Miller Electric AUTO ARC AATC-150 User manual

MAY 1988
FORM:
121988
CWN
ERS
MANUAL
~1I
I I~J
~
II
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON,
WI
54912 USA
ADDITIONAL
COPY PRICE
35
Cents
IMPORTANT
______________
Read
and
understand
the
entire
Contents of
this
manual,
with
special
emphasis
on
the
safety
material
throughout
the
manual,
before
installing,
operating,
or
maintaining
this
equip
ment.
This
unit
and these
instructions
are
for
use
only
by
persons
trained and
experienced
in
the
safe
operation
of
welding
equipment.
Do
not
allow
un
trained
persons
to
install,
operate,
or
maintain this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
Effective
With
Style
No.
JD-1
MODEL
AUTO
ARC
AATC-150
NWSA
CODE
NO. 4579
PAINTED
IN
U S,A

ONEYEARLIMITEDWARRANTY
COVERAGE
-
Miller
Electric
Mfg.
Co.
warrants to
the
buyer
REMEDY
FOR
DEFECTIVE
WELDER
-
Upon
receipt
of
any
who
purchases
this
Auto
Arc
Welder
(Welderl
for
personal,
defective
Welder,
Miller
Electric
will,
at
its
option, repair
or
%
family
or
household
purposes
lConsumerl
that this
Welder
replace
the
defective Welder
at
its
expense,
refund
or
credit
will
be
free
from
defects
in
material and
workmanship
for
a
the
purchase
price
(less
reasonable
depreciation
based
on ac
period
of
one
year
from
the
date of
purchase.
This
warranty
tual
use),
or
reimburse the
Consumer
for
the
cost
of
repair
or
covers
Only
the
original
purchaser
of this
Welder.
Miller
Electric
replacement
at
an
approved
Miller Electric
warranty
station,
does
not authorize
any
party,
including
its
authorized
provided
that
the
purchaser
of that Welder has followed the
distributors,
to offer
any
other
warranty
on
behalf
of Miller
procedure
for
obtaining
warranty
performance
set
forth
below.
~
Electric.
Upon expiration
of
the
warranty
period,
Miller
Electric
The
Welder
so
repaired
or
used
as a
replacement
will
be
ship
~
shall have
no further
liability
related
to
the
Welder,
except
on
ped
to
the
purchaser
of the
defective
Welder,
with
transporta
warranty
claims
made
during
the
warranty
period.
tion
charges
prepaid
to
any
destination
in
the continental
United
States
Itransportation
charges
on
shipments
to
Alaska
THIS
WARRANTY
IS OFFERED
IN LIEU OF
ANY
OTHER
or
Hawaii
will be
paid
only
to
the
nearest
port
of
export).
EXPRESS
WARRANTY;
AND,
EXCEPT TO THE EXTENT
(4
PROHIBITED
BY
APPLICABLE
LAW,
THE
DURATION
OF
ALL IMPLIED
WARRANTIES,
INCLUDING
BUT
NOT
THE PURCHASERS
REMEDIES FOR
A
DEFECTIVE
LIMITED
TO
THE
IMPLIED
WARRANTIES OF MERCHAN-
WELDER,
TO
THE
EXTENT PERMITTED
BY
APPLICABLE

TABILITY
AND
FITNESS FOR
A
PARTICULAR
PURPOSE,
IS
LAW,
ARE LIMITED
TO THE REMEDY
PROVIDED
BY THIS
LIMITED
TO THE
DURATION OF
THIS
WARRANTY. WARRANTY:
AND,
TO THE EXTENT
ENFORCEABLE
UNDER
APPLICABLE
LAW,
MILLER ELECTRIC
SHALL
IN
(4,
Some
states
do
not
allow limitations
on
how
long
an
implied
NO EVENT BE LIABLE FOR
CONSEQUENTIAL,
INCIDENTAL
~
warranty
lasts,
so
the
above
limitation
may
not
apply
to
you.
OR SPECIAL DAMAGES
ARISING OUT OF THE USE
OF,
OR
(
This
warranty
gives
you
specific
legal rights,
and you
may
also
INABILITY
TO
USE,
THE
WELDER,
WHETHER BASED
ON
have
other
rights
which
vary
from
state
to state.
BREACH
OF THIS
WARRANTY,
MILLER
ELECTRICS
NEGLIGENCE
OR
OTHER
TORT,
OR
ON ANY THEORY
OF
STRICT LIABILITY.
Except
as
specified
below,
Millers
warranty
does
not
apply
to
components
having
normal
useful
life of less
than
one
(1
I
year,
such
as
spot
welder
tips,
relay
and
contactor
~
Some
states
do
not
allow
the exclusion
or
limitation
of
con
~...
parts
that
come
in
contact
with the
welding
wire
including
sequential
or
incidental
damages,
so
the
above
limitations
may
nozzles and
nozzle
insulators
where
failure
does
not
result from
not
apply
to
you.
defect
in
workmanship
or
material.
it$~
Miller
shall
be
required
to honor
warranty
claims
on
war-
PROCEDURE FOR
OBTAINING
WARRANTY
PERFORMANCE
c3i~
~
ranted
Equipment
in
the
event
of failure
resulting
from
a
defect
As
soon as
any
defect
in
a
Welder
becomes
known,
the
pur
within
the
following
periods
from
the
date
of
delivery
of
Equip-
chaser
of
the
Welder
must,
within
thirty
(301
days,
notify
an
ment
to
the
original
user:
approved
Warranty
Station
or
Miller Electric
in
writing
of the
c3t~
1.
Arc
welders,
power
sources,
and
components
1
defect.
The
purchasei
must
then,
within
the
one
year
warranty
year
period,
return
the
Welder
to
Miller Electric
at
the
following
ad-
2.
Original
main
power
rectifiers
3
years
dress:
(labor
-
1
year
only)
3.
All
welding
guns,
feeder/gunsand plasma
torches...
~c~~
Miller Electric
Mfg.
Co.
4.
Replacement
or
repair
parts,
exclusive
of labor
.
.
60
days
718 South
Bounds
Street
P.O.
Box 1079
WHAT
IS NOT
COVERED
-
This
warranty
does
not
extend
Appleton,
Wisconsin
54912
c.~..
to
any
Welder
subjected
to
misuse,
neglect,
accident,
or
in
~
warranty
repair
by
anyone
except
Miller
Electric.
Further,
this
All
transportation
charges
to
Warranty
Station
or
Miller Electric
warranty
only
extends
to
those
purchasing
the
Welder
for
per-
must
be
prepaid.
-
sonal,
family
or
household
purposes.
Commercial
and
in
dustrial
users are
given
a
different
warranty.

SECTION
1

SAFETY
RULES
FOR
OPERATION OF
ARC
WELDING
POWER
SOURCE
1-1.
INTRODUCTION
We learn
by
experience.
Learning safety
through
per
sonal
experience,
like
a
child
touching
a
hot
stove
is
harmful,
wasteful,
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. Re
search,
development,
and
field
experience
have
evolved
reliable
equipment
and safe
installation,
opera
tion,
and
servicing
practices.
Accidents
occur
when
equipment
is
improperly
used
or
maintained.
The
rea
son
for the
safe
practices
may
not
always
be
given.
Some
are
based
on common
sense,
others
may
require
technical
volumes
to
explain.
It is wiser
to
follow
the
rules.
Read
and
understand
these safe
practices
before
at
tempting
to
install,
operate,
or
service the
equipment.
Comply
with
these
procedures
as
applicable
to
the
par
ticular
equipment
used and
their
instruction
manuals,
for
personal
safety
and for
the
safety
of others.
Failure
to
observe these
safe
practices
may
cause
seri
ous
injury
or
death. When
safety
becomes
a
habit,
the
equipment
can
be used with
confidence.
These
safe
practices
are
divided into
two
Sections:
1 -Genaral
Precautions,
common
to
arcwelding
and
cut
ting;
and 2-Arc
Welding (and Cutting)
(only).
Reference standards:
Published Standards
on
safety
are
also
available
for
additional and
more
complete
pro
cedures than
those
given
in
this manual.
They
are
listed
in
the
Standards
Index
in
this manual.
ANSI
Z49.1 is
the
most
complete.
The National
Electrical
Code,
Occupational
Safety
and
Health
Administration,
local industrial
codes,
and
local
inspection requirements
also
provide
a
basis for
equip
ment
installation,
use,
and
service.
1-2.
GENERAL
PRECAUTIONS
Different
arc
welding
processes,
electrode
alloys,
and fluxes
can
produce
different
fumes,
gases,
and
radiation levels.
In
addition
to
the
information
In
this
manual,
be
sure
to
consult
flux
and electrode
manufacturers Material
Safety
Data Sheets
(MSDS5)
for
specific
technical data
and
precaution
ary
measures
concerning
their material.
A. Burn
Prevention
Wear
protective clothing-gauntlet gloves designed
for
use
in
welding,
hat,
and
high safety-toe
shoes.
Button
shirt collar
and
pocket flaps,
and
wear
cuff less
trousers
to
avoid
entry
of
sparks
and
slag.
Wear helmet with
safety goggles
and
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.
Repiace
cover
glass
when
broken,
pitted,
or
spattered.
See 1
-3A.2.
Avoid
oily
or
greasy
clothing.
A
spark
may
ignite
them.
Hot metal
such
as
electrode stubs
and
workpieces
should
never
be
handled
without
gloves.
Medical
first
aid and
eye
treatment.
First
aid
facilities
and
a
qualified
first
aid
person
should
be
available
for
each
shift unless
medical
facilities
are
close
by
for
im
mediate
treatment
of flash
burns
of the
eyes
and skin
burns.
Ear
plugs
should
be
worn
when
working
on
overhead
or
in
a
confined
space.
A
hard hat should
be
worn
when
others
work
overhead.
Flammable
hair
preparations
should
not
be
used
by
per
sons
intending
to
weld
or
cut.
B. Toxic
Fume
Prevention
Severe
discomfort,
illness
or
death
can
result from
fumes,
vapors,
heat,
or
oxygen
enrichment
ordepletion
that
welding (or
cutting)
may
produce.
Prevent
them
with
adequate
ventilation
as
described in
ANSI Stan
dard Z49.1
listed
in
Standards
Index. NEVER
ventilate
with
oxygen.
Lead
-,cadmium-,
zinc-,
mercury
-,
and
beryllium-bear
ing
and
similar
materials,
when welded
(or
Cut)
may
pro
duce
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-sup
plied respirator.
For
beryllium,
both
must
be
used.
Metals
coated
with
or
containing
materials
that emit
toxic
fumes
should
not
be
heated unless
coating
is
re
moved
from the
work
surface,
the
area
is
well
ventilated
and,
if
necessary,
while
wearing
an
air-supplied
respira
tor.
Work
in
a
confined
space
only
while
it is
being
ventilated
and,
if
necessary,
while
wearing
an
air-supplied
respira
tor.
Gas
leaks
in
a
confined
space
should
be
avoided.
Leaked
gas
in
large
quantities
can
change
oxygen
con
centration
dangerously.
Do
not
bring
gas
cylinders
into
a
confined
space.
Leaving
confined
space,
shut
OFF
gas
supply
at
source
to
prevent
possible
accumulation
of
gases
in
the
space
if
downstream
valves
have
been
accidentally
opened
or
left
open.
Check
to
be
sure
that the
space
is
safe
before
re-entering
it.
Vapors
from
chlorinated
solvents
can
be
decomposed
by
the heat
of
the
arc
(or
flame)
to
form
PHOSGENE,
a
highly
toxic
gas,
and other
lung
and
eye
irritating
prod
ucts.
The ultraviolet
(radiant)
energy
of the
arc
can
also
decompose
trichloroethylene
and
perchloroethylene
121988
Page
1

vapors
to
form
phosgene.
DO NOT
WELD
or
cut
where
solvent
vapors
can
be
drawn
into the
welding
or
cutting
atmosphere
or
where
the
radiant
energy
can
penetrate
to
atmospheres
containing
even
minute
amounts
of
trichioroethylene
or
perchloroethylene.
C. Fire
and
Explosion
Prevention
Causes
of
fire and
explosion
are:
combustibles reached
by
the
arc,
flame,
flying
sparks,
hot
slag
or
heated
mate
rial;
misuse
of
compressed
gases
and
cylinders;
and
short circuits.
BE
AWARE THAT
flying sparks
or
falling
slag
can
pass
through
cracks,
along pipes,
through
windows
or
doors,
and
through
wall
or
floor
openings,
out
of
sight
of
the
goggled
operator.
Sparks
and
slag
can
fly
35 feet.
To
prevent
fires
and
explosion:
Keep
equipment
clean and
operable,
free of
oil,
grease,
and
(in
electrical
parts)
of metallic
particles
that
can
cause
short
circuits.
If
combustibles
are
in
area,
do
NOT
weld
or
cut.
Move
the
work
if
practicable,
to
an area
free of combustibles.
Avoid
paint
spray
rooms,
dip
tanks,
storage
areas,
venti
lators. If
the work
cannot
be
moved,
move
combustibles
at
least 35 feet
away
out
of reach of
sparks
and
heat;
or
protect
against
ignition
with suitable and
snug-fitting,
fire-resistant
covers or
shields.
Walls
touching
combustibles
on
opposite
sides should
not
be
welded
on
(or
cut).
Walls,
ceilings,
and
floor
near
work
should b~e
protected by
heat-resistant
covers
or
shields.
Fire
watcher
must
be
standing by
with
suitable
fire
extin
guishing
equipme
nt
during
and
for
sometime
after
weld
ing
or
cutting
if:
a.
appreciable
combustibles
(including building
construction)
are
within 35 feet
b.
appreciable
combustibles
are
further than
35
feet but
can
be
ignited by sparks
c.
openings
(concealed
or
visible)
in
floors
or
walls
within 35 feet
may
expose
combustibles
to
sparks
d.
combustibles
adjacent
to
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
A6.O,
listed
7
in
Standards
Index.
This
includes:
a
thorough
steam
or
caustic
cleaning
(or
a
solvent
or
water
washing, depending
on
the
combusti
bles
solubility)
followed
by purging
and
inerting
with
ni
trogen
or
carbon
dioxide,
and
using protective
equip
ment
as
recommended
in
A6.O.
Waterfilling
just
below
working
level
may
substitute
for
inerting.
A
container
with unknown
contents
should
be
cleaned
(see
preceding
paragraph).
Do
NOT
depend
on
sense
of smell
or
sight
to
determine
if
it
is safe
to
weld
or
cut.
Hollow
castings
or
containers
must
be vented
before
welding
or
cutting.
They
can
explode.
Explosive
atmospheres.
Never
weld
or
cut
where
the
air
may
contain
flammable
dust,
gas,
or
liquid
vapors
(such
as
gasoline).
D.
Compressed
Gas
Equipment
Standard
precautions.
Comply
with
precautions
in
this
manual,
and those
detailed
in
CGA
Standard
P-i
,
SAFE
HANDLING OF
COMPRESSED
GASES
IN
CYLIN
DERS,
listed
11
in
Standards
Index.
1.
Pressure
Regulators
Regulator
relief
valve
is
designed
to
protect
only
the
regulator
from
overpressure:
it
is
not
intended
to
protect
any
downstream
equipment.
Provide
such
protection
with
one or
more
relief
devices.
Never
connect
a
regulator
to
a
cylinder containing
gas
other than
that for
which
the
regulator
was
designed.
Remove
faulty
regulator
from service
immediately
for
repair
(first
close
cylinder
valve).
The
following
symp
toms
indicate
a
faulty
regulator:
Leaks-if
gas
leaks
externally.
Excessive
Creep-if
delivery
pressure
continues
to
rise
with downstream
valve closed.
Faulty
Gauge-if
gauge
pointer
does
not
move
off
stop
pin
when
pressurized,
nor
returns
to
stop
pin
after
pres
sure
release.
Repair.
Do
NOT
attempt
to
repair.
Send
faulty
regula
tors
for
repair
to
manufacturers
designated repair
cen
ter,
where
special
techniques
and tools
are
used
by
trained
personnel.
2.
Cylinders
Cylinders
must
be
handled
carefully
to
prevent
leaks
and
damage
to
their
walls, valves,
or
safety
devices:
Avoid
electrical
circuit
contact
with
cylinders
including
third
rails,
electrical
wires,
or
welding
circuits.
They
can
produce
short
circuit
arcs
that
may
lead
to
a
serious
ac
cident.
(See
l-3C.)
ICC
or
DOT
marking
must
be
on
each
cylinder.
It
is
an
assurance
of
safety
when
the
cylinder
is
properly
han
dled.
Identifying
gas
content.
Use
only
cylinders
with
name
of
gas
marked
on
them;
do
not
rely
on
color
to
identify
gas
content.
Notify
supplier
if
unmarked.
NEVER
DEFACE
or
alter
name,
number,
or
other
markings
on a
cylinder.
It is
illegal
and
hazardous.
121988
Page
2

Empties:
Keep
valves
closed,
replace
caps
securely;
mark
MT;
keep
them
separate
from
FULLS
and
return
promptly.
Prohibited
use.
Never
use a
cylinder
or
its
contents
for
other than
its
intended
use,
NEVER
as a
support
or
roller.
Locate
or
secure
cylinders
so
they
cannot
be
knocked
over.
Passageways
and
work
areas.
Keep
cylinders
clear
of
areas
where
they
may
be
struck.
Transporting cylinders.
With
a
crane,
use a secure
sup
port
such
as
a
platform
or
cradle.
Do
NOT lift
cylinders
off the
ground by
their valves
or
caps,
or
by
chains,
slings,
or
magnets.
Do
NOT
expose
cylinders
to excessive
heat,
sparks,
slag,
and
flame,
etc.
that
may
cause
rupture.
Do
not
al
low
contents
to
exceed
130F.
Cool
with
water
spray
where such
exposure
exists.
Protect
cylinders
particularly
valves
from
bumps,
falls,
falling
objects,
and weather.
Replace
caps
securely
when
moving
cylinders.
Stuck valve.
Do
NOT
use a
hammer
or
wrench
to
open
a
cylinder
valve
that
can
not
be
opened by
hand.
Notify
your
supplier.
Mixing
gases.
Never
try
to
mix
any gases
in
a
cylinder.
Never
refill
any
cylinder.
Cylinder fittings
should
never
be
modified
or ex
changed.
3.
Hose
Prohibited
use.
Never
use
hose other than
that de
signed
for
the
specified
gas.
A
general
hose
identifica
tion
rule is:
red
for
fuel
gas, green
for
oxygen,
and black
for
inert
gases.
Use
ferrules
or
clamps
designed
for
the
hose
(not
ordi
nary
wire
or
other
substitute)
as
a
binding
to
connect
hoses
to
fittings.
No
copper
tubing
splices.
Use
only
standard
brass
f
it
tings
to
splice
hose.
Avoid
long
runs
to
prevent
kinks and
abuse.
Suspend
hose
off
ground
to
keep
it from
being
run
over,
stepped
on,
or
otherwise
damaged.
Coil
excess
hose
to
prevent
kinks
and
tangles.
Protect
hose
from
damage
by sharp
edges,
and
by
sparks,
slag,
and
open
flame.
Examine hose
regularly
for
leaks,
wear,
and
loose
con
nections. Immerse
pressured
hose
in
water;
bubbles
in
dicate
leaks.
Repair leaky
or
worn
hose
by
cutting
area
out and
splic
ing (1-2D3).
Do
NOT
tape.
4.
Proper
Connections
Clean
cylinder
valve outlet of
impurities
that
may
clog
orifices and
damage
seats
before
connecting
regulator.
Except
for
hydrogen,
crack valve
momentarily,
pointing
outlet
away
from
people
and
sources
of
ignition.
Wipe
with
a
clean
lintless cloth.
Match
regulator
to
cylinder.
Before
connecting,
check
that
the
regulator
label and
cylinder
marking
area,
and
that
the
regulator
inlet
and
cylinder
outlet
match.
NEVER
CONNECT
a
regulator designed
for
a
particular
gas
or
gases
to
a
cylinder
containing
any
other
gas.
Tighten
connections.
When
assembling
threaded
con
nections,
clean
and
smooth
seats
where
necessary.
Tighten.
If
connection
leaks,
disassemble,
clean,
and
retighten
using
properly
fitting
wrench.
Adapters.
Use
a
CGA
adapter
(available
from
your
sup
plier)
between
cylinder
and
regulator,
if
one
is
required.
use
two
wrenches
to
tighten
adapter
marked
RIGHT
and
LEFT
HAND threads.
Regulator
outlet
(or
hose)
connections
may
be
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
be
fore
opening
cylinder
(or
manifold
valve)
by
turning
ad
justing
screw
in
(clockwise).
Draining
prevents
exces
sive
compression
heat
at
high
pressure
seat
by
allowing
seat
to
open
on
pressurization.
Leave
adjusting
screw
engaged
slightly
on
single-stage
regulators.
Stand
to
side
of
regulator
while
opening
cylinder
valve.
Open
cylinder
valve
slowly
so
that
regulator
pressure
in
creases
slowly.
When
gauge
is
pressurized
(gauge
reaches
regulator
maximum)
leave
cylinder
valve
in
fol
lowing
position:
For
oxygen,
and inert
gases,
open
fully
to
seal
stem
against
possible
leak.
For fuel
gas, open
to
less
than
one
turn
to
permit
quick
emergency
shutoff.
Use
pressure
charts
(available
from
your
supplier)
for
safe
and
efficient,
recommended
pressure
settings
on
regulators.
Check for
leaks
on
first
pressurization
and
regularly
there-after.
Brush
with
soap
solution
(capfull
of
Ivory
Liquid*
or
equivalent
per
gallon
of
water).
Bubbles
indi
cate
leak.
Clean
off
soapy
water
after
test;
dried
soap
is
combustible.
E. User
ResponsibIlities
Remove
leaky
or
defective
equipment
from
service
im
mediately
for
repair.
See
User
Responsibility
statement
in
equipment
manual.
F.
Leaving
Equipment
Unattended
Close
gas
supply
at
source
and
drain
gas.
G.
Rope
Staging-Support
Rope staging-support
should not
be
used
for
welding
or
cutting
operation;
rope
may
burn.
Trademark
of
Proctor &
Gamble.
121988
Page
3

1-3.
ARC
WELDING
Comply
with
precautions
in
1-1, 1-2,
and this section.
Arc
Welding,
properly
done,
is
a
safe
process,
but
a
careless
operator
invites
trouble. The
equipment
carries
high
currents
at
significant
voltages.
The
arc
is
very
bright
and hot.
Sparks
fly,
fumes
rise,
ultraviolet
and
in
frared
energy
radiates,
weldments
are
hot,
and
com
pressed
gases
may
be
used.
The
wise
operator
avoids
unnecessary
risks
and
protects
himself and
others
from
accidents. Precautions
are
described
here and
in
stan
dards
referenced
in
index.
H.
Burn
ProtectIon
Comply
with
precautions
in
1-2.
The
welding
arc
is
intense
and
visibly bright.
Its radiation
can
damage
eyes,
penetrate
lightweight
clothing,
reflect
from
fight-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
long-sleeve
clothing (particularly
for
gas-shielded
arc)
in
addition
to
gloves,
hat,
and
shoes
(1-2A).
As
nec
essary,
use
additional
protective clothing
such
as
leather
jacket
or
sleeves,
flame-proof
apron,
and
f
ire-re
sistant
leggings.
Avoid
outer
garments
of untreated
cot-
Bare
skin
protection.
Wear
dark,
substantial
clothing.
Button
collar
to
protect
chest
and
neck
and button
pock
ets to
prevent
entry
of
sparks.
2.
Eye
and
Head
Protection
Protect
eyes
from
exposure
to
arc.
NEVER
look
at
an
electric
arc
without
protection.
Welding
helmet
or
shield
containing
a
filter
plate
shade
no.
12
or
denser
must
be
used
when
welding.
Place
over
face before
striking
arc.
Protect
filter
plate
with
a
clear
cover
plate.
Cracked
or
broken helmet
or
shield
should
NOT
be
worn;
radiation
can
pass
through
to
cause
burns.
Cracked,
broken,
or
loose
filter
plates
must
be
replaced
IMMEDIATELY.
Replace
clear
cover
plate
when
bro
ken,
pitted,
or
spattered.
Flash
goggles
with side
shields
MUST
be
worn
under
the helmet
to
give
some
protection
to
the
eyes
should
the
helmet
not
be
lowered
over
the
face
before
an arc
is
struck.
Looking
at
an
arc
momentarily
with
unprotected
eyes
(particularly
a
high
intensity
gas-shielded
arc)
can
cause
a
retinal
burn that
may
leave
a
permanent
dark
area
in
the
field
of vision.
3.
Protection
of
Nearby
Personnel
Enclosed
welding
area.
For
production
welding,
a
sepa
rate
room
or
enclosed
bay
is best.
In
open
areas,
sur
round
the
operation
with
low-reflective,
non-combusti
ble
screens
or
panels.
Allow
for
free air
circulation,
par
ticularly
at
floor
level.
Viewing
the weld.
Provide
face
shields for all
persons
who
will be
looking
directly
at
the
weld.
Others
working
in
area.
See
that all
persons
are
wearing
flash
goggles.
Before
starting
to
weld,
make
sure
that
screen
flaps
or
bay
doors
are
closed.
I.
Toxic
Fume
Prevention
Comply
with
precautions
in 1-2B.
Generator
engine
exhaust
must
be
vented
to
the
outside
air. Carbon
monoxide
can
kill.
J.
FIre
and
Explosion
Prevention
Comply
with
precautions
in
1-2G.
Equipments
rated
capacity.
Do
not
overload
arc
weld
ing
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
ves
sel.
It
creates
a
brittle
area
that
can
cause
a
violent
nip
ture
or
lead
to
such
a
rupture
under
rough
handling.
K.
Compressed
Gas
Equipment
Comply
with
precautions
in 1-2D.
L.
Shock Prevention
Exposed
hot conductors
or
other
bar
metal
in
the
weld
ing
circuit,
or
in
ungrounded,
electrically-HOT
equip
ment
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
matwhen
dampness
or
sweat
can
not
be
avoided.
Sweat,
sea
water,
or
mois
ture
between
body
and
an
electrically
HOT
part-or
grounded
metal-reduces
the
body
surface
electrical
re
sistance,
enabling
dangerous
and
possible
lethal
cur
rents to
flow
through
the
body.
1.
Grounding
the
Equipment
When
arc
welding
equipment
is
grounded
according
to
the
National
Electrical
Code,
and
the
work
is
grounded
according
to
ANSI
Z49.1
Safety
In
Welding
And
Cut
ting,
a
voltage
may
exist
betweenthe
electrode
and
any
conducting object.
Examples
of
conducting
objects
in
clude,
but
are
not
limited
to,
buildings,
electrical
tools,
work
benches,
welding
power
source
cases,
workpieces,
etc.
Never
touch
the
electrode and
any
metal
object
unless
the
welding
power
source
Is
off.
When
installing,
connect
the
frames of
each
unit
such
as
welding
power
source,
control, worktable,
and
water
cir
culatorto
the
building
ground.
Conductors
must
be
ade
quate
to
carry
ground
currents
safely.
Equipment
made
electrically
HOT
by
stray
current
may
shock,
possibly
f
a
tally.
Do
NOT
GROUND to
electrical
conduit,
orto
a
pipe
carrying
ANY
gas
orflammable
liquid
such
as
oil
orfuel.
121988
Page
4

Three-phase
connection. Check
phase
requirements
of
equipment
before
installing.
If
only
3-phase
power
is
available,
connect
single-phase equipment
to
only
two
wires
of the
3-phase
line.
Do
NOT
connect
the
equip
ment
ground
lead
to
the third
(live)
wire,
or
the
equipment
will
become
electrically
HOT-a
dangerous
condition
that
can
shock,
possibly
fatally.
Before
welding,
check
ground
for
continuity.
Be
sure
conductors
are
touching
bare
metal of
equipment
frames
at
connections.
If
a
line
cord
with
a
ground
lead
is
provided
with
the
equipment
for connection
to
a
switchbox,
connect
the
ground
lead
to
the
grounded
switchbox.
If
a
three-prong
plug
is
added for
connection
to
a
grounded
mating
re
ceptacle,
the
ground
lead
must
be connected
to
the
ground
prong
only.
If
the
line
cord
comes
with
a
three-
prong
plug,
connect
to
a
grounded
mating
receptacle.
Never
remove
the
ground
prong
from
a
plug,
or use a
plug
with
a
broken
off
ground
prong.
2.
Electrode
Holders
Fully
insulated
electrode
holders
should be
used. Do
NOT
use
holders
with
protruding
screws.
3.
Connectors
Fully
insulated
lock-type
connectors
should
be
used
to
join
welding
cable
lengths.
4.
Cables
Frequently
inspect
cables for
wear,
cracks
and
damage.
IMMEDIATELY
REPLACE
those
with
excessively
worn
or
damaged
insulation
to
avoid
possibly-lethal
shock
from
bared
cable.
Cables
with
damaged
areas
may
be
taped
to
give
resistance
equivalent
to
original
cable.
Keep
cable
dry,
free
of
oil
and
grease,
and
protected
from hot metal and
sparks.
5.
Terminals
And
Other
Exposed
Parts
Terminals
and
other
exposed
parts
of
electrical
units
should
have
insulating
covers
secured before
opera
tion.
6.
Electrode
a.
Equipment
with
output
on/oft
control
(contactor)
Welding
power
sources
for
use
with
the
gas
metal
arc
welding
(GMAW),
gas
tungsten
arc
welding
(GTAW)
and
similar
processes
nor
mally
are
equipped
with
devices that
permit
on
off
control
of the
welding
power
output.
When
so
equipped
the
electrode
wire
becomes
elec
trically
HOT
when
the
power
source
switch
is
ON
and
the
welding
gun
switch
is
closed.
Never
touch
the electrode
wire
or
any conducting
ob
ject
in
contact
with
the
electrode
circuit
unless
the
welding
power
source
is off.
b.
Equipment
without
output
on/off
control
(no
contacto
r)
Welding
power
sources
used
with
shielded
metal
arc
welding
(SMAW)
and
similar
proc
esses
may
not
be
equipped
with
welding
power
output
on-off
control
devices.
With
such
equip
ment
the
electrode is
electrically
HOT
when
the
power
switch is turned
ON.
Never
touch the
electrode
unless the
welding
power
source
is
of
f.
7.
Safety
Devices
Safety
devices
such
as
interlocks and
circuit breakers
should
not
be
disconnected
or
shunted
out.
Before
installation,
inspection,
or
service,
of
equipment,
shut
OFF
all
power
and
remove
line
fuses
(or
lock
or
red-tag
switches)
to
prevent
accidental
turning
ON
of
power.
Disconnect
all cables
from
welding
power
source,
and
pull
all 115 volts
line-cord
plugs.
Do
not
open
power
circuit
or
change
polarity
while weld
ing.
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.
M. Protection
For
Wearers of
Electronic
Life
Sup
port
Devices
(Pacemakers)
Magnetic
fields
from
high
currents
can
affect
pacemaker
operation.
Persons
wearing
electronic
life
support
equipment
(pacemaker)
should consult with
their doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
1-4.
STANDARDS
BOOKLET
INDEX
For
more information,
refer
to
the
following
standards
or
their
latest
revisions
and
comply
as
applicable:
1.
ANSI
Standard
Z49.1,
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from
the
American
Welding
Society,
550 N.W. LeJeune
Rd,
Miami,
FL
33126.
2.
NIOSH,
SAFETY
AND HEALTH IN
ARC
WELDING
AND
GAS
WELDING
AND
CUTTING
obtainable
from
the
Superintendent
of
Documents,
U.S. Gov
ernment
Printing
Office,
Washington,
D.C.
20402.
3.
OSHA,
SAFETY
AND
HEALTH
STANDARDS,
29CFR
1910,
obtainable
from
the
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C. 20402.
4.
ANSI
Standard
Z87.1,
SAFE
PRACTICES
FOR
OCCUPATION
AND
EDUCATIONAL
EYE
AND
FACE
PROTECTION obtainable
from
the Ameri
can
National
Standards
Institute,
1430
Broadway,
New
York,
NY 10018.
5.
ANSI
Standard
Z41.1,
STANDARD
FOR
MENS
SAFETY-TOE
FOOTWEAR obtainable
from the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
6.
ANSI Standard
Z49.2,
FIRE
PREVENTION
IN
THE
USE
OF
CUTTING
AND
WELDING
PROCESSES
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
121988
Page
5

7.
AWS
Standard
A6.0,
WELDING
AND
CUTTING
CONTAINERS
WHICH
HAVE
HELD
COMBUS
TIBLES
obtainable
from
the
American
Welding
So
ciety,
550
N.W.
LeJeune
Rd, Miami,
FL
33126.
8.
NFPA
Standard
51,
OXYGEN-FUEL
GAS
SYS
TEMS FOR
WELDING,
CUTTING,
AND
ALLIED
PROCESSES
obtainable
from the National Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
9.
NFPA
Standard
70,
NATIONAL
ELECTRICAL
CODE
obtainable
from
the National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
10.
NFPA
Standard
51B,
CUTTING
AND
WELDING
PROCESSES
obtainable from the National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
11.
CGA
Pamphlet
P-i,
SAFE
HANDLING
OF COM
PRESSED GASES
IN
CYLINDERS
obtainable
from the
Compressed
Gas
Association,
1235 Jef
ferson Davis
Highway,
Suite
501,
Arlington,
VA
22202.
12.
CSA Standard
W117.2,
CODE
FOR
SAFETY
IN
WELDING
AND
CUTTING
obtainable from
the Ca
nadian
Standards
Association,
Standards
Sales,
178 Rexdale
Boulevard, Rexdale,
Ontario,
Canada
M9W 1R3.
13.
NWSA
booklet,
WELDING SAFETY
BIBLIOGRA
PHY
obtainable
from
the National
Welding
Supply
Association,
1900
Arch
Street,
Philadelphia,
PA
19103.
14.
American
Welding
Society
Standard
AWSF4.1,
RECOMMENDED
SAFE
PRACTICES
FOR
THE
PREPARATION
FOR
WELDING
AND
CUTTING
OF
CONTAINERS
AND
PIPING
THAT
HAVE
HELD
HAZARDOUS
SUBSTANCES,
obtainable
from
the
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126.
15.
ANSI Standard
Z88.2,
PRACTICE FOR
RESPIRA
TORY
PROTECTION,
obtainable
from
the
Ameri
can
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
SECTION
2

INTRODUCTION
Max.
Rated
Welding
Cu~rrent
Welding
Power
Source
Voltage
Range
Dimensions
Weight
Net
I
Ship
30 lbs.
32
lbs.
(13.6 kg) (15
kg)
150
amperes
at
20%
duty cycle
20
-
80 Volts
AC
Height
-
7
1/4
in
(184
mm)
Width
-
8
1/2
in
(216
mm)
Length
-
14
in
(356 mm)
Figure
2-1.
SpecIfications
2-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual and
on
various
la
bels,
tags,
and
plates
provided
on
the
unit
pertains
to
equipment
design,
installation,
operation,
maintenance,
and
troubleshooting
which
should
be
read,
understood,
and
followed for the safe
and
effective
use
of this
equip-
me
nt.
B.
Safety
The
installation,
operation,
maintenance,
and trouble
shooting
of
arc
welding equipment
requires practices
and
procedures
which
ensure
personal
safety
and
the
safety
of others.
Therefore,
this
equipment
is
to
be
in
stalled,
operated,
and
maintained
only by qualified
per
sons
in
accordance
with
this
manual and all
applicable
codes such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1

Safety
Rules
For
Operation
Of
Arc
Weld
ing
Power
Source.
Safety
instructions
specifically
pertaining
to
this
unit
ap
pear
throughout
this
manual
highlighted by
the
signal
words
WARNING and
CAUTION
which
identify
differ
ent
levels
of
hazard.
WARNING
statements
include
installation,
operating,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could result
in
serious
personal
injury
or
loss of life.
CAUTION
statements
include
installation,
operating,
and maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
minor
personal
injury
or
damage
to
this
equipment.
A
third
signal
word,
IMPORTANT
highlights
instruc
tions which need
special
emphasis
to
obtain the
most
ef
ficient
operation
of
this
equipment.
2-2. RECEIVING-HANDLING
Priorto
installing
this
equipment,
clean
all
packing
mate
rial
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
121988
Page
6

transit
must
be
filed
by
the
purchaser
with the
carrier.
A
copy
of
the
bill
of
lading
will
be
furnished
by
the
manu
facturer
on
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
itis
essentialthat
Model
Description
and
Serial
(or
Style)
Numbers
of the
equipment
be
supplied.
2-3.
DESCRIPTION
This unit
converts
the
output of
an
ac
welding
power
source
to
provide
dc
output
for
Shielded
Metal Arc Weld
ing
and
scratch
start
Gas
Tungsten
Arc
Welding.
The
unit is
equipped
with
2
four-foot
interconnecting
cables
and
jack plugs.
The
cooling
fan
operates
on
the
welding
power
source
secondary voltage.
2-4.
DUTY
CYCLE
(Figure
2-2)
The
duty
cycle
is the
percentage
of the
ten
minute
period
that
this unit
can
be
operated
at
a
given
output
without
causing
damage
and
overheating.
This
unit is rated
at
20
percent
duty
cycle.
This
means
the unit
can
be
oper
ated at
rated
load for
two
minutes
out
of
every
ten.
Dur
ing
the
remaining
eight
minutes,
the
unit
should
idle
to
permit
proper
cooling.
If
the
welding
amperes
are
de
creased,
the
duty
cycle
will increase.
Figure
2-2
enables
the
operator
to
determine
the
output
of the unit
at
vari
ous
duty
cycles.
a
CAUTION:
EXCEEDING
DUTY
CYCLE
RAT
INGS
will
damage
the
unit.
I
Do
not
exceed
indicated
duty
cycles.
SECTION
3-INSTALLATION
3-1.
LOCATION
The
service
life and
efficiency
of
the
unit
are
reduced
when it
is
subjected
to
high
levels
of
dust,
dirt,
moisture,
corrosive
vapors,
and
extreme
heat.
4A
CAUTION:
RESTRICTED
AIR
FLOW
causes
overheating
and
possible
damage
to
inter
nal
parts.

Do
not
restrict
air flow
to
any
part
of
the
con-
trol.
3-2.
FIELD
INSTALLATION ONTO
SW2225
(If
appli
cable)
(Figure
3-1)
WARNING: ELECTRIC SHOCK
can
kill.

Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source,
and dis
connect
input
power
employing lockout/tagging
procedures
before
beginning
this installation.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit breaker
or
other
discon
necting
device.
To
install unit
onto
SW2225,
proceed
as
follows:
1.
install
brackets
to
unit
using
sheet
metal
screws
in
wrapper.
2.
Drill
two
5/32
in.
(4 mm)
diameter
holes in
SW2225
wrapper
on
each
side
at
locations
shown
in
Figure
3-1.
3.
install
unit
onto
SW2225
wrapper
using
supplied
screws.
3-3.
CONNECTION
TO
WELDING
POWER
SOURCE
(Figure
3-2)
4A
WARNING:
ELECTRIC
SHOCK
can
kill.

Shut
down
the
welding
power
source
and
be
sure
it
cannot
be
accidentally
energized
before
connecting
the
converter.
IMPORTANT:
If
the
welding
power
source
has
weld
output
terminals,
install
lugs
of
adequate
amperage
ca
pacity
to
the
cables
from
the
converter.
300
250
RATED
OUTPUT

~-

U,
iu
150
~
w
0.
~
4
~100
uJ
~
75
50~
-.
~h





- -
~


10
15
20 25 30 40
50
00
70 00
90
100
%
DUTY
CYCLE
8-088 987
Figure
2-2.
Duty
Cycle
Chart
a
121988
Page
7

A.
Jack
Plug
Assembly
4A
WARNING:
ELECTRIC SHOCK
can
kill;
ARCING
can
burn
skin
or
damage
electrical
connections.

Do
not
touch live electrical
parts.

Be
sure
that unit
is
completely
shutdown
be
fore
making
any
weld
output
connections.

Do
not
change position
of the
welding
cable
jack
plugs
while
welding.

Be
sure
the
jack
plugs
are secure
in
correct
receptacles
before
welding.
The
red
jack
plugs
are
supplied
to
provide
connections
to
the weld
output
receptacles
on
the
welding
power
source.
Assemble the
jack
plugs
as
follows:
1.
Remove
1
inch
(25.4
mm)
of
insulation from
one
end of
welding
cable.
2.
Clamp
cable
in
a
vise
with the uninsulated
end
ex
tending
upward
out
of vise
approximately
1-3/4
inches
(44.5
mm).
3. Place
steel tie
wire
(item
A)
approximately
1/4
inch
(6.4
mm)
from end of
insulation.
4.
Make
a
half
turn
around
the cable
bringing
looped
ends
of
tie wire
together.
A~
B?L1~
D
E
~
~
F
~
024.4
Figure
3-2.
Jack
Plug
InstallatIon
11.
Insert
the 1/4-20
setscrews
into the
center
and
bot
tom
holes
in
jack plug
and
tighten
(E).
12.
Remove
cable from
vise
and insert
jack
plug
into
in
sulating
sleeve.
Slide
insulating
sleeve
over
jack
plug
and
cable
until hole
in
insulating
sleeve
lines
up
with
remaining
hole
in
jack
plug (F).
13.
Insert the 8-32
self-tapping
screw
(F)
through
hole
in
insulating
sleeve
into
jack plug
and
tighten.
B.
Cable Installation
Connect
the
cables
from
the
converter to
the
appropri
ate
weld
output
receptacles
on
the
welding
power
source.
IMPORTANT: lithe
welding
power
source
has
high
and
low
current
ranges,
best
welding
results
wi//be
obtained
using
the
range
with
higher
open
circuit
voltage.
3-4.
WELD
OUTPUT
CONNECTIONS
4A
WARNING:
ELECTRIC
SHOCK
can
kill;
ARCING
can
burn
skin
or
damage
electrical
connections.

Do
not
touch
live
electrical
parts.

Be
sure
that
unit
is
completely
shut
down
be
fore
making
any
weld
output
connections.

Do
not
change
position
of
the
welding
cable
jack
plugs
while
welding.

Be
sure
the
jack plugs
are secure
in
correct
receptacles
before
welding.
5. Insert
a
3/8
inch
(9.5
mm)
diameter rod
through
looped
ends
of
tie
wire.
6.
Twist tie wire
(B)
until
entire tie wire
is
twisted
and is
tight
around
insulation
of
cable.
7.
Clip
off
looped
ends
of
tie
wire.
8.
Bend
the
twisted tie
wire
over
and
along
the side
(C)
of
uninsulated
portion
of
cable.
9.
Wrap
the
strip
of
copper
foil
tightly
around
uninsu
lated end of
cable
and
twisted tie
wire
(D).
10.
Push
the
jack plug
onto
cable
over
copper
foil
(E).
Figure
3-1.
Installation
On
Top
Of SW2225
121988
Page
8

Give
the
jack
plugs
a
quarter
turn
when
inserting
into
the
receptacle.
To
remove
the
jack
plugs,
give
a
quarter
turn
in
the
opposite
direction
while
withdrawing.
For dc
reverse
polarity
output,
connect
the
electrode
ca
ble
to
the
POSITIVE
receptacle
and
the
work
cable
to
the
NEGATIVE
receptacle.
Fordc
straight
polarity,
con
nect
the
electrode
cable
to
the
NEGATIVE
receptacle
and the work
cable
to
the
POSITIVE
receptacle.
SECTION
4
MAINTENANCE
&
TROUBLESHOOTING
IMPORTANT:
Every
six months
inspect
the
labels
on
this unit for
legibility.
All
labels
must
be
maintained
in
a
clearly
readable
state
and
replaced
when
necessary.
See
the
Parts List
for
part
number of
labels.
4-1. FAN
MOTOR
This unit
is
equipped
with
an
exhaust
fan
and relies
on
forced draft for
adequate cooling.
The
fan
motor
is
manufactured with lifetime sealed
bearings
and
re
quires
no
maintenance.
4-2.
INTERNAL
CLEANING
a
WARNING:
ELECTRIC
SHOCK
can
kill.

Do
not
touch live electrical
parts.

Shut
down
welding
power
source
and discon
nect
input
power
employing
lockout/tagging
procedures
before
inspecting, maintaining,
or
servicing.
Lockoutltagging procedures
Consist
of
pad
locking
line disconnect switch
in
open
position,
removing
fuses
from fuse
box,
or
shutting
off
and
red-tagging circuit
breaker
or
other
disco
n
necting
device.
HOT SURFACES
can cause severe
burns.

Allow
cooling period
before
servicing.
Every
six
months
blow
out
or vacuum
dust
and dirt
from
around
the
internal
components.
Remove
the
wrapper
TO
from the
unit,
and
use a
clean,
dry
airstream
or vacuum
suction for
the
cleaning operation.
If
dirty
or
dusty
condi
tions
are
present,
clean
the unit
monthly.
4-3.
OVERLOAD
PROTECTION
a
WARNING:
ELECTRIC SHOCK
can
kill.

Do
not
touch
live electrical
parts.

Shutdown
welding
powersource
and discon
nect
input
power
employing
lockout/tagging
procedures
before
inspecting,
maintaining,
or
servicing.
Lockout/tagging procedures
consist
of
pad
locking
line disconnect switch
in
open
position,
removing
fuses
from fuse
box,
or
shutting
off
and
red-tagging
circuit breaker
or
other
discon
necting
device.
IMPROPER
FUSES
can
damage
unit.

Be
sure
replacement
fuse
is
same
size,
type,
and
rating
(see
Parts
List).
The
rectifier
Ri
is
protected
from
overload
by
a
fuse
Fl.
The
fuse
Fl
opens
if
rating
or
duty cycle
is
exceeded,
interrupting
weld
output.
To
replace
Fl,
proceed
as
follows:
1.
Remove unit
wrapper.
2.
Check
Fl,
and
replace
if
necessary.
3.
Reinstall
unit
wrapper.
z
Figure
4-1.
Circuit
Diagram
Circuit
Diagram
No.
A-096
722
C~
C3
NEC.
POS.
121988
Page
9

(0 03
03
-u
CD CD
0
10
1
10
~21~
20
.25
24
1
33
Part
of
Item
33
10-088
548
Figure
A

Complete
Assembly

Item
Dia.
No.
Mkgs.
Part
No.
-
Description
Quantity
Figure
A
Complete
Assembly
1
039
8b0
RECEPTACLE,
jack
plug-red
(consisting
of)
1
2
039
768
NUT,
terminal-molded
red
3
010 291
WASHER,
flat-nylafil
5/8
ID
x
1/4
OD
x
1/8
1
1
4
604
668
NUT,
self-locking
hex
1/2-20
2
5
086 296
RECEPTACLE,
jack plug
1
6
605
787
WASHER,
lock-internal
tooth
1/2
1
7
Z
088
935
STABILIZER
1
8 115
104
CONNECTOR,clamp-cable
1/2
2
9
600
317
CABLE,
copper-stranded
No.
4
(order
by
ft)
8 ft
10
039
6~8
PLUG,
jack-red
(consisting
of)
11
019833
STRIP,coppero.010x2-1/2x3/4
2
1
12
010521
WIRE,tie
I
13
602
178
SCREW,
set-socket
hd 1/4-20
x
3/8
2
14
101 219
PLUG,
jack
1
15
602
814
INSULATOR,
red
1
16
602 160
SCREW,
seif-tapping-fillister
hd
8-32
x
1/4
1
17
005
656
BLADE,
fan
6
inch
4
wing
30
deg
1
18
FM
088
317
MOTOR,
80 volts
60
hz
3000
RPM
1
19
+088
779
WRAPPER
1
047
497
LABEL,
general
precautionary
1
20
088 910
RECTIFIER,
silicon
diode-positive
(consisting of)
1
21
Cl
,2
031
689
CAPACITOR,
ceramic 0.01
uf 500 volts
dc
22
Dl
,2
087
~98
DIODE,
85
amp
300
volts
straight polarity
2
2
23
083
1~47
GROMMET,
screw
8-10
push
in
24
088
924
RECTIFIER,
silicon
diode-negative
(consisting
of)
2
1
25
DC3,4
087 999
DIODE,
85
amp
300 volts
reverse
polarity
2
26
C3,4
031
689
CAPACITOR,
ceramic
0.01
uf
500
volts dc
2
083
147
GROMMET,
screw
8-10
push
in
2
27
Cl
,R5
044
842
SUPPRESSOR
I
28
088
607
BUS
BAR,
rectifier
neg
to
stud
29
088
757
CASE
SECTION,
base/front/rear
1
1
30 Fl
*088 568
FUSE,
link
100
amp
250
volts
1
31
091 101
STRIP,
support-lead
1
32
035
133
ANGLE,
mtg-panel
1
33
039
801
RECEPTACLE,
jack plug-black
(consisting
of)
1
34
605 787
WASHER,
lock
internal
tooth
1/2
1
35
086
296
RECEPTACLE,
jack plug
1
36
604 668
NUT,
self-locking
hex
1/2-20
2
37 010
291
WASHER,
flat
nylafil
5/8
ID
x
1/4
OD
x
1/8
1
38
039
796
NUT,
terminal-molded black
1
39
NAMEPLATE
(order
by
model
and
style number)
1
089 379
BRACKET,
mtg-AATC15O
to
welding
power
source
2
*Recommended
Spare
Parts
When
ordering
a
component
originally displaying
a
precautionary
label,
the
label
should
also
be
ordered.
BE
SURE TO
PROVIDE
MC
DEL AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
121988
Page
11