVE +A,
Sana — |
ELECTRODE
NEGATIVE AC
CIA Nu
QUTF OR
BE SURE R POINTS
DIRECTLY D OUTPUT
DO NOT SWITCH
UNDER LOAD
— 6.1
Ref. ST-120 923-B
Figure 4-4. Output Selector Switch
OM-351 Page 11
NOTE (+
Amperage ranges on the unit nameplate are for GTA W welding. See Table 2-1for —
YN
SMAW ranges.
1 Range Selector Switch
a 20 - 280 №) АС NN Use switch to select ac or dc weld
i 20-280===DC amperage range.
2. If desired amperage is in the over-
GTAN RANGE lapping area of two ranges, set
“ Switch in the lower range for better
fine amperage control (see
Figure 4-8).
5-55 50-450
Ny AC Ny AC
5-60 45-450
RAN OR —
BE SURE R POINTS
DIRECTLY D OUTPUT
DO NOT SWITCH
UNDER LOAD
\_ O = /
Figure 4-5. Range Selector Switch
1 Amperage Adjustment Con-
trol
Use control to adjust amperage
within range selected by Range
( Selector switch.
The numbers are a percentage of
AMPERAGE the range selected and not an ac-
1 tual value.
50 Control may be adjusted while
40 60 welding.
Ret. ST-130 230-8
OM-351 Page 12
Figure 4-6.
Amperage Adjustment Control
à WARNING
4 ELECTRIC SHOCK can kill.
— . ,
* Do not touch live electrical parts.
e Do not touch weld output terminals when contactor is energized.
# Do not touch electrode and work clamp at the same time.
swarn7. 1 10/91
Weld output terminals are [> NN
EE OUTPUT
d wh h
On and Power is On. O> cameron Pa
AE
\ 7
1 Qutput (Contactor) Control
Switch
Use switch to select way of control-
fing unit output.
For weld output, place switch in On
position.
For remote output control, place
switch in Remote 14 position (see
Section 3-6).
Figure 4-7. Qutput (Contactor) Control Switch
14 [7 PANEL
\.
1 Amperage Control Switch
Use switch to select way of control-
ling amperage adjustment.
For front panel control, place switch
in Panel position.
For remote control, place switch in
Remote position. See Example be-
low.
2 Remote Foot Control
3 Remote Hand Dial
4 Remote Hand Control
ln
EXAMPLE Of Combination Remote Amperage Control
;
{
3
2
0
les
$
В
Va
Set Switches ———>» Set Range — Set Percentage — Adjust Remote Control
_— O
In Example:
Min =20 A AC
50 Percentage Of Range = 50%
Max = 150 A AC (50% of 20 to 280)
2
Min
(20 AAC)
Max o
— (150 AAC)
100
80
6
ST-159 059 / Ref. ST-120 923-B / ST-130 230-B / 85-0769 / 5-0774
Fiqure 4-8. Amperage Control Switch
OM-351 Page 13
1 Postflow Time Control
Use control to set the length of time
(— gas (and water if applicable) flows
after the welding stops.
POSTFLOW TIME Adjust time according to size of
tungsten electrode in torch.
3
(>> OUTPUT
(CONTACTOR)
3/32
2.4mm
ON
1 6mm CA > 6.4mm | Connect
Remote Device
To Use
Post-Flow
Time Control
0040 Ng В о
Ч Imm TUNGSTEN SIZE
Figure 4-9. Postflow Time Control
A WARNING
USING HIGH FREQUENCY WITH THE SHIELDED METAL ARC WELDING PROCESS can resultin
serious personal injury.
* Place the High Frequency switch in the Off position before using the Shieided Metal Arc Welding (SMAW) process.
1 Start Amperage Switch
On — provides start amperage set
2 START on Start Amperage control.
N A ¡AMPERAGE Off — provides no start amperage.
a 2 Start Amperage Controi
40 50 80 Use control to set amperage for
N starting arc. After arc is started,
30 N 70 weld amperage slopes up or down
to setting of Amperage control or
remote control if one is used.
20 80 Start amperage is always within
the range selected on the Range
10 90 Selector switch.
0 100
1 \.
OFF | on
N J
Figure 4-10. Start Amperage Controls
OM-351 Page 14
A WARNING
USING HIGH FREQUENCY WITH THE SHIELDED METAL ARC WELDING 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.
1 High Frequency Switch
(a N 40 50 2 Start - provides HF for arc starting
HIGH FREQUENCY X o.
HF 1 30 Ll 70 Off — provides no HF. Use Off for
SMAW (stick electrode) welding.
20 80 Continuous -- provides HF continu-
ously throughout the weld.
HF O HF , ,
a A 2 High Freguency Intensity
START CONT, 10 90 Control (Figure 3-5)
| Use control to change amount of
HF O 0 100 HF energy used to start and main-
\_ OFF HIGH FREQUENCY tain the arc. Set as low as practical
INTENSITY to prevent interfering with electron-
- ic equipment.
G> OUTPUT
(CONTACTOR)
| ON
Connect
Remote Device
To Use
High-Frequency
Circuit
Figure 4-11. High Frequency Controls
1 Power On Push-Button
Switch
Pilot Light
1 3 Power Off Push-Button
ON | Switch
Use push-button switches to turn
unit and pilot light On and Off. If in-
put power is interrupted, the power
POWER 7 2 On push button must be pressed to
turn the unit On again.
ое? (> >
Figure 4-12. Power Switch And Pilot Light
OM-351 Page 15
NOTE 7
The shielding gas preflow switch on the Relay Control board PC2 must be placed in
the desired position when the Spot Time option is present (see Section 5-4).
1.5
1.0
OFF
SPOT TIME
es 1
2.5 3.0
To Use Spot
Time Circuit
1 Spot Time Switch
Place switch in the On position to
turn on spot weld circuitry.
Place switch in the Off position to
turn off spot weld circuitry. Put
switch in the Off position while do-
ing Shielded Metal Arc Welding
(SMAW).
2 Spot Time Control
Use control to set time for Gas
Tungsten Arc (GTAW) spot welds.
Spot time begins at arc initiation. If
the arc is broken 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 is
opened. The spottimer resets after
the contactor opens.
Connect
Remote Device
Figure 4-13. Spot Time Controls (Optional)
1 AC Or DC Voltmeter
Voltmeter displays voltage at the
weld output terminals, but not nec-
essarily the welding arc due to
cable resistance, poor connec-
tions, etc.
2 AC Or DC Ammeter
Ammeter displays weld amperage
output of unit.
OM-351 Page 16
Figure 4-14. Ammeter And Voltmeter (Optional)
A WARNING
BUILDUP OF SHIELDING GAS can harm health or kill.
e Shut off shielding gas supply when not in use.
warnt.1 9/91
Shielding Gas Cylinder
Valve
Ww nN =
Torch Output Control
4 4 Foot Control
3
Open valve on cylinder just before
welding.
Torch or foot control turns weld
OR output and gas flow on and off.
Close valve on cylinder when fin-
ished welding.
sh3.2* 2/92 - Ref. 3-0621-0 7 ST-159 059
Figure 4-15. Shielding Gas
Install Select Insert Put On Turn On
Connect )) Tungsten (See )) Tungsten Personal Safety Set Controis ) Shielding Gas
Equipment Section 8) Into Torch Equipment
Turn On
) Welding 2) Begin Welding )
Source
Figure 4-16. Sequence Of Gas Tungsten Arc Welding (GTAW) And Gas Tungsten Arc Spot Welding
35b8.1* 9/92
Install & Select Put On Insert Turn On
Connect Electrode Persona! Safety Set Controls Electrode Welding Power
Equipment Equipment into Holder Source
) Begin Welding )
Figure 4-17. Sequence Of Shielded Metal Arc Welding (SMAW)
ssb7.1* 9/92
OM-351 Page 17
SECTION 5 - MAINTENANCE & TROUBLESHOOTING
A WARNING
ELECTRIC SHOCK can kill. «+
® Do not touch live electrical parts.
e Turn Off welding power source, and disconnect ~~
input power before inspecting, maintaining, or
MOVING PARTS can cause injury.
* Keep away from moving parts.
servicing.
| STATIC ELECTRICITY can damage parts
HOT PARTS can cause severe burns. on circuit boards.
e Allow cooling period before maintaining or & ® Роб оп grounded wrist strap BEFORE handling
servicing. a boards or parts.
$2
* Use proper static-proof bags and boxes.
Maintenance to be performed oniy by qualified
>
z{
persons. swarng.t* 10/9+
5-1. Routine Maintenance
I 3 Months A Turn Off all power before maintaining. as 3 Months
> Replace <> replace
Fy Replace ("7 Cracked
= Cables Parts
14-Pin Cord
Clean .
y And
oil Tighten =
Weld
Terminals Gas Hose - Torch Cable
Replace
Unreadabie
Labels
Y
Adjust
Spark
Gaps
ST-149 841-A
Figure 5-1. Maintenance Schedulie
5-2. Overload Protection
READ SAFETY BLOCKS at start of
4) WARNING } Section 5 before proceeding.
A. Overheating
Thermostat TP1 protects the unit from damage due to overheating. If stabilizer Z gets too hot, TP1 opens and weld
output stops. The fan keeps running to cool the transformer. Wait several minutes before trying to weld.
OM-351 Page 18
B. Fuses And Circuit Breakers
1 Circuit Breaker CB1
CB1 protects transformer T1 24
volts ac winding.
If CB1 opens, weld output stops.
Manually reset CB1.
2 Circuit Breaker CB2
CB2 protects transformer T1 115
voits ac winding.
if CB2 opens, devices using 115
volts ac from duplex receptacle
RC2 would stop. Manually reset
CB2.
3 Fuse F1 (See Parts List For
Rating)
115V 15A "VAC
F1 protects transformer T1 control
circuit winding.
if F1 opens, the unit provides mini-
mum output with no amperage
controi. Turn Off welding power
source and disconnect input power
before checking F1.
ST-160 520 / Ref, ST-110 838-C / Ref. ST-130 230-B / Ref. ST-120 923-B
Figure 5-2. Overload Protection
5-3. Adjusting Spark Gaps
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
Turn Off welding power source and
disconnect input power,
Loosen screw on lower front panel
and open access door,
1 Tungsten End Of Point
Do notclean ordress tungsten. Re-
place point if tungsten end disap-
pears.
2 Spark Gap
Normal spark gap is 0.008 in (0.203
mm).
if spark gaps are okay, reinstall
door. If adjustment is needed, con-
tinue as follows:
3 Adjustment Screws
Loosen screws. Place gauge of
Tools Needed: proper thickness in spark gap.
4 Pressure Point
о © 5/32 in . , .
Apply slight pressure at point until
gauge is held firmly in gap. Repeat
= > gauge adjustment with other gap.
| Tighten adjustment screws.
0.008 in (0.203 mm) Close access door.
Ref. ST-158 640 / Ref. 35-0042
Fiqure 5-3. Adjusting Spark Gaps |
OM-351 Page 19
5-4. Setting Preflow Function For Spot Weld Timer Option
4 WARNING
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
NOTE (+
Contactor Control from Remote 14 receptacle.
To disable gas valve and prevent gas preflow for Shielded Metal Arc (SMAW)
welding, place Output (Contactor) switch in On position, and disconnect Remote
CRY CHG
CH
€ okákuL OL IE =a о
ACS
Tools Needed:
ЕЕ =
Shielding gas preflow is available
when the spot weld timer option is
present. Preflow provides gas flow
for about two seconds before an
arc is started.
if the spot weld timer option is pres-
ent, set shielding gas preflow ac-
cording to the weld process in use.
Turn Off welding power source and
disconnect input power. Open up-
per front access door.
1 Relay Control Board PC2
2 Preflow On/Off Switch $1
Switch positions are marked on
PC2. Setswitch in desired position.
Close and secure upper front
access door.
/
Es 0 To CD oo eee
——_—> es sem, A 2
Ret. 57-158 641 / SA-157 845
OM-351 Page 20
Figure 5-4. Setting Preflow Function For Spot Weld Timer Option
5-5. Troubleshooting
.
servicing.
7 WARNING
ELECTRIC SHOCK can Kill.
Do not touch live electrical parts.
e Turn Off welding power source, and disconnect
input power before inspecting, maintaining, or
MOVING PARTS can cause injury.
‚ ® Keep away from moving parts.
HOT PARTS can cause severe burns.
e Allow cooling period before maintaining or
on circuit boards.
STATIC ELECTRICITY can damage parts
e Put on grounded wrist strap BEFORE handling
Be sure electrode is dry and proper type for SMAW.
Be sure tungsten is correct size for GTAW.
Use proper size and type weld cable.
servicing. | boards or parts.
® Use proper static-proof bags and boxes.
milo Troubleshooting to be performed only by qualified
Table 5-1. Welding Trouble
Trouble Remedy Section
No weld output; unit completely inop- |— — =i Place line disconnect switch in the On position. ——- 3-98
erative; pilot light PL1 not on.
Check and repiace line fuse(s) or reset circuit breaker CB1. an 3-98
Check for proper input connections. — -= 3-98
Check for proper jumper link positions. — 3-9A
Reset circuit breaker CB1. — 5-28
Check contactor W. ——— ——
No weld output: fan on; pilot kght PL1 f— — — If remote control is not used, place Output (Contactor) switchinOn [— — -= 3-6,
on, position. If remote control is used, place switch in Remote 14 posi- Figure 4-7
tion, and be sure remote control is connected to Remote 14 recep-
tacie.
Be sure Range Selector switch is not between positions. — — - Figure 4.5
Check remote control. — — -= ——
Unit overheated. Allow unit to cool with fan On. —.. 5-24
Have Factory Authorized Service Station check Relay Control |[— — -= ——
board PC2.
Low weld output; no control of weld out- — — —ji If Amperage Control switch is in Remote position, connect remote |— — -= 3-6,
put. amperage control to Remote 14 receptacle RC1. Figure 4-8
Check fuse F1 and replace if open. — — > 5-28
Have Factory Authorized Service Station check Mag Amp Control f— — -» —
board PC1.
Erratic weld output. — — -»| Clean and tighten all weld connections. or er 3-3, 3-5
OM-351 Page 21
Trouble
Remedy
Fan motor FM does not run.
et aan afi
Check Power switch S1.
Check fan motor FM.
No 115 volts ac output at duplex recep-
tacle RC2; weld output available.
Reset circuit breaker CB2.
Tungsten electrode oxidizing and notre-
maining bright after conclusion of weld.
La zn
Shield weld zone from drafts.
Increase postfiow time.
ren ie =
Check and tighten all gas fittings.
Properly prepare tungsten.
Replace torch parts if water has jeaked into torch.
Lack of high frequency; difficulty in es-
tablishing an arc.
kr li
Select proper size tungsten.
Place High Frequency switch in correct position.
Check High Frequency Intensity control R7 setting.
Be sure that electrode holder cable is not close to any grounded
metal.
Check cables and torch for cracked insulation or bad connections.
Repair or replace necessary parts.
Check spark gaps and adjust if necessary.
No high frequency.
Check position of High Frequency switch S4.
If High Frequency switch 54 is in Start position, check control relay
CR1.
Have Factory Authorized Service Station check Relay Control
board PC2.
Wandering arc - poor control of direc-
tion of arc.
Reduce gas flow rate.
Select proper size tungsten.
Properly prepare tungsten.
Section
5-2B
Figure 4-9
3-8
8-2
8-1
Figure 4-11
Figure 4-11
2-3
Figure 4-11
— — al
— — -»
3-8
8-1
8-2
OM-351 Page 22
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SECTION 6 — ELECTRICAL DIAGRAMS
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OM-351 Page 23
A)
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=É
=
4
| Figure 6-2. Wiring Diagram For Welding Power Source
OM-351 Page 24
GHD A
(GREEN)
GHO B
(GREEN)
HO DGD TERM]
УВВ (52)
ELECTRODE
oO Jo
SD-137 012
OM-351 Page 25
SECTION 7 — HIGH FREQUENCY
A WARNING
HIGH-FREQUENCY RADIATION can interfere with radionavigation, safety services, computers,
and communications equipment.
mod&.1 11/92
[= e Have only qualified person familiar with electronic equipment perform this installation.
Za) ) e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the
= installation,
« If notified by the FCC about interference, stop using the equipment at once.
e Have the installation regularly checked and maintained.
e Keephigh-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding
as shown in Figure 7-3 to minimize the possibility of interference.
1 Gas Tungsten Arc Torch
A 1 2 High-Frequency Voltage
Used to help arc jump air gap be-
tween torch and workpiece and/or
stabilize the arc.
2 3 Submerged Arc Welding Gun
4 Flux
Work 5 High-Frequency Voltage
Gas Tungsten Arc Submerged Arc Used © pel arc reach workpiece
Welding (GTAW) Welding (SAW) gn xa 0693
Figure 7-1. Welding Processes Requiring High-Frequency
1 Sources Of Direct High-
Frequency Radiation
—
High-frequency source (welder
with built-in HF or separate HF
unit), weld cables, torch, work
clamp, workpiece, and work table.
2 Sources of Conduction Of
High-Frequency
Input power cable, line disconnect
switch, and input supply wiring.
3 Sources Of Reradiation Of
High-Frequency
Ungrounded metal objects, light-
ing, wiring, water pipe and fixtures,
external phone and power lines.
5-0694
Figure 7-2. Sources Of High-Frequency Radiation From Incorrect Installation Of High-Frequency Source
OM-351 Page 26
—— Weld Zone
+ Ground All
= Metal Objects
\ And All Wiring
in Cutting Zone
Using #12 AWG Wire
X
Nonmetal
Building >
`
1 High-Frequency Source (Welder With
Built-In HF Or Separate HF Unit)
Ground metal machine case, work output
terminal, line disconnect switch, input sup-
pty, and worktable.
2 Center Point Of Welding Zone
Midpoint between high-frequency source
and welding toreh.
3 Weiding Zone
A circle 50 ft (15m) from center pointin all di-
rections.
4 Weld Output Cables °
Keep cables short and close together.
Workpiece
If Required
By Codes
—
Ground
5 Conduit Joint Bonding
Electrically join (bond) all conduit sections
using copper straps or braided wire (ground
conduit every 50 ft [15 m]).
6 Water Pipe And Fixtures
Ground water pipe every 50 ft (15 m).
7 External Power Or Telephone Lines
Locate high-frequency source at least 50 ft
(15 m) away from power and phone lines.
8 Metal Building Panel Bonding Meth-
ods
Bolt or weld building panels together, install
copper straps or braided wire across seams
and ground frame.
AN 0
Metal Building
$-0695
9 Grounding Rod
Consult National Electrical Code for specifi-
cations.
10 Windows And Doorways
Cover all windows and doorways with
grounded copper screen of not more than
4/4 in (6.4 mm) mesh.
11 Overhead Door Track
Ground the track.
Figure 7-3. Correct Installation Of High-Frequency Source
OM-351 Page 27
SECTION 8 —- TUNGSTEN ELECTRODE
mod2.1 5/92
NOTE _7
For additional information, see your distributor for a handbook on the Gas Tungsten
Arc Welding (GTAW) process.
8-1. Selecting Tungsten Electrode
Table 8-1. Tungsten Size
Electrode Diameter
Amperage Range - Gas Type ¢ - Polarity
DC - Argon — Electrode
Negative/Straight Polarity
DC - Argon - Electrode
Positive/Reverse Polarity
AC - Argon — Using
High Frequency
AC -— Argon —- Balanced
Wave Using High Freq.
Pure Tungsten
(Green Band)
010° Up to 15 * Up to 15 Up to 10
020" 5-20 * 5-20 10-20
‚040° 15-80 * 10-60 20-30
1/167 70-150 10-20 50-100 30-80
3/32" 125-225 15-30 100-160 60-130
1/8 225-360 25-40 150-210 100-180
5/32" 360-450 40-55 200-275 160-240
3/16” 450-720 55-80 250-350 190-300
1/4" 720-950 80-125 325-450 250-400
2% Thorium Alloyed
Tungsten (Red Band)
010” . Up to 25 * Up to 20 Upto 15
0207 15-40 * 15-35 5-20
.040” 25-85 * 20-80 20-60
1/16” 50-160 10-20 50-150 60-120
3/32” 135-235 15-30 130-250 100-180
1/8" 250-400 25-40 225-360 160-250
5/32" 400-500 40-55 300-450 200-320
3/16" 500-750 55-80 400-500 290-390
1/4” 750-1000 80-125 600-800 340-525
Zirconium Alloyed
Tungsten (Brown Band)
0107 * Up to 20 Up to 15
020” * 15-35 5-20
040" * * 20-80 20-60
1/16" * * 50-150 60-120
3/32" * * 130-250 100-180
1/8" * * 225-350 160-250
5/32" * * 300-450 200-320
3/16” * * 400-550 290-390
1/4" * * 600-800 340-525
® Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).
*Not Recommended.
The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode
manufacturers.
OM-351 Page 28
5-0009
8-2. Preparing Tungsten
1
\
al В — 1-1/2 Times
— Electrode Diameter
1 Tungsten Electrode
2 Balled End
Ball end of tungsten before welding
by applying either an ac amperage
slightly higher than what is recom-
mended {or a given electrode diam-
eter (see Table 8-1}, or a dc elec-
trode positive amperage.
Bet. S-0161
Fiqure 8-1. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding
4 CAUTION
=
* Keep flammables away.
Ma | FLYING SPARKS AND HOT METAL can cause injury and start fires.
e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.
warn2.1 3/51
>
E
2-1/2 Times
Electrode Diameter
1 Tungsten Electrode
2 Tapered End
Grind end of tungsten on fine grit,
hard abrasive whee! before weld-
ing. Do not use wheel for other ¡obs
or tungsten can become contami-
nated causing lower weld quality.
Ref. 5-0161
1 1 Stable Arc
2 2 Flat
= Diameter of this flat determines
== amperage capacity.
3 Grinding Wheel
e 3 .
= 4 Straight Ground
©, - e g
. 5 N
4
ideal Tungsten Preparation — Stable Arc Ref. $-0162
1 1 Arc Wander
2 Point
{{ ( cu 5 3 Grinding Wheel
| LPC 4 Radial Ground
/ |
4
Wrong Tungsten Preparation — Wandering Arc Ref $-0162
Figure 8-2. Preparing Tungsten For DC Electrode Negative (DCEN) Welding
OM-351 Page 29
SECTION 9 - PARTS LIST
ST-110 838-C
Ca
UA
Fig 9-5
32 — Fig 9-6
RN
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OM-351 Page 30
Figure 9-1. Main Assembly
Replace Coils At Factory Or Authorized Service Station
item Dia Part
No. Mkgs No. Description Quantity
Figure 9-1. Main Assembly
1 21240 +098 294 .. PANEL, side ........22020 00414 La LA LL LL LA AA La a aa a La 1 2
ee 109 035 .. LABEL, warning electric shock cankilielc ........................ 1
Brenn 121 464 .. COVER, IOP... .. ooo iii i Cee 1
Beda 110881 .. SCREW, .312-18 x 7.000 hex hd pin sil .......................... 6
E L1 .... 098299... СНОКЕ .............. 5..7... коли AL LL Lea aa a aa a a LL 1
Be 108 100 .. RETAINER, bus bar ......... aie, 1
E 012 604 .. HOLDER, fuse crtg 30A 250V .............. 2.0... "e... e... 1
7 ‚ Р1... *012 610 .. FUSE, crtg 25A 250V .......... RR a a aa ae 1
Cee 121 462 .. SHAFT, extension switch (consistingof) ..........................2
2 8 aa 106 398 .... РММ, spring CS .156 X 625 .................... 5... a a a aa 1
‚ 9 ............ 094 609 .... COUPLING, shaftextension ..................... . 0.0... 1
10 ............ 121 463 .... SHAFT, extension ........... iii. 1
1 LL. 106398 .. PIN, spring CS 166 X.825 ......... Lea La a a da na a aan 2
12... 107 881 .. BRACKET, supporttransformerrear ........... aaa 1
13 С20,21 .. 091141 .. CAPACITOR 2... aaa eandendononora rana 2
14.... TE" . 034587 .. TERMINAL ASSEMBLY, pri (Fig9-4) .......... .. ..... . . . .. .. .... 1
18... 098 301 .. FRAME, upright ................. La La a A AA ALL aa 1
Ce ee 134771 .. PLUG, protective .640sq .......... citi iii... 4
Cee. D4,5 ... 082456 .. DIODEASSEMBLY ......... iii Я
16..... W .... 137902 .. CONTACTOR .................. RR AL 1
17 026627 .. GASKET, liftingeye ............ RR 1
18.... 85 . 134 630 .. SWITCH, range . .... oo ee 1
19 ............ 030.170 .. BUSHING, snap-innyl .750 1D x 1.000mtg hole .................... 1
20 ‚ 56 .... 134629 .. SWITCH, polarity/range . ....... 0. 00raaaoaaa 1
21 .... C1 . 107211 .. CAPACITOR, polyp met film 35uf 480VAC .......... RAR 3
22 O 025 142 .. BRACKET, mtgcapacitor .......... iii 1
23 ............. Fig 9-5 .. PANEL, rear weomponents ........... ._.ocore:reeceee decora, 1
24 .... R5.... 030965 .. RESISTOR, WW fxd 100W 100 ohm ...........—...... 00 0. e. 1
25... .. Z .... 098302 .. STABILIZER, (consistingof) ............... i... 1
Cee TP1 ... 026181 .... THERMOSTAT, NC .... iii |
26 .... MAT . 109633 .. AMPLIFIER, (consistingof) ........... a... 1
C27 aaa 0 098 194 .... COIL, contact LH .......22020 10001 14 AA LL LA aa Va 4 1
‚ 28 ............ 098192 .... COIL, contactac ............ вне иене, 1
‚ 29 ............ 098193 .... COIL, contact RH . . . ...... adorada, 1
BO No 098 280 .. BRACKET, support amplifier . ......... ... a La a ae 2
C31 121 632 .. BASE aaa a aeaenamononarereneeonao on 1
C32 ............ 128702 .. HF CONTROL, (Fig 9-6) ........ iii iii. 1
IB ada. 010 647 .. PIN, spring CS .156 x 1.250 ......... i, 2
REC RES 098 279 .. HANDLE, switch range ............. iii, 2
BB e. Fig 9-2 .. PANEL, front w/empnts ................. 2... 2000000000 1
.36............ 107 880 . . BRACKET, support transformer front ........... ................. 1
. 37. T1 . 140548 .. TRANSFORMER, power main 200/230/360 (consistingof) ........... 1
‚38 ............ 140 605 ....COIL, prijsec ............... ae aanoacecao 1
37... T1 .... 140545 .. TRANSFORMER, power main 230/460/575 (consistingof) ........... 1
38 ............ 140 606 .... COIL, prijsec ............. 22 e a nonracacaro. 1
Ce ee aaa 140505 .. KIT, label ..... 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-351 Page 31
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 9-2. Panel, Front w/Components (Fig 9-1 Item 35)
1 RC1 . 143976 .. CONNECTOR w/SOCKETS, (consistingof) ....................... 1
Cee 079534 .... CONNECTOR, circ skt push-in 14-18ga Amp 663586 ............ 14
Cee 134 734 .. CONNECTOR, circ 14 pin plug Amp 213571-2
eee 134 731 .. CONNECTOR, circ pin push-in 14-18ga Amp 213603-1
ean 079 739 .. CONNECTOR, circ clamp str rif sz 17-20 Amp 206322-2
eee C8.... 144299 .. LEAD ASSEMBLY, elect ............. 1
ada. C9 .... 144303 .. LEAD ASSEMBLY, elect ........ .... 1
Cee C10 ... 144300 .. LEAD ASSEMBLY, elect .......... 7
Cee C22 ... 144302 .. LEAD ASSEMBLY, elect ............ 7
anar C23 ... 144301 .. LEAD ASSEMBLY, elect .......... 1
O nnarada 010855 .. RETAINER, screw No. 2 ......... i een, 2
3 . R60 ... 030686 .. POTENTIOMETER, C sitd sft 1/T 2W 2 megohm .................. 1
4 . R12 ... 035897 .. POTENTIOMETER, Csltdsft 1/T2W 1Kohm ..................... 2
OM-351 Page 32
37
36 35 34
39 — Fig 9-3
N.
>
41
ST-110 639-E
Figure 9-2. Panel, Front w/Components
Quantity
Item Dia. Part
No. Mkgs. No. Description
Figure 9-2. Panel, Front w/Components (Fig 9-1 Item 35) (Continued)
5 ..... 54 .... 011610 .. SWITCH, tgl SPDT 10A 125VAC . .... i,
6 ..... S3.... 089085 .. SWITCH, tgi SPST 20A 125VAC .... ii.
Too S2 . 011622 .. SWITCH, tgl 3PDT 15A 125VAC ......112110 11100 tata a aa a LL
8 ..... S1.... 011609 .. SWITCH, tgl SPDT 15A 125VAC ........ 2 aa ea aa a Lea
9 .... CB1 . 083432 .. CIRCUIT BREAKER, manreset 1IP10A250V .....................
10 ............ 057359 .. BLANK, snap-innyt .375mtghole ................... ...........
11 ....CB2 ... 083995 .. CIRCUIT BREAKER, manreset 1IP15A250VAC ...................
12... .... 010357 .. NUT, speed No, 2 clip on .......... ee ee eee ieee
13 . C24 ... 135664 .. CAPACITOR 112101001004 LL AA LA LA AA LA Aa aa aa a LR
14 . RC2 ... 604176 .. RECEPTACLE, str dx grd 2P3W 15A 125V .......... .... .........
aan da 073 690 .. PLUG, str grd armd 2P3W 15A 125V Arrow Hart 5965V
15 PLG51 .. 084198 .. CONNECTOR, rect 6skt plug Amp 87159-6 (included w/SR1) .........
ee ere 081 378 .. CONNECTOR, rect skt 22-18ga Amp 102100-2 ....................
16 PLG50 .. 141642 .. CONNECTOR PLUG & SOCKETS, {consistingof) .................
Cee 113746 .... CONNECTOR, rect skt 24-18ga Molex 39-00-0038 ..............
17.... PC2 ... 157848... CIRCUIT CARD, relay ......... ite eee
18... ....... 083 147 .. GROMMET, scr 8/10 panel hole .312sq .500 high ..................
19 ............ 098 991 .. ENCLOSURE, circuitcard . . . ........ ci
20 . FL1 . 084 171 .. FILTER, line pwr 115/250V . . ii,
21..... 1T . 098828 .. BLOCK, term 104 10P ......... aa aaa
7 2... кк.к. к. 092 344 .. HEAT SINK RR a 4
„23... Shunt .. 044968 .. SHUNT, resistor ......... eee aaaar o eanrecero,
.. 24... C16,17 .. 109689 .. CAPACITOR ......1211110 0110 LL A La LA LA A AAA LL LL
‚. 25 .. SR2,VR1 . 080907 .. DIODE/SCR,integ bridge ........... i.
.. 268... С14,15 .. 111465 .. CAPACITOR La La a a La La LAVAL
„27..... R8.... 030908 .. RESISTOR, WW fxd 50W 1500hm .............................
..28..... R6.... 030601 .. RESISTOR, WW adj25W1Kohm ..............................
2. 29 ............ 605 741 .. CLIP, mtg resistor .312 ID core ........ aaa.
.30..... С2.... 109 692 .. CAPACITOR ........ 0.0000 ee a AL da a a a ae
.31.... C12 .
— 031 630.
CAPACITOR, elctit 22uf 50VDC
и + и + иди EA E AA AAA
‚ 32 .... SR3 ... 035704 .. RECTIFIER, integ 40A 800М ......... 2.2... Aa
aaa 058 712 .. CLIP, component .437diamtgadhback ..........................
.33.... CR1 . 059267 .. HELAY, encl 12VDC DPDT ... 1.111211 LL LL LL LL A a 4 ea as ae
A a 010494 .. BUSHING, snap-in nyl 1.375 ID x 1.750mtg hole ...................
35 aa 057 357 .. BUSHING, snap-innyl 937 IDx1.125mtghole ....................
36.... PC1 ... 133771 .. CIRCUIT CARD, controlmag amp ............ cuir...
37 PLG60 115093 .. CONNECTOR PLUG & SOCKETS, (consisting of) .................
Ce 113 746 .... CONNECTOR, rect skt 24-18ga Molex 39-00-0038 ...............
38 PLG61 .. 115092 .. CONNECTOR PLUG & SOCKETS, (consistingof) .................
Ce 113746 .... CONNECTOR, rect skt 24-18ga Molex 39-00-0038 ...............
39 . PB1 . 046 746 .. SWITCH, PB (Fig 9-3) 2 ee ee eee
. 40 . PL1 . 048573 .. LIGHT, ind rediens 28V ........... 2... 0recacñeradooroa
DAN, 121613 .. PANEL, front ............ 2... 0reerecaoererecreder—oaro o.
42 ............ 605 583 .. CATCH, spring loaded door .............. iin...
43 nana 134 327 .. LABEL, warning general precautionary . ..........................
‚ 44 a. +121 465 .. DOOR, access front . RK aa aa 20
aaa 128 230 .. LABEL, warning electric shock can killetc ........................
45 . 109013 .. BUSHING, snap-in nyl .375 10 x .562mtghole .....................
‚ 46 ...................... NAMEPLATE, (order by model and serial number) ..................
Y 107 983 .. BLANK, snap-in nyl .500mtg hole ...............—....0em.s0rm0rmere,
‚ 48 ............ 097 924 .. KNOB, pointer ........11111 0010 LL Le LL LA AL LL
49 ............ 097 922 .. KNOB, pointer . ... 2... ererereseenendecronrenreer.
BO Near PLATE, ident control rating (order by model and serial number) ........
CBT еее к.... 078034 .. FASTENER, screwsltdhd .7361g...............................
+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-351 Page 33
Item Part ВЕ
No. No. Description Quantity
046 746 Figure 9-3. Switch, Push Button (Fig 9-2 Item 39)
. 1... 059885... BUTTON, push resetred.................. 22... e reeiearecmievararea i
.2... 018606... SPRING, cprsn .430 0D x .040 wire x 1.500 .......... 2... reco 1
„3... 070068 .. PUSH BUTTON SET, w/cable € housing ............—re..r.00smemera rea. 1
‚4... 081008 .. BRACKET, mtg switch PB. eee, 1
‚ 5... 027 878 .. SWITCH, lim leaf actg SPDT... eee 1
2
;
\ , ;
\ /
1
\ @ 6 >
O .
8
| 5
< 6 > 3
ST-080 214-8 &, 2
< HN
Figure 9-3. Switch, Push Button ee“
<
> 7
> 1
: -
LF
ST-087 333-B
Figure 9-4. Terminal Assembly, Primary
item Part В
No. No. Description Quantity
034 587 Figure 9-4. Terminal Assembly, Primary (Fig 9-1 Item 14)
. 1... 601835... NUT, brs hex 10-32 ............. 2.220. 000.00aa0arrereredenonoaoa a 12
.2... 601 836 .. МОТ, brs hex .250-20 jam hvy ............... 0.2... 0 00rireeranoaanoo 4
. 3... 010915... WASHER, flatbrs .250 ID x ‚625 OD x .031thk . . ........................... 4
. 4... 083426 .. TERMINALBOARD, pri ...... a AL ea a aa 1
.. 5... 038888... STUD, pri bd brs .250-20 x 1.500 ........... iii, 2
‚. 6... 038 887 .. STUD, pribd brs 10-32 x 1.375... . 0002.00, ee ae aa a a a a a ee 6
.. 7... 010813 .. WASHER, На! Бг5 218 10 х .460 ОО х .031thk . ............................ 6
. 8... 038618... LINK, jumper term bd pri ........... RR RR 2
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-351 Page 34
Item Dia. Part |
No. Mkgs. No. Description Quantity
Figure 9-5. Panel, Rear w/Components (Fig 9-1 Item 23)
1 .... FM.... 116190 .. MOTOR, 1/12hp 230V 1550RPM . . i. 1
2 087 462 .. BRACKET, mtgrectifier .. .... aaa 2
3B 2.екн...... 131361 .. CHAMBER, plenum 14 in .......... i, 1
4 iaa 032 604 .. BLADE, fan 14 in 3wg 19deg .375 bore CCW... .................. 1
5 ...222404000 098 305 .. PANEL, rear ....... 2... ere aereo. ena 1
. 6 ....SR1 ... 117041 .. RECTIFIER, si diode (consistingof) ............................. 1
7 R9,VR2 .. 044482 .... SUPPRESSOR ................... PA 1
S .... D1,3 ... 037 956 .... DIODE, rect 275A GOOV SP ....2110 0004 ea aaa. 2
9 . C4-7 ... 031689 .... CAPACITOR, rectifier еи вии евеее, 4
.. 10.... D2.... 037957 .... DIODE, rect 275A 300V RP . ... 2... aaa 1
ade SCR1,2.. 107588 .... THYRISTOR, SCR 300A 300V .......... e Y
LL Lee a aa aa 028 388 .... CLAMP, thyristor rectifier 2.750 ...... .........................2
Ce 026 947 .... STAND-OFF, insul .250-20 x 1.000 Ig х .312thd .................. 2
Dana ara. 028516 ... PIN, springCS 125x.250 ................... 4
5
o
œ
~
6 ST-110 840-A
Figure 9-5. Panel, Rear w/Components
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-351 Page 35
u}
D
LA
dû
P=
o
E
U}
Figure 9-6. HF Panel
OM-351 Page 36
Нет Dia. Part
No. Mkgs. No. Description Quantity
128 702 Figure 9-6. HF Panel (Fig 9-1 Item 32)
e 039 047 .. TERMINAL, pwr output red (consisting of) ..............—.......... 2
2 601 879 .... NUT, stl hex full .500-13 ....... i. 1
Bain 039 044 .... BUS BAR, term bd ............. 2... 0000 nereracvara 1
A 601 880 .... NUT, stl hex jam .500-13 .................... addon aan 1
oS 039 049 .... TERMINALBOARD, red ........... iin. 1
2. 6 ............ 601976 .... SCREW, cap stlhexhd .500-13x1.500 ......................... 1
7 ...C18,19 .. 147869 .. CAPACITOR ...... arado onedóa,rorevoraoa 2
2. 8 1........... 108 100 .. RETAINER, bus bar ......... i iene 1
.. 9 .... R7.... 605828 .. RHEOSTAT, WW 50W 1.50hm ............ 2.00. н вене. 1
AO ............ 124 649 .. STRIP, mtg HF coil ................ .ecedeaoaoananooaco 1
.. 11.... T3.... 128375 .. COIL, HF coupling air RR 1
2 039049 .. TERMINAL BOARD, red ........ i 2
.. 13.... K3 .... 083784 .. RESISTOR, WW ixd 100W 10ohm ............. 2... re. 1
AA 605 742 .. CLIP, mtg resistor 500 ID core .........22220202 00111 LL La Lacan a 1
AB a 128 580 .. ENCLOSURE, HE panel ........ eee 1
.. 16.... C3 .... 106935 .. CAPACITOR, polyp film 10uf 250VAC ............ 2.9. Lau 1
.. 17.... T2 .... 074398 .. TRANSFORMER, high voltage 115V pri 3600V sec 30MA ............ 1
e AB e, 107219... STRIP, insulator .............. 2... ee ea 4 A 4 nara anarema 1
2. 19 ............ 020 623 .. SPARK GAP ASSEMBLY, (consistingof) ......................... 1
20. 095 621 .... BASE, spark gap ..........eoecerarer0 ae a0caerredorerneeno 1
2 LL 11120 020 622 .... HOLDER, points .......... 2... aa a aa a aa a LL LL LL LL 4
.22.....G ... “020603 .... POINT, spark gap .........0000 000444 4 a La a a ae a a a a ana ee 4
aaa aan 602 023 .... SCREW, cap st! sch 10-24 x .750 ......... A
.. 23.... G13 ... 096761 .. CAPACITOR, mica .002uf 10000VDC ............ i. 1
dr LL 097 922 .. KNOB, pointer . . ee ee a ae 1
.. 25.... GS1 .. +109930 .. VALVE, 24VAC 2 way 1/4 IPS 1/8 orf ....... aaa 1
2. 26 ........... +010 296 .. FITTING, hose brselb M 1/4NPT x 625-18RH .................... 2
*Recommended Spare Parts.
+ These items are not part of HF Panel.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-351 Page 37
Description
Quantity
Optional Equipment
. METER KIT, (consisting of)
. METER SET, AC (consisting of)
PANEL, front meter box
PANEL, rear meter box
WRAPPER, meter box
METER, volt AC 0-100 scale
METER, amp AC 0-500 scale
..... FILTER, HF AC amp meter
FILTER, HF DC volt & amp meter
. TRANSFORMER, current 500/5
. COVER, top
. BUSHING, snap-in nyl .625 ID x .875mtg hole
. METER KIT, (consisting of)
. METER SET, DC (consisting of)
Dia Part
Mkgs No.
aaa 041 934
aaa aaa 111 609
SE 108 956 .....
Cee 108 957 .....
Ce 108 961 .....
‚ М2 ...... 025 645 .....
‚ А2...... 025 649 .....
.P2...... 025 700
.P1...... 025701 .....
CT1 ..... 110924...
ano 126 752 .
RS 010 493 .
RS 041 936 .
Cee 111610.
aaa 108 956 .....
Ce 108957 .....
Ce 108 961 .....
‚ М1 ...... 025 638 .....
y 025664 .....
‚ Р1...... 025 701 .....
RS 126752 ....
Shunt . 030081 ..
Ce 010493 ...
aaa 041 938 ..
Ce 111 611 ....
aaa 108 959 .....
Cee ea 108 958 .....
RS 108 955 .....
.V2...... 025 645 .....
A 025638 .....
‚A2...... 025 649 .....
‚ А1...... 025 664 .....
‚ Р1...... 025701 .....
‚ Р2...... 025 700 .....
СТ1 ..... 110924...
Shunt . 030081 ....
Cee ea 126752 ....
aaa 010 493 ..
Cea 042 246 .
PC2 ..... 157 844...
CRI ..... 107 524 ....
PLG52 ‚ 072566 ....
Cee 081378 ....
R59 ..... 028 768 ..
Ce 097 922 ..
‚S7...... 011609 ....
PANEL, front meter box
PANEL, rear meter box
WRAPPER, meter box
METER, volt DC 0-100 scale
METER, amp DC 50MV 0-500 scale
FILTER, HF DC volt & amp meter
COVER, top
. SHUNT, meter 50MV 500A
. BUSHING, snap-in nyl .625 1D x .875mtg hole
METER KIT, (consisting of)
PANEL, front meter box
PANEL, rear meter box
WRAPPER, meter box
= = = = # = + = + = +
Bb 4 A = ол
BE ow hoy hk od к a = 0m
* = = AR
a & * ® = 4 +* = = +»
= a + = a a = = =: + =
и + “+ =
и я + и + 1 oF
+ # 1 # тт о в Кая
+ 4 4 4 4 4 7 8m om op om
= a к я А в Ч = # #
PF = тит тя
= = =: = = + = = = …
= = = = = + = = = a
LL LL LR LL LR LL LL
LL LL LL LL LL
LL LL LL LL LL 10
AL 4 LVL LL LL LL LL LL RL LL LA LL LL LL LA LL LAS
LL LL LL LL LL LL LL
aaa aaa aaa ano
ee ee ee 110
Ce
LL anarerdoer_ooera
Ce ee ee ee aa
DE
ee LL
PT
LL LL LL LL 111.
LIL LL LL LL LL LL 0
ee выоеые
ER
FE
21 1 4 4 4 4 4 1 ALL 4111111 LS
LL LL LL LL LL 11
KERN aaa
ee or—erdowo dadarer
Ce LL LL
LL LL LL LL LL 10
Мы
METER SET, AC/DC (consisting of) ............ ..................
oe LL LL RL L0
LL LL LL LL RL LL RAR ALL
= HE & 4 кв А Ка нон 5 = =m =m 4 =m = ss ss 1 = ¥ F WW оч ов оч + 4 EW ss EH 4 mE A A
METER, volt AC 0-100 scale
METER, volt DC 0-100 scale
METER, amp AC 0-500 scale
METER, amp DC 50MV 0-500 scale
FILTER, HF DC volt & amp meter
FILTER, HF AC amp meter
. TRANSFORMER, current 500/5
SHUNT, meter 50MV 500A
COVER, top
. BUSHING, snap-in nyl .625 1D x .875mtg hole
PRE- FLOW/SPOT TIMER, (consisting of)
. CIRCUIT CARD, relay
RELAY, encl 12VDC 3PDT
CONNECTOR, rect 8skt plug cabie Amp 87159-8
CONNECTOR, rect skt 22-18ga Amp102100-2
. POTENTIOMETER, C sitd sft 1/T 2wW 350K ohm
. KNOB, pointer
SWITCH, tgi SPDT 15A 125VAC
* = = tv Ww F > EF 3 EF mE 7 mE F E EN N a 4 = 4 #
= ¥ # = = = = & 5 ww # Ww + W = WwW N N FB HE = EH om
4 = ны и ® 4 в 4+ м от чот оч жи ти ви ож =» +
в ки ки а 4 ан и кон FT om OF OW" + "WOE oA OE Eom
= = # 4 + = 5 = WNW OF ER OF A + A FB EH BE A mA x
4 =m & =m = = = E ww yy =m Fp ar 1 + FF EH OE A mw oA m=
я ея и =: = + = + = + 4 = = mB 4 в оч ти вм
# и = кн ноя К и око + 4 1 4 & 4 wm 4 + + 4 + 4 F =m pg = Ww Ww Ww FPF mE mw 4 4
= : = ® тои отн тои EE & EH #* BE = ¥ #6 #4 4 ¥ 4 Fk 4 k 4 & 4 = 4 ww + FT F FT F FB ENE FT EN a4 EN + §F AL HE + =
= = = чо к > к + ни BF = = 4 + = + = = #4 p
. = чи чин кон = a + = 4 и 4 4 я ва *
+" # NN % поминки том я и OE EW OT om OE EN BoE EE = 4 OF 4 =m wow wow
# # m= ®% ини нон ян + и ож ой + чи оч вн нон a 4 WE к на он в я на ти ти =
= = x = & 4 4 du + ити тн ти жи +
ок че ме м точит ни не и ава в q
т я ки ке 4 к тж EE кин ен в и * a + 4 x
т и ки + пан жк к в 4 AAA A, F OW W #& mE отн ок mE = a4 = a4 8
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-351 Page 38
OPTIONS AND ACCESSORIES
ANALOG METER KITS
Includes voltmeter and ammeter
housed in metal case, which
mounts on top of power source.
Meters RF protected.
Type Factory Field
DC (#041 936) (#041 937)
AC (#041 934) (#041 935)
AC/DC (#041938) (#041 939)
PREFLOW/SPOT TIMER
(#042 246 Factory)
(#042 247 Field)
Includes an adjustable spot time of
0 to 5 seconds, and a fixed preflow
time of approximately 2 seconds.
WATER VALVE KiT
(#042 038 Field only)
NO. 20 RUNNING GEAR
(#041 581)
Four 8 in. (203 mm) poly/rubber
blend wheels with 30 in. (762 mm)
towing handle.
NO. 5CR CYLINDER RACK
(#041 584)
Used with No. 20 running gear.
NO. 3WA WELDING
ACCESSORIES
(#040 043)
35 ft. (10.6 m) No.1/0 electrode
cable with electrode holder and lug
attached, 30 ft. (9 m) No.1/0 work
cable with lugs attached, welding
helmet, and wire scratch brush.
REMOTE CONTROLS AND
SWITCHES
RHC-14 HAND CONTROL
(#129 340)
Miniature hand control for remote
current and contactor control.
Dimensions: 4 in. (102 mm) x
4 in. (102 mm) x 3—1/4 in. (82 mm).
Includes 20 ft. (6 m) cord and
14--pin Amphenol plug.
RFC—14 FOOT CONTROL
(#129 339)
Foot current and contactor control.
20 ft. (6 m) cord and 14—pin
Amphenol plug.
RMLS—14 SWITCH
(4129 337)
Momentary— and maintained
—contact rocker switch for
contactor control. Push forward for
maintained contact and back for
momentary contact. Includes 20 ft.
(6 m) cord and 14—pin Amphenol
plug.
FTC-14
(#129 338)
Remote fingertip control can be
taped to TIG torch, contactor and
current control. Includes 28 ft. (8.5
m) cord and 14-pin plug.
Pre-wired.
EXTENSION CABLES FOR
14-PIN REMOTE CONTROLS
(4122972) 10 ft. (3 m)
(4122973) 25 ft. (7.6 m)
(#122 974) 50 ft. (15.2 m)
(#122 975) 75 ft. (22.9 m)
WELDING TORCHES
MT-18, 350 AMPS (MAX.)
For hand-held manual
applications.
Only available with “bonded”
tri-flex cable assembly.
Explanation of Model
Description
MT = Miller Torch
18 = 350 Amps
12 = 12ft (3.8 m) cable
25 = 25ft. (7.6 m) cable
\ = Gas Valve
Note: Water—cooled torches require
power cable adapter (#116 228).
MT—18 Models
(#116 151) MT-18-12
(4116 152) MT-18-25
(4116 153) MT-18V-12
(4116 154) MI-18V-25
Includes torch body with handle,
300HS heat shield, long backcap,
and cable assembly.
MT-18 TORCH KIT
(4129 592) 12-1/2 ft. (3.8 m)
(4129 591) 25 ft (7.6 т)
Inciudes hose and hardware
hook-up kit (THK-1), consumable
accessory kit (TAK—3),
regulator/flowmeter (HRF-2425),
ground cable with clamp, and
power cable adapter.
WATER COOLANT
SYSTEMS
For detailed information regarding
coolant systems, refer to Literature
Index NO. AY/7.2.
COOLMATE™ 4
(#042 288) 115 VAC, 50/60 Hz
(#042 289) 230 VAC, 50/60 Hz
4 gal. (15.1 L) tank capacity. Used
with water-cooled torches rated up
to 600 Amps.*
RADIATOR 1A AND 2A
(#042 492) Radiator 1A, 115
VAC
(#042 493) Radiator 2A, 230
VAC
1.5 gal. (5.7 L) tank capacity. Used
with water-cooled torches rated up
to 500 Amps.*
WATERMATE™ 1A AND 2A
(#042 495) Watermate 1A,
115 VAC
(#042 496) Watermate 2A,
230 VAC
2 gal. (7.6 L) tank capacity. Used
- with water—cooled torches rated up
to 500 Amps.*
"Note: This may vary, depending on the
torch design and cable length.
SUGGESTED WIRE
FEEDER
(Spray Transter)
$5-325 VOLTAGE SENSING
WIRE FEEDERS
Refer to Literature Index No.
M/6.21.
SPOOLMATIC® 30A
(#130 831)
200 Amp, 100% duty cycle,
air—cooled 1 |b. spool gun with 30
ft. (9.1 m) cable assembly.
WC-115A WELD CONTROL
(#137 546)
Designed for use with the
Spoolmatic 30A spool gun and a
DC power source having only
115VAC available.
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