Miller DIALARC HF, DIALARC HF-P Owner's Manual

3 April 1975 FORM: OM-315 Effective with serial No. HF826825 MODEL STOCK NO. DIALARC HF 901 782 DIALARC HF-P 901 788 MILLER ELECTRIC MFG. CO. APPLETON, WISCONSIN, USA 54811 ANTE, TOM NWSA CODE NO. 4579 зоо 0 A ONDOOBNOADCDOCADOCOAOONOONOCOCONNANOOOCNOOCOAOdONAOANCANOS Y VV OU OU SOU VU UE UN ed hal 25 5 Ed ES - 1 DODDOOOCCODOOOCOOaOOCODOOCOOOONL N ARSACLODODDNDACALOOONOOOOOCGCOOOOCOwOOdOU vd OI O OOOO JIIOOE WARRANTY MILLER Electric Mfg. Co., Appleton, Wisconsin, warrants all new equipment to be free from defects in material and factory workmanship for the periods indicated below, provided the equipment is installed and operated according to manufacturer's instructions. цоп р UU OUVVUUTOTGAIUTUUWUUd TUU dVwSsHo TTT MILLER Electric Mfg. Co.'s obligation, under this warranty, is limited to replacing or repairing any defective part or correcting any manufacturing defect without charge during the warranty period if MILLER’S inspection confirms the existence of such defects. MILLER'S option of repair or replacement will be f.o.b. factory at Appleton, Wisconsin or f.o.b. a MILLER authorized service facility, and therefore no compensation for trans- portation costs of any kind will be allowed. The warranty period, beginning on the date of sale to the original purchaser-user of the equipment, will be as A O O PD E E E LWW ULL follows: 1, Arc welders, power sources, and components — 1 year 2. Original main power rectifiers — 3 years (unconditionally) 3. MHFC-L1 Feeder, MHG-35C1, 20E, 20K, and all guns and torches — 90 days 4. All other Millermatic Feeders — 1 year 5. Mag-Diesel engine on DEL-200 — 6 months 6. All other engines — 1 year Engine Warranties are covered by the engine manufacturers, subject to their procedures and to be handled through their authorized local Service Stations or agencies. No warranty will be made in respect to trade accessories, such being subject to the warranties of their respective manufacturers. MILLER Electric Mfg. Co. will not be liable for any loss or consequential damage or expense accruing directly or indirectly from the use of equipment covered in this warranty. This warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied. DOQDOUDO0ODO0ODOOODOdODO0ODODEOEQUODQUD COUSCOUS Оооо ОО Оооо р CR UT QU UF EF KF EF oJ oF LF LF NY EF OF LF LF LI UJ UF OJ DROOL D0000QC 0000000000000 00000C0CQ000Q0000Q000000B000Q0B0800 ¢ O 1d dl 0 UN Y Y 1 1 CICR UE CS CI CRUE EF 14 14 E ES UB Y KN Y Y ee a NN AUSUEUSSAUS OO Dodo dd udd hdd odô und vd doudou dou OPTIONAL ACCESSORIES means No. 2 WA Welding Accessories (Stock No. 040 039) Consists of 35 feet of No. 2 electrode cable with insulated electrode holder, 30 feet of No. 2 ground cable, ground clamp, welding helmet, wire scratch brush. Jack plugs are fumished with the welder. No. 2B {Stock No. 040 014) Four 8” solid rubber tired wheels with towing handle. No. 1BCR (Stock No. 040 010) Same as No. 1B, but with provisions for carrying two gas cylinders, No. 2BCR (Stock No. 040 015) Same as No. 2B, but with provisions for carrying two gas cylinders. RHC-3 {Stock No. 040 056) Remote hand amperage control. Supplied with 20° cable and plug. RFC-3A (Stock No. 040 068) Remote foot amperage control. Supplied with 20° cable and plug. RFC-23AG (Stock No. 041 161) Remote foot control for amperage and contactor. Supplied with 20” cable and plug. RHS-2G (Stock No. 041 157) Momentary contact {normally open) hand switch for remote contactor control. Fastens to TIG torch handle. CERTIFICATE NAME OF EQUIPMENT: MODEL NO. SERIAL NO. DATE This equipment has been type-tested under standardized field test conditions as recommended by the Joint Industry Committee on High Frequency Stabilized Arc Welding Machines found to rad- ¡ote less than 10 microvolts per meter at a distance of one mile, the maximum allowable limit established by the Federal Communications Commission for equipment of this type. Installations using this equipment on the basis of these tests, may reasonably be expected to meet the radiation limitations established by the Federal Communications Commission, only when installed, operated and maintained as specified in the instruction book provided. USER'S CERTIFICATION The welding equipment identified above has been installed in accordance with the specific instructions applicable to this model as outlined in the instruction book furnished, It is being used only for the purpose for which it was intended and is being maintained and operated in accordance with the manufacturer's instructions. Date Installed Signed ED TAB | E OF CONTENTS SA Paragraph No. Page No. SECTION 1 — SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE Introduction .....222 4224414 42 4 4 4 4 4 4 a 4 xadudreoraroararernrdanerneoa General! Precautions........12010 444044 4 4 4e 4 4 a 4 ee a 4 4 8 a a 4 ee a ee 6 Arc Welding........2022002 04424444 ea 1e ee 14 41 4e 0 ae a a 1 eee» Standards Booklet Index . ..... 200100010444 1 24 1 aa 2 a a a 8 ea a eue» — — — sk SONT Bow = = SECTION 2 — INTRODUCTION General eee НИЕ Receiving-Handling ........._.c_e-eoreanerarare ene ar2eonerecere. | Description ..........eeeeereearanaveróreravcracanvenanenemera Safety .....eecrereremrrreremderererononenaenamanaooneari arena Ro RR MY & (0 № > th сл eL SECTION 3 — INSTALLATION Location st tt ee ee ee eae ee eee Electrical Inpüt Connections ........._eerecarereo rr inane eens Secondary Welding Connections ........e—.—.ewe.eororzerervereovec. Remote Amperage Control Connections .........e_._eee.eeeeraacoa Contactor Control Connections. ........e.eeceeevaeneereraaroe one. Coolant Valve Connections ..........eeeeenegeonerenanoare vere. Shielding Gas Valve Connections ...........—ee_e.errecrrorrereecoa. ‘2 0 © WWW MW мо о) сл В О Юге ONO “YO SECTION 4 — FUNCTION OF CONTROLS Power Switch oc ti ee ee ee eee 4 a a a 0 0 Range Selector Switch... co oi eee Amperage Adjustment Control .... ee Amperage Control Receptacle & Switch... ........... oat. Control Circuit Overload Breaker ..... iii eee tees Weld Selector Switch . «o.oo i re ee eae Contactor Control Receptacle & Switch .............. oo... High Frequency Switch ... Li iit eae Post-Flow Timer ....... cc. inate 4 a 0 a 0 ee eee 115 Volts AC Receptacle RR 4 4 4 a 1 ea 0 a + Duty Cycle 1.221021 ee i ere ea Ran Volt-Ampere Curve ... 1.122210 0 01244 144 482 440 4 44 4 KEG 1 вов ов В бы ев въ юн оо мо о вор > D © (O © © © © CO CO © D — — =mk SECTION 5 — SEQUENCE OF OPERATION 5-1, Shielded Metal-Arc {Stick Electrode) Welding ....................... 10 5-2. Gas Tungsten-Arc (TIG) Welding. .... oc. oii ei iin 10 5 - 3. Shuttind Down i ee ee eee eee a ee 0 11 SECTION 6 — MAINTENANCE 6-1. Fan Motor ......22220 222004 ea aa sa ee ae a ae ee ee sa es aan en 0 11 6-2. Transformer ..........e0rree0eneadre na oavereoavacanooaaronó en 11 6-3. Rectifier ...... a ee et ee ee eee ee ea ee 11 6-4, OpPark Сар oo it eee ee eee eae da vera 11 SECTION 7 — TROUBLESHOOTING Paragraph No. Page No. SECTION 8 — CERTIFICATION FOR HIGH FREQUENCY ARC WELDING EQUIPMENT 8-1. General ........ RR PA 13 8 - 2. General Information ..L.1.2 2114414 1 ee 4 La 1 a a ea ea aan a 6 13 3-3. Power Service .....1010 20 4 84 0 4 a 4 4 a a 0 a 4 aa ua na ae eee eae 13 8-4, Welding Machine «ie ere te eens 13 8-5, Welding Leads .......2224 4004444 a ee ea a a AV La teen 14 8-6. Wiring in the Vicinity of the Welding Area ............. ccc... ... 14 8- 7. Grounds Li ee eee 14 8-8 Metal Building 0.00 eee etter eta ea, 14 8-9. Individual Installation Certification . . . . ... o.oo ite ieee 15 8-10. Check List... iti te eee ee ee ee eee ee eee 15 PARTS LIST mem SECTION 1-SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE mum 1-1. INTRODUCTION We learn by experience. Learning safety through personal experience like a child touching a hot stove 1s harmful, waste- ful, and unwise. 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, devel- opment, and field experience have evolved reliable equipment and safe installation, operation, and servicing practices. Acci- dents occur when equipment is improperly used or maintained. The reason for the safe practices may not always be given. Some are based on common sense, others may require technical volumes to explain. It is wiser to follow the rules. Read and understand these safe practices before attempting to install, operate, or service the equipment. Comply with these procedures as applicable to the particular equipment used and their instruction manuals, 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, Responsibilities of installer, user, and serviceman. Installa- tion, operation, checking, and repair of this equipment must be done only by a competent person, experienced with such equipment. These safe practices are divided into two Sections: 1 - General Precautions, common to arc welding and cutting; and 2 - Arc Welding (and Cutting) (only), Reference standards: Published Standards on safety are also available for additional and more complete procedures than those given in this manual. They are listed in the Standards Index in these safety rules. ANSI 249.1 is the most complete. The National Electrical Code, Occupation Safety and Health Administration, local industrial codes, and local inspection - requirements also provide a basis for equipment installation, use, and service, GENERAL PRECAUTIONS Burn Prevention Wear protective clothing - leather (or asbestos) gauntlet gioves, 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. Avoid oily or greasy clothing. A spark may ignite them, Hot metal such as electrode stubs and workpieces shoyld 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 uniess medical facilities are close by for immediate treatment of fiash burns of the eyes and skin burns, Ear plugs should be warn when working on overhead or in a confined space. A hard hat should be worn when others work overhead. Flammable hair preparations should not be used by persons intending to weld or cut. Toxic Fume Prevention Adequate ventilation, 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 ANSI Stan- dard Z49.1 listed 1 in Standards index. NEVER ventilate with oxygen. Lead, cadium, zinc, mercury, and beryllium bearing and simi- tar materials, when welded {or cut) may produce harmful concentrations of toxic fumes. Adequate local exhaust ventilation must be used, or each person in the area as well as the operator must wear an air-supplied respirator. For beryllium, both must be used. Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed from the work surface, the area is well ventilated, or the operator wears an air-supplied respirator. Work in a confined space only while it is being ventilated and, if necessary, while wearing an air-supplied respirator. Gas leaks in a confined space should be avoided. Leaked gas in large quantities can change oxygen concentration danger- ously. Do not bring gas cylinders into a confined space. Leaving confined space, shut OFF gas supply at source. The. space will then be safe to re-enter, if downstream valves have been accidently opened or left open, Vapors from chlorinated solvents can be decomposed by the heat of the arc (or flame) to form PHOSGENE, a highly toxic gas, and other lung and eye irritating products. The uitra- violet (radiant) energy of the arc can also decompose tri- chloroethylene and perchioroethylene 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 atmosphares containing even minute amounts of trichlorethylene or perchlorethylene. 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 fiy 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. M combustibles are in ama, do NOT weld or cut. Move the work if practicable, to an area free of combustibles. Avoid paint spray rooms, dip tanks, storage areas, ventilators. If the work can not be moved, move combustibles at least 35 feet away out of reach of sparks and heat; or protect against ignition with suitable and snug-fitting, fire-resistant covers or shields. Walls touching combustibles on opposite sides should not be welded on {or cut). Walls, ceilings, and floor near work should be protected by heat-resistant covers or shields. Fire watcher must be standing by with suitable fire ex- tinquishing equipment during and for some time after welding or cutting if: a. appreciable combustibles (including building construc- tion) are within 35 feet Ь. appreciable combustibles are further-than 35 feet but can be ¡gnited by sparks e. openings (concealed or visible) in floors or wails within 35 feet may expose combustibles to sparks d. combustibles adjacent to walls, ceilings, roofs, or metal partitions can be ignited by radiant or conducted heat. Hot work permit should be obtained before operation to ensure supervisor's approval that adequate precautions have been taken. After work is done, check that area is free of sparks, glowing embers, and flames. An empty container that held combustibles, or that can produce flammable or toxic vapors when heated, must never be welded on or cut, unless container has first been cleaned as described in AWS Standard AB.0, listed 3 in Standards index. OM-315 Page 1 Page 2 This includes: a thorough steam” or caustic cleaning (or: a solvent or water washing, depending on the combustible's solubitity) followed by purging and inerting with nitrogen or carbon dioxide, and. using protective equipment as: recommended in AB8.0. 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 r sight to determine if itis safe to weld or cut. Hollow castings or containers must be vented befare welding or cutting. They can explode. Explosive atmospheres. Never weld or cut where the air may con tain flammable dust, gas, or liquid vapors (such as gaso- itne Compressed Gas Equipment Standard precautions. Comply with precautions in this manual, and those detailed in CGA Standard P-1, PRECAU- TIONS FOR SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, listed 6 in Standards index. 1. Pressure Regulators Regulator relief valve is designed to protect only the regula tor from overpressure; it is not intended. to protect any downstream equipment. Provide such protection with one or more relief devices. - . a Never connect a regulator to a cylinder containing vas ‚other than that for which the regulatory was designed. | : Remove faul ty regulator from service immediately forrepair (first close cylinder valve! The following symptoms jr indicate a faulty regulator: at ae 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 emt son Son faulty regulators for repair to manufacturer's designated repair center, where special techniques and tools are used by trained personnel. 2. Cylinders | | Cylinders must be handled carefully to prevent leaks and damage to their walls, valves, or safety devices: Avoid electrical circuit contact with cylinders including third . rails, electrical wires, or welding circuits. They can produce short circu ares 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. Et is illegal and hazard ous. -Empties: Keep valves closed, replace caps securely; mark MT; keep thém separate from FULLS and. return promptly. Prohibited use. Never use a cylinder. or. its contents for other than its intended use, NEVER a.a support or, roller. Secure from faliing. Chain or secure cylinders upright when a regulator {and hose). are connected toit. Passageways and work areas. Keep cylinders clear of areas where they may be struck. - , | Transporting cylinders. With a crane, use a secure support such as a platform. or cradle. Po NOT lift cylinders. off the ground by their valves or caps, or oy chains, slings, or mag- nets. 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 particulary valves from bumps, falls, falling objects, and weather. Replace caps securely when moving cylinders, ` Stuck valve. Do NOT use a hammer or metal wrench to open a cylinder valve that can not be opened by hand. Notify your supplier. Mixing gases. Never ty to mix any gases ina cylinder. ; Never refill any cylinder. Cylinder fi fittings should never be modified or exchanged. 3 Hose - | В Prohibited -use. Never use hose other than that designed for the specified gas. A general hose identification rule is: red for fuel 93s, green for oxygen, and black fori inert gases. Use ferrules or. clamps designed for the hose (not ordinary wire or other substitute). asa binding to connect hoses to | fetings. ‘No copper tubing spices. Use only standard brass fittings to splice hose, Avoid long runs 16 prevent Kinks and abuse. Suspend hose off * ground to kesp it from being run over, stepped on, or other- — wise damaged. Coil excess hose to prevent kinks and tangles. Protect hose “from damage. by sharp edges, ‘and by sparks, siag, and open flame. Examine ‘hose regulary’ for leaks, wear, and loose соппес- tions. Immerse pressured” hose in. water; bubbles indicate leaks. a Repair leaky or worn’ hose: by cutting area out and spli icing (1:23). Do NOT use tape. - 4. ‘Proper Connections Clean eylinder vaive 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 lint less cloth: - "Match regulator. 1 to cylinder. Before connecting, check that the regulator label and cylinder marking agree, and that the ‘reguiator inlet and cylinder outlet match. NEVER CON- NECT a regulator designed for a particular gas or gases to a cylinder containing any other gas. "Tighten connections. When assembling threaded connections, clean and. smooth. seats where necessary. Tighten, If connec- ‘tion leaks, disassemble, clean, and retighten, For metal-to- metal seating, use correct wrenches, available from your supplier. For O-ring connections, hand tighten, _ Adapters. Use a-CGA adapter (available from your supplier) between cylinder and regulator, if one is required. Use two wrenches to tighten adapter marked RIGHT and LEFT HAND threads. ‘Regulator outlet (or hose) connections may be identified by right hand threads for oxygen and left hand threads (with grooved hex on nut or shank) for fuel gas. 5. Pressurizing Steps: - Drain regulator of residual gas through suitable vent before opening cylinder: {or manifold valve) by turning adjusting screw in (clockwise). Draining prevents excessive compression heat at.high pressure seat by allowing seat to open on pressurization. Leave adjusting screw engaged slightly on single-stage regulators. Before opening cylinder valve, check that hoses are connected and that downstream valves are closed. - “Stand to sidé of regulator while opéning eytinder valve. Open. cylinder” valve siowiy so that regulator pressure increases slowly. When gauge 1s pressurized (gauge reaches regulator maximum} leave cylinder valve in following position: For oxygen, and inert gases, open fully to seal stem against 1-3. possible teak. 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. !: will reduce backfiring and chance of flashbacks. Check for leaks on first pressurization and regularly there- after. Brush with soap solution (capful of lvory Liquid* or equivalent per gallon of water}. Bubbles indicate leak, Ciean off soapy water after test; dried soap is combustible. User Responsibilities Remove leaky or defective equipment from service immed- tatety and repair them only if recommended in equipment instruction manual. Send others for repair to manufacturer's designated repair center where special techniques and tools are used by trained personnel. Refer to User Responsibilities statement in equipment manual. Leaving Equipment Unattended Close gas supply at source and drain gas. Rope Staging-Support Rope staging-support shouid not be used for welding or cutting operation; rope may burn. ARC WELDING Comply with precautions in 1-2 and this section. Arc Weld- ing, properly done, is a safe process, but a careless operator invites trouble. The equipment carries high currents ai signifi- cant voltages, The arc is very bright and hot. Sparks fly, fumes rise, ultraviolet and infrared energy radiates, weld- ments are hot, and compressed gases may be used. The wise operator avoids unnecessary risks and protects himself and others from accidents. Precautions are described hers and in standards referenced in index. Burn Protection Comply with precautions in 1-2. The welding arc is intense and visibly bright. 1s radiation can damage eyes, penetrate lightweight clothing, refiect 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 PRECAUTIONS, 1. Protective Clothing Wear longsleeve clothing {particularly for gas-shielded arc) in addition to gloves, hat, and shoes (1-2A). As necessary, use additional protective clothing such æ teather 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. 9 or denser must be used when welding. Place over face before striking arc. Protect filter plate with a clear cover plate. Cracked or broken helmet or shield shouid NOT be worn; radiation can pass through to cause burns, Cracked, broken, or {oose filter plates must be replaced IM- MEDIATELY. Replace clear cover plate when broken, pitted, or spattered. Fiash goggles with side shields MUST be worn under the helmet to give some protection to the eyes should the helmet not be lowered over the face before an arc is struck. Looking at an arc momentarily with unprotected eyes (particularly a high intensity gas-shieided arc) can cause a retinal burn that may leave a permanent dark area in the fieid of vision. - *Trademark of Proctor & Gamble. 3. Protection of Nearby Personnel Enclosed welding area. For production welding, a separate room ar enclosed bay is best. In open areas, surround the “operation with low-reflective, non-combustible screens or panels. Allow for free air circulation, 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 al! persons are wearing flash goggles. Before starting to weld, make sure that screen flaps or bay doors are closed. Toxic Fume Prevention Comply with precautions in 1-2B. Generator engine exhaust must be vented to the outside air. Carbon monoxide can kill. 7 Fire and Explosion Prevention Comply with precautions in 1-2C. Equipments 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. Ft creates a brittle area that can cause a violent rupture or lead to such a rupture later under rough handling. Compressed Gas Equipment Comply with precautions in 1-2D. 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 dampness 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 installing, connect the frames of each unit such as welding power source, control, work table, and water circula- tor to the building ground. Conductors must be adequate to carry ground currents safely. Equipment made electrically HOT by stray current may shock, possibly fatally. Do NOT GROUND to electrical conduit, or to a pipe carrying ANY gas or a flammable liquid such as oil or fuel. Three-phase connection. Check phase requirement of equipment before installing. If only 3-phase power ls available, connect single-phase equipment to only two wires of the 3-phase tine. Do NOT connect the equipment ground lead to the third (live) wire, or the equipment will become electrically HOT - a dangerous condition that can shock, possibly fatally. Before welding, check ground for continuity. Be sure conductors are touching bare metal of equipment frames at connections. y If a line cord with a ground lead is provided with the equipment for connection to aswitehbox, connect the ground lead to the grounded switchbox. If a three-prong plug is added for connection to a grounded mating receptacle, the ground lead must be connected to the ground prong only. If the line cord comes with a three-prong plug, connect to a grounded mating receptacle. Never remove the ground prong from a plug, or use a plug with a broken off ground prong. OM-315 Page 3 Page 4 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. bh. Terminals Terminals and other exposed parts of electrical units should have insulating covers secured before operation, 6. Electrode Wire Electrode wire becomes electrically HOT when the power switch of gas metal-arc welding equipment is ON and welding gun trigger is pressed. Keep hands and body clear of wire and other HOT parts, 7. Safety Devices Safety devices such as interlocks and circuit breakers should not be disconnected or shunted out. Before installation, inspection, or service, of equipment, shut OFF all power and remove line fuses (or lock or red-tag switches) to prevent accidental turning ON of power. Discon- nect all cables from welding power source, and pull ali 115 volts fine-cord plugs. 1-4. 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. STANDARDS BOOKLET INDEX For more information, refer to the following standards or their latest revisions and comply as applicable: 1. ANSI Standard 248.1, SAFETY IN WELDING AND CUTTING obtainable from the American Welding - Society, 2501 NW 7th St., Miami, Fla. 33125. 2. ANSI Standard Z87.1, SAFE PRACTICE FOR OCCUPA- TION AND EDUCATIONAL EYE AND FACE PROTEC- TION, obtainable from American National Standards Institute, 1430 Broadway, New York, N.Y, 10018. 3. American Welding Society Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable same as item 1. 4. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING AND CUTTING, obtainable from the National Firs Protection Association, 470 Atlantic Avenue, Boston, Mass. 02210. 5. NFPA Standard 51B, CUTTING AND WELDING PRO- CESSES, obtainable same as item 4, 6. CGA Pamphlet P-1, SAFE HANDLING OF COM- PRESSED GASES iN CYLINDERS, obtaineble from the Compressed Gas Association, 500 Fifth Avenue, New York, N, Y. 10036, 7. OSHA Standard 29 CFR, Part 1910, Subpart Q, WELD- ING, CUTTING AND BRAZING. ————]——.0 2 SECTION 2 - INTRODUCTION ———e—mmmmemmesmeenmnennÜnmnnnn Rated ; Welding Welding Rated Current Current Amperes Input Welding Weiding Amperes Ranges At Rated Load Output Current Current (Gas (Gas Max. __60/Hiz Single Phase 0 {| Weigh Amperes Ranges Tungsten- Tungsten- Qoen- | (208) vera eight {Shielded | (Shielded . Are) Arc) Circuit] 200 | 230 | 460 Dimensions (Pounds) Model | Metal-Arc) | Metal-Arc) (TIG) (T1G) Voltage; Volts | Volts | Volts | KVA | KW (Inches) Net | Ship AC AC AC AC 250 amps LOW 10-45 200 amps | LOW 10-45 75 Without at MED 35-160 at MED 40-165 Power 30 volts HIGH 85-295 | 40% Duty | KIGH 140-310 99 30 45 20.6 | 12.8 476 | 486 Factor | 40% Duty Cycle Height-26-5/8 Cycle 125 amps at Width -19 100% Duty Cycle Depth -33 DC DC oc | co | | - 200 amps | LOW 10-50 250 amps | LOW 10-55 76 | & With at MED 35-150 at MED 40-190 84 | 76 | 38 | 17.5 | 128 486 | 496 Power | 40volts | HIGH 80-270 | 40% Duty | HIGH 125-310 Factor | 60% Duty Cycle Cycle Figure 2-1. Specifications LINE POWER INPUT MAIN 115 VOLTS À 115 VOLTS CIRCUIT TERMINALS SWITCH VOLTAGE XFMR SECONDARY "OVERLOAD BREAKER | —— JUMPER PRIMARY | WI > | LINKS 30 VOLTS CONTROL 8 1115VOLTSAC SECONDARY En OAD 3 | ™ RECEPTACLE WINDING L BR POWER _SRÉAKER À RELAY CRY CONTACTOR Me eon] | qe mE) : ©. GAS I CONTROL À. OF TIMER VALVE MAIN SELECTOR MAGNETIC ÿ | CONTACTOR | RECTIFIERN | swiTCH AMPLIFIER § CONTACTS ‘ СОМТАСТОВ NO CONTACTS | Comunal] | ra ACUTE THERMOSTAT CONTROL N OF RELAY COOLANT CONTROL | CR2 В МРЕНАСЕ STANDARD - À : Y | 2 RECEPTACLE] ‚REMOTE Aita TAC OF RELAY POST-F LOW TIMER TD1 WELD SELECTOR | | swiTcH В SECONDARY | WORK OUTPUT | TERMINALS ELECTRODE | y , | HIGH HIGH- À OFF RECTIFIER À FREQUENCY SPARK FREQUENCY Ba OE RELAY > CON. | FREQUENCY В XFMA GAPS XFMR CR? TINUCUS то SWITCH T3 START IN.O. CONTACTS OF RELAY CRT TB-000 510 Figure 2-2. Block Diagram When requesting information concerning this equipment, it is essential that Model Description and/or Stock Number and Serial (or Style) Numbers of the equipment be supplied. 2-3. DESCRIPTION This unit is a single-phase welding power source which pro- duces ac and dc welding current, This welding power source is designed to be used in conjunction with the Shielded Metal-Arc (Stick Electrode) and Gas Tungsten-Arc {TIG) Welding processes. . SAFETY Before the equipment is put into operation, the safety section at the front of this manual should be read completely. This will help avoid possible injury due to misuse or improper welding applications. 2-1. GENERAL This manual has been prepared especially for use in famitiar- izing personnel with the design, installation, operation, maintenance, and troubleshooting of this equipment. All information presented herein should be given careful consideration to assure optimum performance of this equipment. . RECEIVING-HANDLING Prior to installing this equipment, clean all packing material from around the unit and carefully inspect for any damage that may have occurred during shipment. Any claims for loss or damage that may have occurred in transit must be filed by the purchaser with the carrier. A copy of the bill of tading and freight bili will be furnished by the carrier on request if occasion to file claim arises. The following definitions apply to CAUTION, IMPORTANT, and NOTE blocks found throughout this manual: OM-315 Page 5 Under this heading, installation, operating, and maintenance procedures or practices will be found that if not carefully followed may create a safety hazard to | personnel. 1 IMPORTANT Under this heading, installation, operating, and maintenance procedures or practices will be found that if not carefully followed may result in damage to equip- I ment. - I LOCATION (Figure 3-1} A proper installation site should be selected for the welding power source if the unit is to provide dependable service, and remain relatively maintenance free. A proper installation site permits freedom of air movement into and out of the welding power source, and also least subjects the unit to dust, dirt, moisture, and corrosive vapors. A minimum of 18 inches of unrestricted space must be maintained between the welding power source front and rear panels and the nearest obstruction. Also, the underside of the welding power source must be kept completely free of obstructions. The installation site should also permit easy removal of the welding power source outer enclosure for maintenance functions. IMPORTANT Do not place any filtering device over the intake air passages of the welding power source as this would restrict the volume of intake air and thereby subject the welding power source internal components to an overheating condition and subsequent failure. War- L ranty is void if any type of filtering device is used. 1 Holes are provided in the welding power source base for mounting purposes. Figure 3-1 gives overall dimensions and the base mounting hole layout. 3" 23-5/8" 7/6” Dia. 4 Holes 1-1/2" TC-000 321 Page 6 Figure 3-1. Dimensional Drawing On most welding power sources a lifting device is provided for moving the unit. However, if a fork lift vehicle is used for lifting the unit, be sure that the lift forks are long enough to extend completely under the base. Under this heading, explanatory statements will be found that need special emphasis to obtain the most efficient operation of the equipment, SECTION 3 - INSTALLATION === === ==—=——— o IMPORTANT The use of lift forks too short to extend out of the opposite side of the base will expose internal components to damage should the tips of the lift forks I penetrate the bottom of the unit. ; 3-2. ELECTRICAL INPUT CONNECTIONS It is recommended that a Line Disconnect Switch be’ installed in the input circuit to the welding power source. This would provide a safe and convenient means to completely remove all electrical power from the welding power source whenever it is necessary to : I perform any internal function on the unit. N Before making electrical input connections to the welding power source, ‘machinery lockout procedures’ should be employed. If the connection is to be made from a line disconnect switch, the switch should be padlocked in the open position. If the connection is made from a fuse box, remove the fuses from the box and padlock the cover in the closed position. If lock- ing facilities are not available, attach a red tag to the line disconnect switch {or fuse box} to warn others i that the circuit is being worked on. 1 Input Electrical Requirements This welding power source is designed to be operated from a single-phase, 60 Hertz, ac power supply which has a line voltage rating that corresponds with one of the primary voltages shown on the welding power source nameplate. Consult the loca! electric utility if there is any question about the type of electrical system available at the installation site or how proper connections to the welding power source are to be made. Input Conductor Connections Do not connect the input conductors to the single- phase power supply until all input electrical connec- I tions have been made to the welding power source. I It is recommended that the input conductors be of the heavy rubber covered type or be installed in solid or flexible conduit. Select the proper size input conductors and fuse from Table 3-1. Table 3-1. Input Conductor and Fuse Size is lower than the highest voltage for which the unit was designed, the jumper links will have to be moved to the proper Input Conductor Size (AWG) Cuse Size In Amperes position before operation of the welding power source com- Model 200V [230V [460V | 575V 200V | 230V] 460V 575V mences. Figure 3-3 shows the various positions for which the Without P.F.C. | No. 31No. 3 (No. 8 | No. 8 150 | 150 | 70 | 60 jumper links may be set on the standard welding power With P.F.C. No. 4 1No. 41No. & |М№о. 10 125 7014 60 60 source. If the input voltages on the welding power source (8) (8) (8) (10) nameplate differ from those shown in Figure 3-3, the input voltage jumper links must be positioned as shown on the in- *Numbers in { } indicate ground conductor size. put voltage label. Insert the two input conductors plus one ground conductor through the access hole on the rear panel. The hole wiil accept standard conduit fittings: See Figure 3-2 for hole location and size. If only one jumper link is required on each of the grouped terminals, it is recommended that the unused jumper links be placed across the terminals which are 10 be used. This will prevent losing the jumper links It is recommended that a terminal lug of adequate | which are not required for this connection. 1 amperage capacity be attached to the ends of the input and ground conductors. The hole diameter in 200 (208) VOLTS 230 VOLTS 460 VOLTS the terminal lug must be of proper size to accommo- а ее (Ла o AER © ooo date the ling and ground terminal studs on the primary es © © c © © o © D | terminal board. й GH, Ly La GR Ly La GR. La La TA-010 586-A Connect the two input conductors to the terminals on the Figure 3-3. Input Voltage Jumper Link Arrangement primary terminal board labeled LO a Canes: the round conductor to the terminal labele ee Figure 32). The remaining end of the ground conductor should be 3-3. SECONDARY WELDING CONNECTIONS connected to a proper ground, Use whatever grounding method that is acceptable to the local electrical inspection It is recommended that the welding cables be kept as short as authority. a possible, placed close together, and be of adequate current CC carrying capacity. The resistance of the welding cables and connections cause a voltage drop which is added to the voltage of the arc. Excessive cable resistance may result in over- loading as well as reducing the maximum current output of which the welding power source 15 capable. The proper operation of any arc welding power source is to a great extent CAUTION | The terminal labeled GRD is connected to the welding power source chassis and is for grounding purposes dependent on the use of weiding cables and connections that only. Do not connect a conductor from the terminal are in good condition and of adequate size. An insulated labeled GRD to any one of the L. or LINE terminals as electrode holder must be used to ensure the operator's safety. this will result in an electrically hot welding power i source chassis. a Table 3-2, Secondary Weld Cable Size WELDINGL TOTAL LENGTH OF CABLE { COPPER) IN WELD CIRCUIT AMPERESÍ *50 | 100 | 150 | 200 | 250 | 200 {| 350 | 400 100 a 4 4 3 2 1 1/0 | 1/0 input Voltage 150 3 3 2 1 1/0 |-2/0 3/0 3/0 Jumper Links 200 2 2 1 |10 |2/0 |3/0 | 4/0 | 4/0 250 1 1 10 |270 |3/0 lazo | 4/0 | 22/0 300 170 | 2% |3/0 |4/0 | 4/0 2-2/0 | 2-3/0 A-002 624 NOTE: *A. 50 FEET OR LESS. *B. CABLE SIZE IS BASED ON DIRECT CURRENT (DC), 60% DUTY CYCLE ANC EITHER A 4 VOLTS OR LESS DROP OR A CURRENT DENSITY OF NOT OVER 300 CIRCULAR MILS PER AMP. *C. WELD CABLE INSULATION WITH A VOLTAGE RATING TO WITHSTAND THE OPEN-CIRCUIT VOLT- AGE (OCV) OF THE WELDING POWER SOURCE MUST BE USED. WHILE MOST WELDING POWER SOURCES = ` fe “| o HAVE AN OPEN-CIRCUIT VOLTAGE OF LESS THAN f 1-3/4" 100 VOLTS, SOME WELDING POWER SOURCES OF / Access Hole SPECIAL DESIGN MAY HAVE HIGHER OPEN-CIRCUIT Ground VOLTAGE. Terminal Use Table 3-2 as a guide for selecting the correct welding Line cable size for the anticipated maximum weld current that will Terminals be used. Table 3-2 takes into account the total cable length for the weld circuit. This means the length of the Electrode Input Voltage Label cable that connects the Electrode Holder to the welding power source and the Work or ground cable between the TC-000 321 welding power source and the work piece. For example: If the Electrode cable is 75 feet long and the Work or ground cable is 25 feet long, select the size cable from Table 3-2 that is recommended for 100 feet. In a situation where a maximum weld current of 150 amperes is anticipated, No. 3 weld Figure 3-2. Input Conductor Connections C. Matching The Welding Power Source To The Avail- cable is recommended for both the Electrode and Work able Input Voltage cables. | The input voltage jumper links provided on the primary ter- To ensure that the weld current output will be in accordance minal board permit the welding power source to be operated with the labeling of the positions on the WELD SELECTOR. from various line voltages. The various voltages from which Switch, connect the electrode holder cable to the ELEC- this welding power source may be operated are stated on the TRODE terminal and the work cable to the WORK terminal, welding power source nameplate, and on the input voltage abel. See Figure 3-2 for location. The input voltage jumper 3 -4, REMOTE AMPERAGE CONTROL CONNECTIONS links on this welding power source are positioned for the (Figure 4-1) - highest of the voltages stated on the nameplate. If the welding power source is to be operated from a line voltage which The AMPERAGE CONTROL Receptacle provides a junction OM-315 Page 7 Range Selector point for connecting a Remote Amperage Control to the amperage control circuitry in the welding power source. To connect the Remote Amperage Control to the AMPER- AGE CONTROL Receptacle, insert the three-prong plug from the Remote Amperage Control into the receptacle and rotate the plug as far as it will turn in a clockwise direction, Once fully rotated, the plug will be locked in the receptacle and will not pull out under stress. . 44) TACTOR CONTROL CONNECTIONS (Figure The CONTACTOR CONTROL Receptacie provides a junction point for connecting a Remote Contactor Control device to the contactor control circuitry in the welding power source, To connect the Remote Contactor Control to the CON- TACTOR CONTROL Receptacle, insert the three-prong plug from the Remote Contactor Control device into the CON- TACTOR CONTROL Receptacle and rotate the plug as far as it will turn in a clockwise direction. The plug will now be locked in the receptacle and will not pull out under stress, . COOLANT VALVE CONNECTIONS (Figure 4-1) ‘A valve is provided in order to control on and off flow of coolant to the electrode holder. The COOLANT Valve input Power Amperage Adjustment Switch High-Frequency Control Switch уу Switch E | Weld Selector и Switch ha м Amperage © Contactor ontro >» —— Control Switch | „De ‚ © | Switch Amperage я Contactor Control | : Control Receptacle . Receptacle 115 Volts ac— ee. Post- Flow Receptacle = Timer … Gas Coolant q Valve Valve a Electrode | Secondary Work . Secondary | Terminal Terminal TB-006 322 Figure 4-1. Front Panel View 4-1. POWER SWITCH (Figure 4-1) Page 8 Piacing the POWER Switch in the ON position will energize the welding power source fan and control circuitry and place the welding power source in a ready-to-weld status. Placing. the POWER Switch in the OFF position will shut the welding power source down, Even though the POWER Switch is in the OFF position and the welding power source is apparently electrically shut down, electrical input power is still present on all circuitry up to the POWER Switch. To completely cut-off all electrical input power to the welding power source, it will be necessary to place the line disconnect switch in the OFF position or remove I the electrical input fuses. 1 . RANGE SELECTOR SWITCH (Figure 4-1) The RANGE SELECTOR Switch provides the capability of selecting from three coarse amperage ranges. The amperage 3-7. SECTION 4-FUNCTION 4 - 3. and output connections both have left hand threading. En- sure that the hose from the coolant source is attached to the connection on the COOLANT Valve labeled IN, The coolant hose from the electrode holder must be attached to the connection on the COOLANT Valve labeled QUT, IMPORTANT If a Coglant Pump is to be used and the Coolant Pump is not equipped with a by-pass network, do not make connections from the Coolant Pump to the COOL- ANT Valve but rather connect the Coolant Pump directly to the electrode holder coolant hoses, Failure to comply may result in damage to the Coolant Pump due to excessive back pressure when the COOLANT 1 Valve is closed. } AMIELDING GAS VALVE CONNECTIONS (Figure A valve is provided in order to control on and off flow of shielding gas to the electrode holder. The Gas Valve input and output connections both have right hand threading. En- sure that the hose from the shielding gas source is attached to the connection on the GAS Valve labeled IN. The shielding gas hose from the electrode holder must be attached to the connection on the GAS Valve labeled QUT. range of each switch position is displayed on the welding power source nameplate. If the amperage desired falls in the overlapping area of two ranges, use the lower of the two ranges, as better fine amperage adjustment is obtained in the lower of the two ranges, IMPORTANT Do not change the position of the RANGE SE- LECTOR Switch while welding or under load as this will cause the contacts of the switch to arc. Arcing across the contacts will cause the contacts to become pitted and thereby eventually to become inoperative, AMPERAGE ADJUSTMENT CONTROL (Figure 4-1) The AMPERAGE ADJUSTMENT Control, located on the upper center portion of the front panel, provides a means of selecting the exact amperage desired within the range being used, Rotating the control in a clockwise direction will increase the amperage output. The contacts of the AMPERAGE ADJUSTMENT Con- trol are of the continuous contact type, thereby making it possible to adjust the amperage output while | welding. | J The scale surrounding the AMPERAGE ADJUSTMENT Con- trol is calibrated in percentage and should not be miscon- strued as an amperage or voltage reading. . AMPERAGE CONTROL RECEPTACLE & SWITCH (Figure 4-1) if a Remote Amperage Control is to be used, make connections from the Remote Amperage Control to the AMPERAGE CONTROL Receptacle as instructed in item 34. When remote control of the amperage is desired, it is essential that the AMPERAGE CONTROL Switch be placed in the REMOTE position. Likewise, if a Remote Amperage Control is not to be utilized, the switch must be in the STANDARD position. When in the STANDARD position, only the AM- PERAGE ADJUSTMENT Control on the front panel will control the amperage. When a Remote Amperage Control is being used, it should be noted that the Remote Amperage Control is functioning as a fine amperage adjustment for the AMPERAGE ADJUST MENT Control setting on the welding power source. For example: H the AMPERAGE ADJUSTMENT Control on the welding power source is set at the mid-range position, the Remote Amperage Control will provide {from the min. to max. positions) fine amperage adjustment on one half of the welding power source output for the current range selected by means of the RANGE SELECTOR Switch. If full adjustment thru use of the Remote Amperage Control of the current range selected is desired, the AMPERAGE ADJUST- MENT Control on the welding power source must be set at the maximum position, . CONTROL CIRCUIT OVERLOAD BREAKER (Fig ure 4-1) The CONTROL CIRCUIT OVERLOAD BREAKER is supplied in order to provide protection to the control circuit components. Should a short occur in the amperage adjust ment control circuit, this breaker would open and thereby cause the weld output to drop to the minimum of the range in use. When this occurs, neither the AMPERAGE ADJUST- MENT Control or Remote Amperage Control will have any Steve on Varying whe weld SuUpU. To place the welding power source in a ready-to-weld status should this circuit breaker trip, the circuit breaker must be manually depressed. Should the circuit breaker continue to trip after each reset, an internal problem in the control circuitry is most probabiy present. Do not attempt any further welding until the trouble has been remedied. . WELD SELECTOR SWITCH (Figure 4-1) The WELD SELECTOR Switch provides a means of selecting either ac, dc straight, or dc reverse polarity without changing the secondary cable connections. Placing the WELD SELECTOR Switch fully up will provide DC STRAIGHT polarity; fully down will provide DC RE- VERSE polarity; the center position wili provide AC weld current. CAUTION \ Do not change the position of the WELD SELECTOR Switch while welding or under load as this will cause the contacts of the switch to arc. Arcing across the contacts will cause the contacts to become pitted and 8 thereby eventually to become inoperative. _ CONTACTOR CONTROL RECEPTACLE 8 SWITCH (Figure 4-1) if a Remote Contactor Control device is to be used, make connections to the CONTACTOR CONTROL Receptacle as instructed in item 3-5, A prerequisite for remote contro! of the contactor, is to have the CONTACTOR CONTROL Switch on the welding power source in the REMOTE position, If this switch is left in the STANDARD position, the contactor will energize as soon as the POWER Switch is positioned to ON. Whenever the CONTACTOR CONTROL Switch is in the STANDARD position, open-circuit voltage will be present at the secondary terminals for as long as the POWER Switch is positioned to ON Le —————————cd] The Remote Contactor Control! device will, when closed, energize the contactor and GAS and COOLANT Valves. {High-frequency wili also be present when the Remote Con- tactor Control device is closed if the HIGH-FREQUENCY Switch is in the START or CONTINUOUS position.) When the Remote Contactor Control device is opened, the contactor will open and suspend the weld output; also the POST-FLOW Timer will energize and begin to time out. . Thermostat Protecti on This welding power source is protected from damage due to excessive overload by a thermostat which is physically located in the main transformer and electrically connected in series with the contactor coil. Should this thermostat detect an overheated condition in the main transformer it will open. As soon as the thermostat has opened, it will cause the contactor to open and thereby suspend all weld output. The symptom of an overload condition would be the inability to cause the contactor to energize by placing the CONTACTOR CONTROL Switch in the STANDARD position or by placing the CONTACTOR CONTROL Switch in the REMOTE position and then closing the Remote Contactor Control Switch. Should an overload condition be noted, leave the POWER Switch in the ON position and allow the welding power source to idle for approximately 5 minutes. After this 5 minute cooling period, the thermostat will automatically close and once again permit normal operation, ‚ HIGH-FREQUENCY SWITCH (Figure 4-1) The HIGH-FREQUENCY Switch, located on the front panel, provides three positions which determines whether the high-frequency will be on or off. . Start Position When in the START position, high-frequency will be present at the welding electrode from the time the contactor is closed until the arc is initiated. Once an arc is established, and even though the contactor 15 closed, the high-frequency will be de-energized. High-frequency will be present again only after the arc is broken and restarted. . Continuous Position The CONTINUOUS position will provide high-frequency for as long as the contactor is closed. The high-frequency and weld current may be shut off during the weld by opening the Remote Contactor Control Switch. . Off Position High-frequency wiil not be available when in the OFF position, even if the contactor is closed. This position must be used when performing Shielded Metal-Arc {Stick Electrode) Welding. Never try to use high-frequency when performing Shielded Metal-Âre {Stick Electrode) Welding. Failure to comply may result in the high-frequency arcing through the electrode holder and seriously injurying I the operator. | . POST-FLOW TIMER (Figure 4-1) An adjustable O to 60 second POST-FLOW Timer is provided for controlling the period of time shielding gas and coolant will be allowed to flow after the arc is extinguished. To select the desired portion of the maximum 60 second post-flow time period available, rotate the adjustable stop arm on the timer until the appropriate setting is obtained, As soon as the arc has been extinguished, the POST-FLLOW Timer will begin to time out the selected period of post-flow time. Once the selected post-flow time has elapsed, the GAS and COOLANT Valves will close and thereby cut-off shieid- ing gas and coolant flow, The timer will then automatically reset and be ready for another weld cycle. or GAS and © function when the CON- the POST-FLOW Timer COOLANT Valves will TACTOR CONTROL Switch is in the STANDARD Neither position. In order to make these items operational, the REMOTE position of the CONTACTOR CONTROL | Switch must be used, } 4-10. 115 VOLTS AC RECEPTACLE {Figure 4-1) À 115 VOLTS AC Receptacle 1S provided on the lower portion of the front panel for operating accessory equipment which requires 115 volts, 60 Hertz electrical power. Up to 10 OM-315 Page 9 amperes of 115 volts ac may be obtained from this receptacle. NOTE A circuit breaker, located behind the lower front access door, is supplied in arder to provide protection to the 115 volts circuitry in the welding power source. Should the amperage draw from the 115 VOLTS AC Receptacle exceed 10 amperes, this circuit breaker ‘would open and prevent any output from the recep tacle, To reset this circuit breaker should it open, manually depress the red button portion of the circuit breaker. Should this circuit breaker continue to open upon reset, an internal trouble is probable and no further use of the 115 VOLTS AC Receptacle shauld be attempted until the trouble has been remedied, hr ——————— | 4-11. DUTY CYCLE (Figure 4-2) Welding power sources are rated on a percent duty cycle based on 10 minute intervals. For example: a 40 percent duty cycle simply means that the welding current is on for 4 minutes, off for 6 minutes, and so on. It must be kept in mind that time intervals of other than 10 minutes will yield different test rating results. As the output is reduced or increased, the duty cycle will increase or decrease, Figure 4-2 enables the operator to determine the safe output of the welding power source at various duty cycles. [RATED OUTPUT 300 250 Ac, rf o < ui 57 mai a 200 ae AT < Shay, ь < ® ^^ u zZ | 8 150 < = >< 100 25 130 40 509 60 70 #0 90100 7 DUTY CYCLE 5.002 976 Figure 4-2. Duty Cycle Chart Never, under any circumstances, operate the welding power source with any portion of the outer enciosure removed. In addition to a safety hazard, improper cooling may result in damage to the welding transformer and the welding power source components, Warranty is void if the welding power source is operated with any portion of the outer enclosure removed, I 2-1 IELDED METAL-ARC (STICK ELECTRODE) . SH WELDING 1. Make secondary welding connections as explained in item 3-3. 2. Select the properelectrode for the welding application and insert it into the electrode holder, 3. Place the WELD SELECTOR Switch in the desired position, 4, Place the RANGE SELECTOR Switch in the desired position. 5. Rotate the AMPERAGE ADJUSTMENT Control to the desired setting. ° 6. If a Remote Amperage Control is not to be used, place the AMPERAGE CONTROL Switch in the STAN- Page 10 IMPORTANT Exceeding the indicated duty cycle will cause the welding. power source to overheat and thereby cause I damage to the welding power source. ] 4-12. VOLT-AMPERE CURVE (Figure 4-3) The volt-ampere curve shows the output voltage available at any given output current within the limits of the minimum and maximum AMPERAGE ADJUSTMENT Control setting. Load voltage is predetermined to a large degree by arc characteristics. With the use of the volt-ampere curve, it is possible to determine the amperage required for a specific load voltage. With reference to the volt-ampere curve (Figure 4-3), the curve shows only the maximum and minimum settings of the AMPER AGE ADJUSTMENT Control for each of the welding current ranges available, Curves of other settings will fall between the maximum and minimum curves shown. 80 70 60 2 50 ll O > 40 50 100 150 200 250 300 350 400 AC AMPERES B-002 974 80 70 60 2 so 5 > 40 Wu a 30 | | о 50 100 150 200 250 300 350 400 450 DC AMPERES Figure 4-3. Volt-Ampere Curves 8-002 970 SECTION 5 - SEQUENCE OF OPERATION = DARD position. if a Remote Amperage Control is to be used, place the AMPERAGE CONTROL Switch in the REMOTE position. 7. Place the CONTACTOR CONTROL Switch in the STANDARD position. 8. Place the HIGH-FREQUENCY Switch in the OFF position, Prior to welding, it is imperative that proper protective clothing (welding coat and gloves) and eye protection I (glasses and/or welding helmet) be put on. Failure to comply may result in serious and even permanent L bodily damage. I 9. Place the POWER Switch in the ON position. 10. Commence weiding. 5-2. GAS TUNGSTEN-ARC (TIG) WELDING 1. Make secondary connections as explained in item 3-3. 2. Select the proper electrode for the welding application and insert it into the electrode holder. 3. Make shielding gas connections as explained in item 3-7 to the GAS Valve and coolant connections as explained in item 3-6 to the COOLANT Valve. 4. Connect the plug from the Remote Contactor Control device to the CONTACTOR CONTROL Receptacle and place the CONTACTOR CONTROL Switch in the - REMOTE position. 5, Place the WELD SELECTOR Switch in the desired position, 6. Place the RANGE SELECTOR Switch in the desired position. 7. Rotate the AMPERAGE ADJUSTMENT Control to the desired setting. 8. 1 a Remote Amperage Control is not to be used, place the AMPERAGE CONTROL Switch in the STAN- DARD position. If a Remote Amperage Control 15 to be used, place the AMPERAGE CONTROL Switch in the REMOTE position, 9. Place the HIGH-FREQUENCY Switch in the desired position, 10. Rotate the POST-FLOW Timer to the desired time setting. 11. Turn on the shielding gas at the shielding gas container and coolant at the coolant source. 12. Place the POWER Switch in the ON position. Be sure the branch circuit or main disconnect switch is open or the electrical input circuit fuses are removed before attempting any inspection or work on the inside of the welding power source. Placing the POWER Switch on the welding power source in the OFF position does not remove voltage from the power terminals inside of the unit, 6-1. FAN MOTOR All modets are equipped with an exhaust fan and rely on forced draft for adequate cooling. The fan motor is manufac- tured with lifetime-lubricated sealed ball bearings and no attention should be required. 65-2, TRANSFORMER Occasional blowing out of the dust and dirt from around the transformer is recommended, This should be done periodically depending upon the location of the unit and the amount of dust and dirt in the atmosphere. The welding power source outer enclosure should be removed and a clean dry air stream should be used for this cleaning operation. . RECTIFIER lt is recommended that the rectifier be cleaned occasionally by blowing it out with compressed ar, This cieaning operation is necessary so that maximum cooling wiii be accom- plished by the air stream, This should be done periodically, depending upon the location of the unit and the amount of dust and dirt in the atmosphere. It is necessary to remove the outer enclosure for this cleaning operation. . SPARK GAP (Figure 6-1) The spark gaps can be readily inspected by opening the access door on the front of the welding power source. The spark gaps are normally set at .008" clearance at the factory. It will be necessary to periodically readjust these after extended operation. Usually inspection and adjustment every three or four months will suffice. Readjustment is also indicated when intermittent operation of the gaps is noted. Usually this occurs when the setting has increased to .013" or greater. _ 13. Commence welding. RIL k TT Prior to welding, it is imperative that proper protective clothing {welding coat and gloves) and eye protection {glasses and/or welding helmet) be put on. Failure to comply may resuit in serious and even permanent bodily damage. 5.3. SHUTTING DOWN 1. Break the arc, 2, Allow the welding power source to idle for 3 minutes with nc load applied. 3, Place the POWER Switch in the OFF position. 4, Turn off the shielding das and coolant ¡fused. If welding is performed in a confined area, failure to turn off the shielding gas supply could result in a buitd-up of gas fumes, thereby endangering personnel | re-entering the welding area. i SECTION 6 - MAINTENANCE mme nn Generally speaking, the high-frequency output varies directly (up to a certain point) with the spark gap spacing. In extreme cases where the greatest amount of high-frequency is needed, it may be necessary to adjust the spark gap setting to .010” or even .013”, This also increases the high-frequency radiation and it is suggested that the minimum gap setting (.004" 10 008"), consistent with good welding operation, be used. Cleaning or dressing the points of the spark gaps is not recommended, as the material at the points is tungsten and is impossible to file. The entire point should be replaced when the tungsten section has completely т disappeared, 1 To Adiust the Spark Gaps, Proceed as Follows: 1. Loosen screw A on both sides. 2. Place feeler gauge of proper thickness between points at gap C. Ww . Apply slight pressure against point B so feeier gauge is held firmiy in gap. - 4. Tighten screws A, TA-020 G23-A2 Figure 6-1. Spark Gap Adjustment OM-315 Page 11 The data collected here, discusses some of the common problems which may occur in this welding power source. The assumption of this data is that a proper welding condition has been achieved and has been used until trouble developed. In all cases of equipment malfunction, the manufacturer's recommendations should be strictly adhered to and followed. If after performing the following procedures the trouble is still not remedied, it is recommended that a serviceman be called. It is recommended that the circuit diagram be used for reference during troubeshooting. TROUBLE PROBABLE CAUSE REMEDY No weiding current. Open line fuse, Replace fuse. POWER Switch defective. Replace switch. Circuit breaker CB2 open. Reset CB2. See item 4-10. Thermostat TP1 open. Allow welding power source to idle for 5 minutes, See item 4-7A. Erratic weld current, Loose welding connections. Secure connections. Bad ordamp electrodes. Use new dry electrodes. fan does not run, POWER Switch defective. Replace switch, Fan motor defective. Replace fan motor, ‘Line fuse open, Replace fuse. Welding current low. CONTROL CIRCUIT OVERLOAD BREAKER open. Reset breaker, See item 4-5, AMPERAGE ADJUSTMENT Control does not control current. AMPERAGE CONTROL Switch in REMOTE position with no Remote Amperage Control connected to AMPERAGE CONTROL Receptacle. Place AMPERAGE CONTROL Switch in STANDARD position or connect a Remote Amperage Control to AMPERAGE CONTROL Receptacle. Tungsten electrode oxidizing and Loose gas fittings on regulator of gas line. Secure gas fittings. not remaining bright after conclusion of weid. Insufficient gas flow. Increase gas flow. Drafts blowing gas shield away from tungsten. Shield welding arc area, Wandering arc, poor control of direction of arc. Tungsten used considerably larger than recommended. Use proper size tungsten. Lack of high-frequency, difficulty Spark gap spacing incorrect, Adjust spark gap (See item 6-4). in establishing the arc, Tungsten larger than recommended for weld current involved, Use proper size tungsten. Leakage of high-frequency from electrode holder lead, Replace lead. FEWETE CONTROL ECÉUTIGNAL-EXTASI "РЛС DHLY Page 12 POWER FACTOR CORACETI Circuit Diagram Circuit Diagram No. CB-901 782-1A men SECTION 8 - CERTIFICATION FOR HIGH FREQUENCY ARC WELDING EQUIPMENT === 8-1. GENERAL 3. Direct radiation from welding leads. Direct radiation from . 2 1 the welding leads, although very pronounced, decreases This following information is necessary to make a proper rapidly with distance from the welding leads. By keeping installation of the high frequency arc welding equipment de- the welding leads as short as possible, the operator can do scribed in this instruction manual. In order to comply with a great deal to minimize interference from the source. Part 18 of the Rules and Regulations of the Federal Com- : munications Commission, the certificate in front of this man- The intensity and frequency of the radiation can be ual must be filled in completely and signed. The certificate altered over wide limits by changing the location and rela- must be kept WITH THE EQUIPMENT AT ALL TIMES to tive position of the welding leads and work. If possible, comply with the regulation. loops and suspended sections should be avoided. The manufacturer of the equipment covered herein has con- 4. Pick-up and reradiation from power lines. Even though ducted approved field tests and certifies that the radiation welding lead radiation falls off rapidly with distance, the can reasonably be expected to be within the legal limits if the field strength in the immediate vicinity of the welding correct installation procedures, as outlined, are followed. area may be extremely high. Unshielded wiring and un- . . grounded metallic objects in this strong field may pick up The importance of a correct Installation cannot be over the direct radiation, conduct the energy for some dis- emphasized since case histories of interference due to high tance, and produce a strong interference field in another frequency stabllized arc Welding Machines have shown that area. invariably an inadequate installation was at fault. - . © This is usually the most troublesome source of interfer- The user of the equipment must complete the certification ence, but careful adherences to proper installation pro- by stating that he has installed the equipment and is using it, cedure as outlined in this booklet will minimize this type according to the manufacturer's instructions. The user must of interference. sign the certification notice appearing in front of this instruction booklet indicating that he has complied with the requirements. 8 - 3. POWER SERVICE In the event that interference with authorized services occurs, The specific installation instructions for making the proper in spite of the fact that the radiation from the welding equip- primary connections to the equipment as outlined in the in- ment is within the specified fimits, the user is required to struction booklet furnished with the equipment, should be take suitable steps to clear the situation. The factory person- followed carefully with one exception as notted in the nel will assist the user by supplying technical information to following paragraph. : clear the situation. Frequently installation instructions specify that the primary in lieu of complying with the installation requirements and power service shall be run in solid or flexible metallic con- the certification of each individual installation, the user may duit. Ordinary helically wrapped conduit is designed for elect to certify his entire plant by having a reputable engin- mechanical protection and is not suitable for electrical shield- eering firm make a plant radiation survey. In such cases, the ing. Only solid metallic conduit or conduit of “equivalent installation instructions incorporated in this instruction electrical shielding ability” should be used to enclose the booklet could very well serve as a guide in minimizing inter- primary power service leads. ference that might be contributed by the high frequency arc welding equipment. Solid metallic shielding shall enclose the primary power service to the equipment from a point 50 feet from the equip- 8-2. GENERAL INFORMATION ment in a unbroken run. In a high frequency stabilized arc Welding Machine installa- This shielding shall be grounded at the farthest point from tion, interfering radiation can escape in four distinct ways as the equipment and should make good electrical contact with outlined below: the casing of the equipment. The ground should be in accordance with the specifications outlined in the section entitled 1. Direct radiation from the welding machine. This is radia- “GROUNDS” and as shown in Figure 8-1. Care should be tion that escapes directly from the Welding Machine case. taken that paint or corrosion at the junction of conduit and This is very pronounced if access doors are left open and case, does not interfere with good electrical contact. unfastened and if the Welding Machine case is not pro- ‚ o perly grounded. Any opening in the metal Welding Ma- There shall be no gap in this shielding run, This simply means chine case will allow some radiation to escape. The high that within 50 feet of the equipment, no portion of the frequency unit of this certified equipment is adeguately power wires serving the equipment shall be unshielded. If shielded to prevent direct radiation of any consequences there is any question about the electrical efficiency of the if proper grounding is carried out. joints between individual conduit sections, outiet boxes and the equipment case, bonding should be carried out by solder- 2. Direct feedback to the power line. High frequency energy ing a copper strap or wire across the joint as shown in Figure may get on the power line by direct coupling inside the 8-2, equipment or the high frequency unit, the power line Clean and bolt then serving as a radiating antenna. Solder [@ Copper Swap e) Solder By proper shielding and filtering, direct coupling ts pre- > — vented in this certified equipment. (a) DemountaSte Bonding Strap for Conduit Joints La At least 50 feet NU. Solder Copper Wire Solder Solid Metatlic Conduit | Line Fuse and ~~ / Switch Box (b) Solid Bonding with Copper Wire for Conduit Joints o o ana due |" Figure 8-2. Two Recommended Methods For Electrical High Frequency Stabilized Weld- Bonding Across Poor Conductivity Conduit Joints Ground ing Machine or Oscillator 8-4. WELDING MACHINE Good electrical contact. Clean metal to metal. | The location of the equipment should be chosen with respect to nearness to a suitable ground connection. The equipment case, firmly bonded to the power conduit, should be grounded to the work terminal of the equipment with a copper cable or braid with rated current carrying capacity equal to or greater than that of the power service wires. OM-315 Page 13 Figure 8-1. Power Service Installation H.F. Stabilized Arc Welding Machine This “work” output terminal of the equipment should then be grounded to a “good electrical ground” (as defined in section entitled “"GROUNDS”) with a short length of welding cable of the same capacity as the “work lead”. (See Figure Welding Machine Case firmly bonded to Power Conduit Work Terminal grounded to driven ground rod or cold water pipe with heavy braided strap or cable Source of . Power . Case grounded to — Work Terminal E Figure 8-3. Ground Connections At Welding Machine Page 14 No change in the wiring or the location of parts inside the equipment, other than power service tap changes or other adjustments specifically covered shall be made. The equipment shall not be modified in any way since changes in the equipment can affect the radiation characteristics and may hol be in accordance with the test data upon which the manufacturer bases his certification. While the equipment is in operation, all access and service doors shall be closed and properly fastened. Spark gap settings shall be maintained at the minimum separ- ation consistent with satisfactory welding results, . WELDING LEADS In order to minimize direct weld lead radiation, the welding leads {electrode lead and work lead) must be kept as short as possible. Certification tests on this machine have been made with leads 25 feet long. Considerable improvement in radiation minimization can be had by shortening the leads as much as possible. Keeping the electrode lead and ground or work lead as close as possible and on the floor serves to reduce the radiation. (See Figure 841. Welding Machine ar Oscillator Electrode Holder Keep leads on ground or boards and 3/4” to 1” apart + Figure 8-4. General Rules For Welding Leads Keep leads as short as possible — never in excess of 25 feet. . WIRING IN THE VICINITY OF THE WELDING AREA As discussed in the general information section, the most serious source of interference is reradiation from wires that are located near the welding area. Any ungrounded electrical conductor in the strong “directly radiated” field, produced by the welding leads, serves as a pick-up device and may conduct the interference for some distance and reradiate strongly at another location. For purpose of simplification and standardization, the space all around the weld zone at a distance of 50 feet in all direc- tions is referred to as the High Field Intensity (H.F.I.) zone. {See Figure 8-5). To minimize radiation of this type all wiring in the H.F.L zone shall be in rigid metallic conduit, lead covered cable, copper braid or material of equivalent shielding efficiency. Ordinary flexible helically wrapped metallic conduit, com- monly referred to as “B.X.” is not satisfactory for shielding, and should not be used. The shield on all wiring should be grounded at intervals of 50 feet and good electrical bonding between sections shall be maintained. This shielding requirement applies to all wiring, including telephone, inter-communication, signal and control and inciden- tal service. rte A „и _ 7 Shielded Wires ^^ Groun ded at / 50 foot intervals L Welding Maching KM ID ad ra a . Electrode a Y Holder | + = Work A Keep ALL unshielded and ungrounded wires out of this High Field Intensity Zone. > — `` N Figure 8-5. General Requirements to Minimize Reradiation Pick-Up In the Vicinity of the Weld Zone Extreme precaution should be taken to make syre that the location of the zone is chosen so that none of the conditions are voided by unshielded wires off the premises but still within the radial dimensions of the H.F.l. zone. This 50 foot H.F.I. zone is a minimum that is imposed on the installation. Certification tests by the manufacturer are based on this limit. Keeping unshielded wires farther than 50 feet from the weld zone will materially aid in minimizing interference. If it is impossible to relocate unshielded wires, that section within the H.F.l. zone, should be placed in conduit and each end of the conduit section grounded. It must be emphasized that all changes in power and lighting wiring should be made by a qualified electr- cian and comply with the Nationa! Electrical Code requirements. Any shielding or relocation of telephone or signal wires must be done either by the service company concerned or with the specific permission of said | company. 1 GROUNDS Frequent reference is made to a “good ground” in previous sections. Although there is considerable leeway in the inter- pretation of this term, for the purpose covered in this booklet the following specifications apply: A “ground” connection should be made to a driven rod at least 8 feet long and driven into moist soil. A cold water pipe can be used in place of the ground rod provided it enters the ground within 10 feet of the equipment to be grounded. All leads connecting the point to be grounded to the ground rod or pipe should be as short as possible since the ground lead itself can become an effective radiating antenna. The effectiveness of a ground in reducing interference de- pends upon the ground conductivity. In certain locations it may become necessary to improve the ground conductivity by treating soil around the ground rod with a salt solution. . METAL BUILDING It is frequently through that operating of high frequency stabilized arc welding equipment in metallic buildings will completely eliminate troublesome radiation. This, however, 1s a false assumption. A metallic building structure, if properly grounded, may serve to reduce direct radiation from the weld zone but will have no effect on conducted interference and reradiation. As a result, all installation requirements necessary for certification must be complied with. 8-10. If the metallic building is not properly grounded, bonding to several good electrical grounds piaced around the periphery of the building will give reasonable assurance that the building itself is not contributing to the radiation. . INDIVIDUAL INSTALLATION CERTIFICATION Any or all of the above installation requirements may be waived by the user if he desires to exercise the option of making an individual field survey of the particular unit installation {or the complete installation if more than one unit is involved), and certifying on that basis. This survey shall be made by a competent engineer in accordance with the test procedure requirements as set forth in Part 18 of the Rules and Regulations of the Federal Communica- tions Commission. Surveys of this nature can cover a single unit or multiple units or may include the complete plant structure. CHECK LIST The following questions may be used by the installer as a check to see if all installation requirements have been met: 1. Has the equipment been located so that ground leads can be kept short? 2. Are the power leads, serving the unit, in conduit? 3. Is there good electrical contact between power conduit and case? 4. Do the conduit couplings make good electrical contact? (!f in doubt, use bonding}. 5. ls there good electrical contact between conduit and switch on service boxes? 6. If rigid metallic conduit is not used, is the shielding used of equivalent shielding efficiency? (Copper sleev- ing, lead covered cable, etc., is satisfactory. Spirally wound flexible metallic conduit is not suitable). 7. Is the conduit system grounded at a point at least 50 feet from the equipment? 8. Is the conduit run complete (without any gap) in the H.F.l. zone? 9. Is the equipment case connected to the work terminal of the secondary? 10. ls the wire used for this connection of sufficient size? 11. Is the work terminal connected to a good electrical ground? 12, Is the cable or copperbraid used for this connection equal to or greater in current carrying capacity than the welding lead? 13. ls this cable as short as possible? 14. Are the spark-gaps set at .008” or less? 15. Are all service and access doors closed and bolted? 16. Are the welding leads less than 25 feet long? 17. Are they as short as possible? 18. Are the welding leads on the floor or placed on a suitable board? 19. Are the welding leads approximately 3/4” to 1” apart? 20. Have you visualized the H.F.l. zone, a sphere with a 50 foot radious centered on the weld zone? 21. Have the unshielded power and light wires originally in this H.F.I. zone been placed in grounded shields or been relocated outside the zone? 22. Have all large metallic objects and any long guy or supporting wires in the H.F.I. zone been grounded? 23. Have you checked so that no external power or telephone lines off the premises are within the zone? 24, Are the grounds driven ground rods? 25. Is a cold water pipe used as ground? 26. If so, does it enter the ground 10 feet or less from the connection? 27. Are the connections to the ground clean and tight? 28. If operated within a metal building, is the building property grounded? If your answer is “yes” to the above questions, you can certify the installation by signing the certificate. OM-315 Page 15 April 1975 FORM: OM-315 Effective with serial No. HF826825 MODEL STOCK NO. DIALARC HF 901 782 DIALARC HF-P 901788 IMODEL/STOCK NO, SERIAL/STYLE NO, DATE PURCHASED PARTS LIST O MILLER ELECTRIC MFG. CO. APPLETON, WISCONSIN, USA 54911 NWSA CODE NO. 4579 Quantity Mode! Item Dia. Factory | Without | With No. Mkgs. Part No. Description PFC PFC Figure A Main Assembly 1 W 032786 CONTACTOR, 60 amp 3 pole 600 volts (See Fig. G Page 6) ...... 1 1 2 000 382 LINK, jumper - contactor ........re.eeeosa0orerewrenrvare 2 2 3 SR3 037568 RECTIFIER, with mounting brackets {consistingof} ........... 1 1 4 601 242 INSULATOR, washer ..........e-eaeanvanvenoaranoreneo 2 2 5 102 363 .BRACKET, mounting - rectifier......... e. cemeraor rre eo. 2 2 6 CR2 034615 RELAY, 115 volts ac 2PDT ............... seemed iiem. 1 1 7 .CR1 034601 RELAY, 24 volts de 2PDT .............. a. ererrerecreene. 1 1 8 R3 030617 RESISTOR, WW adj 25 watt 20000hm ...........eereereren. 1 1 9 039 220 BRACKET, mounting - contactor ........._.eorcerérerorer. 1 1 10 SR2 037601 RECTIFIER, selenium-control ......... oi... 1 1 11 000 072 PANEL, side RR RER a 4e 44 es 1 a 1 a 1e 0 0 2 2 12 000 073 COVER, top 122144000044 044 a 4 2 4 4 4 4 4 4 4e ee ee a aa 00 6 1 1 13 026 627 GASKET, liftingeye ......... iii iii. 1 1 14 025 141 BRACKET, mounting - capacitOr 0a 1 15 C1 025 317 CAPACITOR, paper oil 40 uf 460voltsac........ cc vue... 2 16 Figure B PANEL, rear - with components (See Page 2) ................. 1 1 17 TEl 034587 TERMINAL ASSEMBLY, primary (See Fig. C Page 3) ........ 1 1 18 MA1 039234 AMPLIFIER, magnetic (See Fig. E Page 4) ................... 1 1 19 Z 027 218 STABILIZER ie ee ee eee Le 1 1 20 T1 039232 TRANSFORMER, power - main (See Fig. D Page 3) ............ 1 20 T1 000 080 TRANSFORMER, power - main (See Fig. D Page 3) ............ 1 TP1 020520 THERMOSTAT, normally closed. ........... coon. 1 i 21 027212 BAR, steel 1/4 x 1-1/2 х 18 ..........e—.0m00rercrreaor rea. 2 2 22 039221 BASE .......—r...eemearorararercarveaorededróeoceco, 1 1 23 000 076 HF PANEL (See Fig. F Page 5) ...........oememorrererere.. 1 1 24 000 683 PIPE, black 1/8 х 3 ......rcerererearra cr rarearnararcoerne 2 2 25 Figure H PANEL, front - with components (See Page 7) ................ 1 1 13 14 15 16— Fig B Fig H—25 7 24 23-FigF 22 11 TD-000 891 Figure A — Main Assembly | BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-315 Page 1 item Dia. Factory No. Mkgs. Part No. Description Quantity Figure B Panel, Rear - With Components {See Fig. A Page 1 Item 16) 36 SAT 039391 RECTIFIER, silicon diode (consistingof) ............c... ...... i 37 000 601 . SUPPRESSOR, rectifier {consistingof) .......... ivi. 1 38 R2 030 726 .. RESISTOR, WW fixed 5 watt 1000 ohm ............ cc... 1 39 VST 024471 ..SUPPRESSOR, 1uf2.70hm ..... iii 1 40 037 306 .DIODE, 150 amp 300 volts reverse polarity ........._.eeeeeeceera. 2 41 C4-7 031689 .CAPACITOR, ceramic 0.01 uf 500 volts with 3/16 & 1/4 terminals . . .. 4 42 037 305 .DIODE, 150 amp 300 volts straight polarity ..................... 2 43 038 315 JUNCTION BOARD, diode ...............es20a0rearerec deere, 2 44 010489 TURBING, steel .275 ID x .060 wall x 3/4 111224 вкл кк... 1 45 038243 WINDTUNNEL 1110104244 4444 4 ea a 44 4e a 4 a 8 4 4 a 4 4 4 4 ea ea ea 4 0 1 46 032 604 BLADE, fan 60 Hz 14 inch 3 wing 19 degree .........e_eeoreenvacvo i 47 000 074 PANEL, rear ........... ea a 1 35 215074 STRIP, adapter .......... RK a a aa sa 6 1 49 FM 032603 MOTOR, fan 230 volts (consisting of) ..........eee.esanve dere». 1 024 601 .BEARING ........ .....maagedacaaiaroaida roneaeevvanraroaa 2 36 40 includes (Нет 37-39 _ a Wu CACA E ón НАНОСЯ à PSS т he E e eE , ies NA oe кл г са Te o € О Figure B — Panel, Rear - With Components TD-000 887 BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-315 Page 2 Item Factory No. Part No. Description Quantity Figure C 034 587 Terminal Assembly, Primary (See Fig. A Page 1 Item 17) 61 034 588 TERMINAL BOARD ee eee eee eee en 1 62 038618 LINK, jumper -terminal board . ...... 2 a a ea a a a 1 ane 2 63 038887 STUD, brass 10-32x 1-3/8 with hex collar . .......... ua... 6 64 010913 WASHER, flat - brass 3/16 .........ee_esemeroreoraerarerere vero 6 65 601 835 NUT, brass - hex 10-32 ..................ereredacarervareceereo. 12 66 601 836 NUT, brass - hex jam 1/4-20 ................ 222220 0e0r acia. 4 67 038 888 STUD, brass 1/4-20 x 1-1/2 with hex collar .......... 2.0 nm. smesraca 2 68 INSULATION, stud barfier 11.202144 14 4 04 4 4 4 44 0 4 4 4 4 4e 0 a 0 a ee ue 6 026 631 Figure C — Terminal Assembly, Primary TA-034 587 ПИ “ 7 N EC E {y tE > TC-032 904 ) Figure D — Transformer, Power - Main Quantity Model Item Factory | Without With No. Part No. Description PFC PFC | =: 3 Figure D Transformer, Power - Main (See Fig. À Page 1 [tem 20) а e E «< = 81 **039 233 TRANSFORMER SUBASSEMBLY (consisting of) ......... 1 1 82 026 188 .STRIP, glastic 1/16 x 1.666 x5 ......... cui... 4 4 83 026 966 . WEDGE, hardwood -single bevel 1/4 x 1Tx6............. 2 2 84 **039 174 COIL, primary/secondary ........eem_orrenedode done, 1 84 **039 173 COIL, primary/secondary ..........eeeeeemecoarizeo. 1 **Replace At Factory or Authorized Service Station. | BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. Page 3 Item Factory No. Part No. Description Quantity Figure E 039 234 Amplifier, Magnetic {See Fig. A Page 1 Нет 18) 96 **039 235 AMPLIFIER SUBASSEMBLY „2 ........... 2.5.5.5... к... .. 1 97 023 363 .WEDGE, glastic - single bevel 5/8 х 1/4 х 5 .................. 2 98 039 236 .STRIP, phenolic 3/8 x 2 x 4-1/2 1.111100 4 41414110 aa ta ee 1 99 010400 . WEDGE, hardwood - single bevel 1/4 x 1/2x6 ....... ane 8 100 034 322 .STRIP, glastic 1/16 x 1.666 X 3 .........ereeareredredeero. 8 101 034 323 .STRIP, fiber 1/32 x 2-3/8x 10........ PE ene 2 102 **039 175 COIL, controlac........... 2... er00ñamneeenerercene nn. 4 103 **039 176 COIL, contra de ......... 2... e00edrea ar aarcara., 1 | ; 96 ‘97 98 99 100 101 | - 103 TC-000 889 100 96 Figure E — Amplifier, Magnetic **Replace At Factory or Authorized Service Station. BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-315 Page 4 Item Dia. Factory No. Mkgs. Part No. Description Quantity Figure F 000 076 HF Panel {See Fig. A Page 1 Item 23) 111 014 159 CLAMP, mounting - capacitor .........oreerecveraaroneenrado. 1 112 Rb 030 603 RESISTOR, WW fixed 10watt 10K ohm ....................... 1 113 C3 031 601 CAPACITOR, paper oil 10 uf 600 volts de ........... e... .e.... 1 114 RE 030 965 RESISTOR, WW fixed 100 watt 100 ohm «ovo vive iii iia. 1 115 T2 036 865 TRANSFORMER, 11Bvolts.............e_e ee eee eee eens 1 116 000 681 STRIP, mounting - Col KR 2 117 T3 039177 COIL, coupling - alt 00 i i te ee ee etre ieee 0 ee 1 118 000 682 TUBING, fiber 1/4 ID x 5/16 x 3/4 ........... i iia. 2 119. R4 030 602 RESISTOR, WW fixed 100 watt 10ohm .........e ee. m0d0ra ae 1 120 000 684 MOUNTING BOARD ..........o e... neacasoonvenenenane 1 121 020 623 SPARK GAP ASSEMBLY (consisting of) ............eeeecreeaaos 1 122 020 621 .BASE .......... 2. earerireraveneenavenanenareCrndendoa arar, 1 123 G *020 603 POINT Le ee ce nnena 4 124 020622 . HOLDER, point ........e..eezxenecrorroredareverarare neo a 4 125 010888 .CONNECTOR, holder ......... e... .ararvarenseveroonora 1 126 000 914 LINK, connecting ........ —_—resxesxverdrdodrearócaranoronaaaro ea 1 127 C2 031 602 CAPACITOR, mica 0.002 uf 5000 volts de ...........e... 2. .... 1 a 118 117 TC-000 890 1125 124 123 122, 121 120 119 - Fiqure F — HF Panel *Recommended Spare Parts. BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. Page 5 Item Factory No. Part No. Description Quantity Figure G 032 786 Contactor {See Fig. A Page 1 Item 1) 136 035 837 COIL, contactor 115 volts ...............e.ceedcierr reo 1 137 *035 836 KIT, point - contact ......... e... ..rrrarerceed0nieonrerer. 1 Figure G — Contactor *Recommended Spare Parts | | BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-315 Page 6 Fig H2 162 157 161 | 178 176 175 178 177 166 174 176 175 174 TD-000 888 179 180 Figure H — Panel, Front - With Components Page 7 [tem Dia. Factory No. © Mkags. Part No. Description - Quantity Figure H Panel, Front - With Components (See Fig. A Page 1 Item 25) 151 NAMEPLATE (order by stock, model 8: serial numbers) .......... 1 152 CB1,2 011972 CIRCUIT BREAKER, 10 amp 250 volts ..........ee eeeenererao 2 153 RC3 039 622 RECEPTACLE, grounded - straight 2P3W ..................... | 1 154 RC1 039 607 RECEPTACLE, twistlock 3P3W . _ ..... .... iii. 1 155 S4 000 071 SWITCH, range (See Fig. H1 Page 9)... ....... ci iii... 1 156 000075 PANEL, front .........._e.eer0esorara,eervercreccaaorcerroerr 1 157 52,3 011 609 SWITCH, toggle SPST 10 amp 125 volts ..........—._—.—reeerreeco.. 2 158 S1 025 865 SWITCH, toggle DPDT 60 amp 575 volts ...................... 1 159 R1 030 6563 RHEOSTAT, WW 150 watt T5 ohm ...........eé. Le 4 a 4 a a ae à 1 160 56 011610 SWITCH, toggle SPDT 10 amp 125 volts center off .............. 1 161 RC2 035 493 RECEPTACLE, grounded - twistlock 3P3W .................... - 1 162 55 000 070 SWITCH, selector (See Fig. H2 Page 10) ............ .eeeecex0rs 1 163 014 206 BRACKET, mounting- timer iii. 2 164 TD1 034 836 TIMER, 0-60 seconds 120 volts .... iii iin 1 165 000 383 BUSBAR, terminal Output . o.oo RR к веке. i 166 038 630 TERMINAL, power output (consistingof) ................ ..... 2 167 601 840 NUT, brass- hex jam 1/2-13 i ie een 2 168 602 217 .WASHER, lock - steel external tooth 1/2 ......... vv... 1 169 602 247 WASHER, flat-steel SAE 1/2 1..2... 2..2... к.кв zero, 1 170 038603 .TERMINAL BOARD eK RR 1 171 010912 . PIN, spring 1/8 X 3/8 «oot ee nara 1 172 038 982 .STUD, brass 1/2-13 x 2-5/8 centered drilled ................... 1 173 601 839 . NUT, brass - hex full 1/2-13 ........ RR La a 4e 3 174 010 296 ELBOW, brass - pipe street 90 degree 1/4MPT 5/8-18RH .......... 2 175 014028 ANGLE, mounting - solenoid ...........o_eeexreerarererene e 2 176 GS1,WS1 035601 SOLENOID, 115 volts ac 2 way 1/4IPS port 1/8 orifice (consisting of) .. 1.212202 200 004444 11 40 a 10 4 4 4 ea 4 a 4 10 4 a ee 00 2 033050 .COIL.............. a RR RR RR 4 a a a a ae 1 177 057 084 BUSHING, snap 1/4 1D 3/8 mounting hole ............ereeceero 2 178 010295 ELBOW, brass - pipe street 90 degree 1/4MPT 5/8-18LH .......... 2 179 000 077 DOOR, access - lower front .........._.eñe ee. 0 RR ee a 1 180 605 583 CATCH, springloaded-door ........... ccc... 1 181 035494 CAP, grounded - twistlock 3P3W...........—.. ro recxsererereraa 1 182 KNOB, ball { included with S5 - See Fig. H2) 183 019627 KNOB, pointer «otter ee eee ee et teeters een 1 184 KNOB, ball (included with 54 - See Fig. H1)- BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. | OM-315 Page 8 Item Factory No. Part No, Description Quantity Figure H1 000 071 Switch, Range (See Fig. H Page 8 Нет 155) 196 011839 BRACKET, mounting - support | 4410004444 4444 ea a aa ae 4e 1 197 011 840 BRACKET, mounting - switch (consisting of) ..................... 1 198 010671 SPRING oe es eet re ter te tea 1 199 000530 CONTACT BOARD ASSEMBLY (consistingof) ................... 1 200 011 968 .CONTACT BOARD, stationary ....... eeeerecudooeorerera ao 1 201 011969 .CONTACT BOARD, movable. .......... iii. 1 202 011644 . CONTACT, stationary - switch .........o..e.eeoredooodaoarao 3 203 011645 . CONTACT ASSEMBLY, movable (consistingof) .................. 1 204 011953 ..CONTACT, switch .... i ee eee ieee en 2 205 011074 ..SPRING, pressure ........ .. .e..0nvrenererenmeernare mreno na 1 206 011075 .. SPRING, pressure . ue eee ete ee eee ieee 1 207 100 622 SHIM, guide ni i i i ie eee 3 208 100 623 GUIDE, contact «oo ite eee ee te eee eee ea 5 209 011 841 HANDLE, switch 110022020044 4 14444 4 4 4 4 8 a 4 44 4 0 4 8 0 0 a 4 a 4 0 1 10 0 4 0 1 210 019603 KNOB, ball ı ee ee ee eee Ven à 1 211 014 203 BAR, mounting -supportswitch .......e.eceerrervearoredendcane 1 197 Figure H1 — Switch, Range 200) 201 202 203 39 Includes Item 206 › 199 TE-000 961 BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. Page 9 [tem Factory No. Part No. Description Quantity Figure H2 000 070 Switch, Selector (See Fig. H Page 8 Item 162) 221 000531 CONTACT BOARD ASSEMBLY (consistingof) ................... 1 222 011968 .CONTACT BOARD, stationary er RR 1 223 100623 .GUIDE, contact oot te ie eet te eee ee ee teen as 5 224 100 622 .SHIM, guide . i ee ee eee 3 225 011969 . CONTACT BOARD, movable... ..... cin. 1 226 011645 . CONTACT ASSEMBLY, movable {consistingof) .................. 2 227 011075 ..SPRING, pressure .......e.e _eoesuaarere o aracereroondena. 1 228 011 953 ..CONTACT, switeh ........e eee serve rararendeorarerarerCan e 2 229 011074 ..SPRING, pressure .........._... em m0nvdari a rnnaco reroanarm, 1 230 011 644 CONTACT, stationary - switch .. 122220200444 21 aa ea вене. 6 231 100621 . LINK, connecting- switeh ....120220 00000104 V4 i ieee ieee. 2 232 011841 HANDLE, switen .. 1.220444 4 4 4 14 4 4 4 44 4 4 4 4 4 VA 4 4 4 4 4 4 4 a dae nana 1 233 011840 BRACKET, mounting - switch (consisting of) ..................... 1 234 010671 .SPRING ........ eee ae ea 1 235 014 203 BAR, mounting- support switch 110222040204 14 64 4 4 a ee a ea a 4 ae 6 1 236 011 839 BRACKET, mounting - SUPport .........eeverecverereenrecoenea 1 237 019603 KNOB, ball ............... re ....e0r0seaevencereoverermerenorea 1 229 226 228 Includes 221 4 Item 227 Ro 236 TD-000 962 Figure H2 — Switch, Selector BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS. OM-315 Page 10

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What is the amperage range of the Miller DIALARC HF-P?

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