Miller Electric CP-750E User manual

July
1982 FORM:
OM-254B
OWN
ERS
MANUAL
TI1UHER
~
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS ST.
P.O.
Box
1079
APPLETON,
WI
54912
USA
ADDITIONAL
COPY
PRICE
65
CENTS
NWSA
CODE
NO.
4579
PRINTED
IN
U.S.A.
Effective
With
Serial
No.
JC600199
MODEL
CP-750
E

LIMITED
WARRANTY
EFFECTIVE: JUNE
1.
1979
This
warranty
supersedes
all
previous
MILLER warranties
and
is ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY-Subject
to
the
terms
and
conditions
As
a matter
of
general
policy
only,
Miller
may
honor
claims
hereof,
Miller Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
submitted
by
the
original
user
within
the
foregoing
periods.
to
its Distributor/Dealer
that
all
new
and unused
Equipment
(
furnished
by
Miller
is free
from
defect
in
workmanship
and
In
the
case
of Millers
breach
of
warranty
or
any
other
duty
material
as
of
the
time and
place
of
delivery
by
Miller.
No
war-
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
ranty
is
made
by
Miller
with
respect
to
engines,
trade
ac-
therefore
shall
be,
at
Millers
option
(11
repair
or
(21
replacement
cessories
or
other items manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(31
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of their
respective
manufacturers,
if
any
.
All
Miller
service
station
or
(41
payment
of
or
credit
for the
purchase
engines
are
warranted
by
their manufacturer
for
one
year
from
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
date of
original
purchase. return
of the
goods
at
Customers
risk and
expense.
Upon receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall instruct
the
clai-
~
Except
as
specified
below,
Millers
warranty
does
not
apply
mant
on
the
warranty
claim
procedures
to
be
followed.
to
components
having
normal
useful life of
less
than
one
I
1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
MILLERMATIC
parts
that
come
in
contact
with the
welding
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA-
?
wire
including
nozzles
and
nozzle insulators where failure
does
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY FOR
not
result
from
defect
in
workmanship
or
material.
BREACH OF CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT ARISE
BY
IMPLICATION,
OPERATION OF
LAW,
Miller
shall
be
required
to honor
warranty
claims
on war-
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ranted
Equipment
in
the
event
of failure
resulting
from
a
defect
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
within
the
following
periods
from
the
date
of
delivery
of
Equip-
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH RESPECT
TO
i
ment
to
the
original
user:
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY MILLER
IS
EX
CLUDED
AND
DISCLAIMED
BY
MILLER.
1. Arc
welders,
power
sources
and
components
.
.
1
year
2.
Original
main
power
rectifiers
3
years
EXCEPT
AS
EXPRESSLY
PROVIDED BY
MILLER
IN
(labor
-
1
year
onlyl
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
3.
All
wefding
guns
and
feeder/guns
90
days
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
4.
All other Millermatic
Feeders
1
year
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
5.
Replacement
or
repair parts,
exclusive of labor
.
60
days
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
6.
Batteries
6months
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS OR
CONSUMER
USE.
MILLER
WARRANTIES
DO
NOT
EXTEND
provided
that Miller is notified in
writing
within
thirty
130)
days
TO,
AND NO
RESELLER IS
AUTHORIZED TO
EXTEND
of
the
date
of
such failure.
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
~,
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TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1

SAFETY
RULES
FOR OPERATION
OF ARC
WELDING
POWER SOURCE
1
-
1
Introduction
1
1
-
2.
General Precautions
1
1 3.
Arc
Weldinq
3
1
-4.
Standards
Booklet Index 4
SECTION
2
INTRODUCTION
2-1. General
7
2
-
2.
Receiving-Handling
7
2
-
3.
Description
7
2-4.
Safety
7
SECTION
3
INSTALLATION
3-1.
Location
8
3
-
2.
Electrical
Input
Connections
8
3
-
3.
Secondary
Connections
9
3
.
4. 115
Volts
AC
Receptacles
9
3
-
5.
Contactor
Control
Connections
9
3
-
6.
Remote
Voltage
Control
Connections
10
3-
7.
Slope
Reactor
Connections
10
SECTION
4
FUNCTION
OF CONTROLS
4-1.
PowerSwitch
11
4
-
2.
Voltage
Control
11
4
-
3.
Remote
Voltage
Control
Receptacle
&
Switch
11
4
-
4.
Contactor Control
Receptacle
&
Switch
11
4
-
5.
Circuit
Breaker
Overload
Protection
11
4-6.
Meters
11
4-7.
Duty
Cycle
11
4
-
8.
Volt-Ampere Graph
12
SECTION
5

SEQUENCE OF
OPERATION
5-1.
Gas Metal-Arc
Welding
12
5
-
2.
Shutting
Down
12
SECTION
6
MAINTENANCE
6-1.
FanMotor
12
6
-
2.
Transformer
12
6-
3. Rectifier
13
6
-
4.
Control Circuit
Protection
13
SECTION
7
TROUBLESHOOTING
PARTS
LIST

SECTION
1
-
SAFETY
RULES FOR OPERATION
OF
ARC WELDING
POWER
SOURCE.
1.-i.
INTRODUCTION
-
We learn
by
exper!ence.
Learning
safety
through
personal exp~riance,
liLe
a
child
touching
a
hot
stove
is
harmful,
wasteful,
arid
un
wise.
Let
the
experience
of others teach
you.
Safe
practices developed
from
experience
in the
use
of
welding
and
cutting
are
described
in this
manual.
Research,
development,
and
field
experience
have
evolved
reliable
equipment
and
safe
installation,
opera
tion,
and
servicing
practices.
Accidents
occur
when
equipment
is
improperly
used
or
maintained.
The
reason
for
the safe
practices
may
not
always
be
given.
Some
are
based
on common
sense,
others
may
require
technical
volumes
to
explain.
It
is wiser
to
follow
the
rules.
Read
and understand
these safe
practices
before
at
tempting
to
install,
operate,
or
service
the
equipment.
Comply
with
these
procedures
as
applicable
to
the
par
ticular
equipment
used
and
their instruction
manuals,
for
personal
safety
and
for
the
safety
of
others.
Failure
to
observe
these safe
practices
may
cause
serious
injury
or
death.
When
safety
becomes
a
habit,
the
equipment
can
be
used with
confidence.
These
safe
practices
are
divided
into two
Sections:
1
-
General
Precautions,
common
to
arc
welding
and
cutting;
and 2
-
Arc
Welding
(and
Cutting)
(only).
Reference
standards:
Published
Standards
on
safety
are
also
available
for
additional
and
more
complete
pro
cedures
than those
given
in
this manual.
They
are
listed
in
the
Standards
Index
in
this manual.
ANSI Z49.1
is
the
most
complete.
The
National Electrical
Code,
Occupational
Safety
and
Health
Administration,
local
industrial
codes,
and local
inspection
requirements
also
provide
a
basis for
equip
ment
installation,
use,
and service.
1-2. GENERAL
PRECAUTIONS
A.
Burn
Prevention
Wear
protective
clothing
-
leather
(or
asbestos)
gauntlet gloves,
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
or
glasses
with side
shields
underneath,
appropriate
filter lenses
or
plates
(protected
by
clear
cover
glass).
This
is
a
MUST for
welding
or
cutting,
(and
chipping)
to
protect
the
eyes
from radiant
energy
and
flying
metal.
Replace
cover
glass
when
broken,
pitted,
or
spattered.
See
1-3A.2.
Avoid
oily
or
greasy
clothing.
A
spark
may
ignite
them.
Hot
metal such
as
electrode
stubs and
workpieces
should
never
be
handled
with~iut
gloves.
Medical
first aid
and
eye
treatment.
First
aid
facilities
and
a
qualified
fir~t
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
Adequate
ventilation.
Severe
discomfort,
illness
or
death
can
result
from
fumes,
vapors,
heat,
or
oxygen
enrichment
or
depletion
that
welding
(or
cutting)
may
pi~duce.
Prevent
them
with
adequate
ventilation
as
described
in
ANSI Standard Z49.1
listed
1
in
Standards
index.
NEVER
ventilate
with
oxygen.
Lead
-,
cadmium
-.
zinc
-,
mercury
-,
and
beryllium
-
bearing
and similar
materials,
when
welded
(or
cut)
may
produce
harmful concentrations of toxic
fumes.
Ade
quate
local exhaust
ventilation
must
be
used,
or
each
person
in the
area
as
well
as
the
operator
must
wear
an
air-supplied
respirator.
For
beryllium,
both
must
be
us
ed.
Metals
coated
with
or
containing
materials that
emit
toxic
fumes should
not
be
heated unless
coating
is
removed
from
the
work
surface,
the
area
is
well
ven
tilated,
or
the
operator
wears
an
air-supplied
respirator.
Work
in
a
confined
space
only
while
it
is
being
ven
tilated
and,
if
necessary,
while
wearing
an
air-supplied
respirator.
Gas
leaks
in
a
confined
space
should be avoided.
Leaked
gas
in large
quantities
can
change
oxygen
con
centration
dangerously.
Do
not
bring
gas
cylinders
into
a
confined
space.
Leaving
confined
space,
shut
OFF
gas
supply
at
source
to
prevent
possible
accumulation
of
gases
in
the
space
if
downstream
valves
have
been
accidently
opened
or
left
open.
Check
to
be
sure
that the
space
is
safe before
re-entering
it.
Vapors
from
chlorinated
solvents
can
be
decomposed
by
the
heat
of the
arc
(or flame)
to
form
PHOSGENE,
a
highly
toxic
gas,
and
other
lung
and
eye
irritating
pro
ducts.
The
ultraviolet
(radiant)
energy
of
the
arc
can
also
decompose
trichloroethylene
and
per
chloroethylene
vapors
to
form
phosgene.
DO
NOT
WELD
or
cut
where
solvent
vapors
can
be
drawn
into
the
welding
or
cutting
atmosphere
or
where
the radiant
energy
can
penetrate
to
atmospheres
containing
even
minute amounts
of
trichioroethylene
or
per
chloroethylene.
OM-254
Page
1

C-
Fire
and
ExplosIon
Prevention
Causes
of
fire
and
explosion
are:
combustibles
reached
b
the
arc,
flame,
flying
sparks,
hot
slag
or
heated
naterial;
misuse of
compressed
gases
and
cylinders;
and
short
circuits.
RE
AWARE
THAT
flying sparks
or
falling
slag
can
pass
through
r.raeks,
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.
~
combustibles
are
in
area,
do
NOT
weld
or
cut.
Move
thu work
if
practicable,
to
an
area
free of combustibles.
Avoid
patnt
spray
rooms,
dip
tanks,
storage
areas,
yen
~!ators
If
the
work
cannot
be
moved,
move
com
bustibles
at
least
35
feet
away
out
of
reach of
sparks
and
heat;
or
protect
against
ignition
with
suitable
and
snug-fitting,
fiie-resistant
covers
or
shields.
Walls
touching
combustibles
on
opposite
sides should
not
be
welded
on (or
cut).
Walls,
ceilings,
and
floor
near
work
should be
protected
by
heat-resistant
covers
or
shields.
Fire
watcher
must
be
standing
by
with
suitable
fire
ex
tinguishing
equipment
during
and
for
some
time after
welding
or
cutting
if:
a.
appreciable
combustibles
(including
building
construction)
are
within 35
feet
b.
appreciable
combustibles
are
further than 35
feet
but
can
be
ignited
by
sparks
c.
openings
(concealed
or
visible)
in floors
or
walls
within 35 feet
may expose
com
bustibles
to
sparks
d.
combustibles
adjacent
to
walls,
ceilings,
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 3
in
Standards
index.
This
includes:
a
thorough
steam
or
caustic
cleaning
(or
a
solvent
or
water
washing,
depending
on
the
com
bustibles
solubility)
followed
by
purging
and
inerting
with
nitrogen
or
carbon
dioxide,
and
using
protective
equipment
as
recommended
in
A6.O.
Waterfilling
just
below
working
level
may
substitute
for
inerting.
Page
2
A
container with
unknown
contents
should
be
cleaned
(see
paragraph
above).
Do
NOT
depend
on
sense
of
smell
or
sight
to
determine if
it
is safe
to weld
or
cut.
Hollow
castings
or
containers
must
be
vented
before
welding
or
cutting. They
can
explode.
Explosive
atmospheres.
Never
weld
or
cut where
the
air
may
contain
flammable
dust,
gas,
or
liquid
vapors
(such
as
gasoline).
D.
Compressed
Gas
Equipment
Standard
precautions.
Comply
with
precautions
in
this
manual,
and those
detailed
in CGA
Standard
P-i,
PRECAUTIONS
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
regulator
from
overpressure;
it
is
not
intended
to
protect
any
downstream
equipment.
Provide
such
protection
with
one or
more
relief devices.
Never
connect
a
regulator
to
a
cylinder
containing
gas
other than
that for which the
regulator
was
designed.
Remove
faulty
regulator
from
service
immediately
for
repair
(first
close
cylinder
valve).
The
following
symptoms
indicate
a
faulty
regulator:
Leaks
-
if
gas
leaks
externally.
Excessive
Creep
if
delivery
pressure
continues
to
rise
with
downstream valve closed.
Faulty
Gauge
-
if
gauge
pointer
does
not
move
off
stop
pin
when
pressurized,
nor
returns to
stop
pin
after
pressure
release.
Repair.
Do
NOT
attempt
repair.
Send
faulty
regulators
for
repair
to
manufacturers
designated
repair
center,
where
special
techniques
and tools
are
used
by
trained
personnel.
2.
Cylinders
Cylinders
must
be
handled
carefully
to
prevent
leaks
and
damage
to
their
walls,
valves,
or
safety
devices:
Avoid
electrical circuit
contact
with
cylinders
in
cluding
third
rails,
electrical
wires,
or
welding
cir
cuits.
They
can
produce
short
circuit
arcs
that
may
lead
to
a
serious
accident.
(See
1-3C.)
ICC
or
DOT
marking
must
be
on
each
cylinder.
It
is
an
assurance
of
safety
when
the
cylinder
is
properly
handled.
Identifying
gas
content.
Use
only
cylinders
with
name
of
gas
marked
on
them;
do not
rely
on
color
to
identify
gas
content.
Notify
supplier
if
unmarked.
NEVER
DEFACE
or
alter
name,
number,
or
other
markings
on
a
cylinder.
It
is
illegal
and
hazardous.

Empties:
Keep
valves
closed,
replace
caps
securely;
mark
MT;
keep
them
separate
from
FULLS and
return
promptly.
Prohibited
use.
Never
use
a
cylinder
or
its
contents
for
other
than
its
intended
use,
NEVER
as a
support
or
roller.
Locate
or secure
cylinders
so
they
cannot
be knocked
over.
Passageways
and
work
areas.
Keep
cylinders
clear
of
areas
where
they
may
be
struck.
Transporting
cylinders.
With
a
crane,
use
a
secure
sup
port
such
as a
platform
or
cradle.
Do
NOT
lift
cylinders
off
the
ground
by
their valves
or
caps,
or
by
chains,
slings,
or
magnets.
Do
NOT
expose
cylinders
to
excessive
heat,
sparks,
slag,
and
flame,
etc.
that
may
cause
rupture.
Do
not
allow contents to
exceed
130F. Cool
with
water
spray
where
such
exposure
exists.
Protect
cylinders
particularly
valves
from
bumps,
falls,
falling
objects,
and
weather.
Replace
caps
securely
when
moving
cylinders.
Stuck
valve.
Do
NOT
use a
hammer
or
wrench
to
open
a
cylinder
valve that
can
not
be
opened
by
hand.
Notify
your
supplier.
Mixing
gases.
Never
try
to
mix
any
gases
in
a
cylinder.
Never
refill
any
cylinder.
Cylinder
fittings
should
never
be
modified
or
exchang
ed.
3.
Hose
Prohibited
use.
Never
use
hose
other
than
that
designed
for
the
specified
gas.
A
general
hose
identification
rule
is:
red
for
fuel
gas,
green
for
oxygen,
and
black for
inert
gases.
Use
ferrules
or
clamps
designed
for
the
hose
(not
or
dinary
wire
or
other
substitute)
as
a
binding
to
connect
hoses to
fittings.
No
copper
tubing
splices.
Use
only
standard
brass
fit
tings
to
splice
hose.
Avoid
long
runs
to
prevent
kinks
and
abuse.
Suspend
hose
off
ground
to
keep
it
from
being
run
over,
stepped
on,
or
otherwise
damaged.
Coil
excess
hose
to
prevent
kinks and
tangles.
Protect
hose
from
damage by
sharp
edges,
and
by
sparks,
slag,
and
open
flame.
Examine
hose
regularly
for
leaks,
wear
and
loose
con
nections.
Immerse
pressured
hose in
water;
bubbes
in
dicate
leaks.
Repair
leaky
or worn
hose
by cutting
area
out and
splic
ing
(1-2D3).
Do
NOT
use
tape.
4.
Proper
Connections
Clean
cylinder
valve
outlet
of
impurities
that
may
clog
orifices
and
damage
seats
before
connecting
regulator.
Except
for
hydrogen,
crack valve
momentarily,
pointing
outlet
away
from
people
and
sources
of
ignition.
Wipe
with
a
clean
lintless cloth.
Match
regulator
to
cylinder.
Before
connecting,
check
that
the
regulator
label
and
cylinder marking
agree,
and
that the
regulator
inlet
and
cylinder
outlet match.
NEVER
CONNECT
a
regulator
designed
for
a
particular
gas
or
gases
to
a
cylinder
containing
any
other
gas.
Tighten
connections.
When
assembling
threaded
con
nections,
clean and
smooth
seats where
necessary.
Tighten.
If
connection
leaks,
disassemble,
clean,
and
retighten using
properly fitting
wrench.
Adapters.
Use
a
CGA
adapter
(available
from
your
sup
plier)
between
cylinder
and
regulator,
if
one
is
required.
Use two
wrenches to
tighten
adapter
marked
RIGHT
and
LEFT
HAND
threads.
Regulator
outlet
(or hose)
connections
may
be
iden
tified
by
right
hand
threads
for
oxygen
and
left hand
threads
(with
grooved
hex
on
nut
or
shank)
for fuel
gas.
5.
Pressurizing
Steps:
Drain
regulator
of
residual
gas
through
suitable
vent
before
opening
cylinder
(or
manifold
valve)
by turning
adjusting
screw
in
(clockwise).
Draining
prevents
ex
cessive
compression
heat
at
high
pressure
seat
by
allowing
seat to
open
on
pressurization.
Leave
adjusting
screw
engaged
slightly
on
single-stage
regulators.
Stand
to
side
of
regulator
while
opening
cylinder
valve.
Open
cylinder
valve
slowly
so
that
regulator pressure
in
creases
slowly.
When
gauge
is
pressurized
(gauge
reaches
regulator
maximum)
leave
cylinder
valve
in
following
position:
For
oxygen,
and
inert
gases,
open
fully
to
seal
stem
against
possible
leak.
For
fuel
gas,
open
to
less
than
one turn
to
permit
quick
emergency
shutoff.
Use
pressure
charts
(available
from
your
supplier)
for
safe
and
efficient,
recommended
pressure
settings
on
regulators.
Check
for
leaks
on
first
pressurization
and
regularly
there-after.
Brush
with
soap
solution
(capful
of
Ivory
Liquid*
or
equivalent
per
gallon
of
water).
Bubbles
in
dicate
leak.
Clean
off
soapy
water
after
test;
dried
soap
is
combustible.
E.
User
Responsibilities
Remove
leaky
or
defective
equipment
from
service
im
mediately
for
repair.
See
User
Responsibility
statement
in
equipment
manual.
*Trademark
of
Proctor
&
Gamble.
OM-254
Poge
3

F.
Leaving
Equipment
Unattended
(dose
ga;
supply
at
source
and drain
gas.
G.
~pe
Staging-Support
Rope
staging~suppoi-t
should
not
be
used for
welding
or
c~tting
operation;
rope
may
burn.
1
-3. ARC
WELDING
-
Comply
with
precautions
in
-1,
1
-2,
and
this
section.
Arc
Welding, properly
done,
k
a
safe
process,
but
a
careless
operator
invites
trouble.
The
equipment
carries
high
currents
at
significant
oltages.
The
arc
is
very
bright
and hot.
Sparks
fly,
fumes
rise, ultraviolet
and
infrared
energy
radiates,
weldments
are
hot,
and
compressed
gases
may
be
us
eJ.
The
wise
operator
avoids
unnecessary
risks
and
pro
tects
himself
and
others
from
accidents. Precautions
ar~~
described
here
and
in
standards referenced
in
index.
A.
Burn
Protection
Comply
with
precautions
in
1-2.
The
welding
arc
is
intense
and
visibly
bright.
Its radia
i~ori
can
damage
eyes,
penetrate
lightweight clothing,
reflect
from
light-colored
surfaces,
and
burn
the
skin
ard
eyes.
Skin
burns
resemble
acute
sunburn,
those
from
gas-shielded
arcs are
more
severe
and
painful.
DONT
GET
BURNED;
COMPLY WITH PRECAU
TIONS.
1.
Protective
Clothing
Wear
long-sleeve
clothing (particularly
for
gas-shielded
arc)
in addition
to
gloves,
hat,
and
shoes
(1-2A).
As
necessary,
use
additional
protective
clothing
such
as
leather
jacket
or
sleeves, flame-proof
apron,
and fire-
resistant
leggings.
Avoid
outergarments
of
untreated
cotton.
Bare skin
protection.
Wear
dark,
substantial
clothing.
Button collar to
protect
chest
and
neck
and button
pockets
to
prevent
entry
of
sparks.
2.
Eye
and Head Protection
Protect
eyes
from
exposure
to
arc.
NEVER
look
at
an
electric
arc
without
protection.
Welding
helmet
or
shield
containing
a
filter
plate
shade
no.
12
or
denser
must
be
used when
welding.
Place
over
face before
striking
arc.
Protect
filter
plate
with
a
clear
cover
plate.
Cracked
or
broken
helmet
or
shield
should
NOT
be
worn;
radiation
can
pass
through
to
cause
burns.
Cracked,
broken,
or
loose
filter
plates
must
be
replaced
IMMEDIATELY.
Replace
clear
cover
plate
when
broken,
pitted,
or
spattered.
Flash
goggles
with side
shields
MUST be
worn
under
the helmet
to
give
some
protection
to
the
eyes
should
the helmet
not
be
lowered
over
the
face
before
an
arc
is
struck.
Looking
at
an arc
momentarily
with
unprotected
eyes
(particularly
a
high intensity
gas-shielded
arc)
can
cause a
retinal
burn that
may
leave
a
permanent
dark
area
in
the field
of
vision.
3.
Protection
of
Nearby
Personnel
Enclosed
welding
area.
For
production
welding,
a
separate
room
or
enclosed
bay
is best.
In
open
areas,
surround
the
operation
with
low-reflective,
non-
combustible
screens
or
panels.
Allow
for
free
air
circula
tion,
particularly
at
floor
level.
Viewing
the
weld.
Provide face
shields for
all
persons
who will
be
looking
directly
at
the
weld.
Others
working
in
area.
See
that
all
persons
are
wearing
flash
goggles.
Before
starting
to
weld,
make
sure
that
screen
flaps
or
bay
doors
are
closed.
B. Toxic Fume
Prevention
Comply
with
precautions
in
1-2B.
Generator
engine
exhaust
must
bevented
to
the
outside
air. Carbon
monoxide
can
kill.
C.
Fire
and
Explosion
Prevention
Comply
with
precautions
in
1-2C.
Equipments
rated
capacity.
Do
not
overload
arc
welding equipment.
It
may
overheat cables and
cause a
fire.
Loose cable connections
may
overheat
or
flash
and
cause a
fire.
Never strike
an
arc
on a
cylinder
or
other
pressure
vessel. It
creates
a
brittle
area
that
can cause a
violent
rupture
or
lead
to
such
a
rupture
later
under
rough
handling.
D.
Compressed
Gas
Equipment
Comply
with
precautions
in
1-2D.
E.
Shock Prevention
Exposed
hot conductors
or
other
bare
metal
in
the
welding
circuit,
or
in
ungrounded,
electrically-HOT
equipment
can
fatally
shock
a
person
whose
body
becomes
a
conductor.
DO NOT
STAND, SIT,
LIE,
LEAN
ON,
OR TOUCH
a
wet
surface
when
welding,
without
suitable
protection.
Page
4

To
protect
against
shock:
5.
Terminals
And
Other
Exposed
Parts
Keep
body
and
clothing
dry.
Never
work in
damp
area
without
adequate
insulation
against
elecirical shock.
Stay
on
a
dry
duckboard,
or
rubbe
rriat
when
damp
ness or
sweat
can
not
be
avoided.
Sweat,
sea
water,
or
moisture
between
body
and
an
electrically
HOT
part
-
or
grounded
metal
-
reduces the
body
surface
electrical
resistance,
enabling dangerous
and
possibly
lethal
currents to
flow
through
the
body.
1.
Grounding
the
Equipment
When
installing,
connect
the frames
of
each unit
such
as
welding
power
source,
control,
work
table,
and
water
circulator
to
the
building
ground.
Conductors
must
be
adequate
to
carry
ground
currents
safely.
Equipment
made
electrically
HOT
by
stray
current
may
shock,
possibly
fatally.
Do
NOT GROUND
to
electrical
conduit,
or
to
a
pipe
carrying
ANY
gas
or
a
flammable
li
quid
such
as
oil
or
fuel.
Three-phase
connection.
Check
phase
requirements
of
equipment
before
installing.
If
only
3-phase
power
is
available,
connect
single-phase
equipment
to
only
two
wires
of the
3-phase
line.
Do
NOT
connect
the
equip
ment
ground
lead to
the
third
(live)
wire,
or
the
equip
ment
will
become
electrically
HOT
-
a
dangerous
condi
tion
that
can
shock,
possibly
fatally.
Before
welding,
check
ground
for
continuity.
Be
sure
conductors
are
touching
bare metal of
equipment
Frames
at
connections.
If
a
line cord
with
a
ground
lead is
provided
with the
equipment
for connection
to
a
switchbox,
connect
the
ground
lead
to
the
grounded
switchbox. If
a
three-
prong
plug
is
added
for
connection
to
a
grounded
mating receptacle,
the
ground
lead
must
be
connected
to
the
ground
prong
only.
If the
line
cord
comes
with
a
threeprong plug,
connect to
a
grounded mating
recep
tacle.
Never
remove
the
ground
prong
from
a
plug,
or
use
a
plug
with
a
broken
off
ground
prong.
2.
Electrode Holders
Fully
insulated electrode
holders
should be
used.
Do
NOT
use
holders
with
protruding
screws.
3.
Connectors
Fully
insulated
lock-type
connectors
should be
used
to
join
welding
cable
lengths.
4.
Cables
Frequently inspect
cables
for
wear,
cracks and
damage.
IMMEDIATELY
REPLACE those
with
excessively
worn
or
damaged
insulation
to
avoid
possibly
-
lethal
shock
from
bared cable.
Cables
with
damaged
areas
may
be
taped
to
give
resistance
equivalent
to
original
cable.
Keep
cable
dry,
free
of oil
and
grease,
and
protected
from hot
metal
and
sparks.
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
arid
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
equip
ment,
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
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.
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
Le
Jeune
Rd,
P.O.
Box
351040,
Miami,
FL
33135.
2.
NIOSH,
SAFETY
AND
HEALTH
IN
ARC
WELDING
AND
GAS WELDING
AND
CUTTING
obtainable
from the
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C. 20402.
3.
OSHA,
SAFETY
AND
HEALTH
STANDARDS,
29CFR
1910,
obtainable
from
the
U.S. Govern
ment
Printing
Office,
Washington,
D.C. 20402.
4.
ANSI Standard
Z87.1,
SAFE PRACTICES
FOR
OCCUPATION
AND
EDUCATIONAL
EYE AND
FACE PROTECTION obtainable
from the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
5. ANSI
Standard
Z41.1,
STANDARD
FOR
MENS
SAFETY-TOE
FOOTWEAR
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
OM-254
Page
5

6.
ANSI Standard
Z49.2,
FIRE PREVENTION
IN
THE
USE OF
CUTTING
AND
WELDING PRO
CESSES obtainable
from
the
American National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018
7.
AWS
Standard
A60,
WELDING
AND
CUT
TING CONTAINERS
WHICH
HAVE HELD
COM
BUSTIBLES
obtainable
from
the
American
Welding
Society,
550
Le
Jeune
Rd.,
P.O. Box
351040,
Miami,
FL
33135.
8.
NFPA
Standard
51,
OXYGEN
-
FUEL
GAS
SYSTEMS
FOR
WELDING
AND
CUTTING
ob
tainable
from the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
9.
NFPA
Standard
70-1978,
NATIONAL
ELEC
TRICAL
CODE
obtainable
from the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
10
NFPA
Standard
SiB,
CUTTING
AND
WELDING
PROCESSES
obtainable
from
the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
11.
CGA
Pamphlet
P-i,
SAFE
HANDLING
OF
COM
PRESSED
GASES
IN
CYLINDERS
obtainable
from
the
Compressed
Gas
Association,
500
Fifth
Avenue,
New
York,
NY
10036.
12.
CSA
Standard
Wi
17.2,
CODE
FOR
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from
the
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
13.
NWSA
booklet,
WELDING
SAFETY
BIBLIOGRAPHY
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
Prepara
tion for
Welding
and
Cutting
of
Containers and
Piping
That
Have
Held Hazardous
Substances,
obtainable
from
the
American
Welding
Society,
550
Le
Jeune
Rd.,
P.O.
Box
351040,
Miami,
FL
33135.
15.
ANSI
Standard
Z88.2
Practice
for
Respiratory
Protection
obtainable
from
the
American
Na
tional
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
P~iqe
6

SECTION
2-
INTRODUCTION
Rnted
Welding
Current
Amperes
Load
Voltage
Ranges
Maximum
Open-
Circuit
Voltage
Amperes
Input
At
Rated
Load
Output
60
Hz.
Three-Phase
kw
Dimensions
(Inches)
Weight
(Poundsl
Net
I
Ship
230
Volts
460
Volts kva
150
75
59.8
~
750@
50 Volts
100%
Duty
Cycle
25-56
74
46.4
Height
-
57-1/4
Width
-
27-1/2
Depth-49
I
~
1726
I
1826
I
This
manual has been
prepared
especially
for
use
in
familiar
izing
personnel
with
the
design,
installation,
operation,
main
tenance,
and
troubleshooting
of this
equipment.
All
informa
tion
presented
herein
should
be
given
careful consideration to
assure
optimum
performance
of this
equipment.
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the
unit and
carefully inspect
for
any
damage
that
may
have
occurred
during
shipment,
Any
claims
for
loss
or
damage
that
may
have occurred
in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill of
lading
and
freight
bill
will
be
furnished
by
the manufacturer
on
request
if
occasion to
file
claim
arises.
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.
This
unit
is
a
three-phase
welding
power
source
which
pro
duces
dc
welding
current.
This
welding
power
source
is
de
signed
specifically
for
use
with the
Gas
Metal-Arc
(GMAWI
Welding
process.
2-4.
SAFETY
Before the
eqwpment
is
put
nto
operation,
the
safety
sec
tion
at
the
front
of this
manual
should be
read
completely.
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
Figure
2-).
Specifications
2-1.
GENERAL
Figure
2-2.
Block
Diagram
2-2.
RECEIVING-HANDLING
TB-901
181-lB
This will
help
avoid
possible
injury
due
to
misuse
or
improper
welding
applications.
The
following
definitions
apply
to
CAUTION,
IMPORTANT,
and
NOTE
blocks
found
throughout
this
manual:
Under
this
heading,
installation,
operating,
and main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
hazard
to
person
nel.
2-3.
DESCRIPTION
1
I
I
rTA~1
I
I
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will be
found
that
if
not
carefully
followed
may
result
in
damage
to
equip
ment.
~NOTE
~
U
I
U
U
OM-254
Page
7

SECTION
3
- INSTALLATION
2.1.
LOCATION
(Figure
3-1)
A
p
oper
installation
site
should
be
selected
for
the
welding
po..:r
roirce
it
the
unit
is
to
provide
dependable
service,
and
emain
relatively
maintenance
free.
A
proper
installation
site
permits
freedom
of
air
movement
mm
md
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 main
tained
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.
place
an
ove
r
the in
ta
ke
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

ranty
is void
if
any
type
of
filtering
device
is
used
3-2. ELECTRICAL INPUT
CONNECTIONS
NOTE
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
perform
any
internal
function
on
the
unit.
I
CAUTION
Before
making
electrical
input
connections
to the
welding
power source,
machinery
lockout
proce
duret
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
that
the
circuit
is
being
worked
on.
Holes
are
provided
in the
welding
power
source
base
for
mounting
purposes.
Figure
3-1
gives
overall
dimensions
and
the
base
mounting
hole
layout.
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.
IMPORT
The
use
of
lift
forks
too short
to extend
out
of the
opposite
side of
the base
will
expose
internal
com
ponents
to
damage
should the
tips
of
the
lift
forks
penetrate
the
bottom
of the
unit.
Figure
3-1.
Dimensional
Drawing
and Base
Mounting
Hole
Layout
A.
Input
Electrical
Requirements
This
welding
power
source
is
designed
to
be
operated
from
a
three
phase,
60
Hertz,
ac
power
supply
which has
a
line
voltage
rating
that
corresponds
with
one
of
the
primary
volt
ages
shown
on
the
welding
power
source
nameplate.
Consult
the
local
electric
utility
if
there
is
any
question
about
the
type
of
electrical
system
available
at
the
installation
site
or
how
proper
connections
to
the
welding
power
source are
to
be
made.
B.
Input
Conductor Connections
CAUTION
U
Do
not
connect
the
input
conductors
to
the three-
phase
power
supply
until
all
input
electrical
connec
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
con
duit.
Select the
proper
size
input
conductors
and
fuse
from
Table 3-1.
Table 3-1.
Input
Conductor
and
Fuse
Size
Input
Conductor
Size
-
AWG
Fuse
Size
In
Amperes
230V
380V
460V
575V 230V
380V
460V
575V
1/0
3
4
6
225
150
125
90
16) (61 (8) (8)
Numbers
in
I
I
are
ground
conductor
sizes.
Insert the three
input
conductors
plus
one
ground
conductor
through
the
access
hole
on
the
rear
panel.
This
hole will
accept
standard conduit
fittings.
See
Figure
3-2
for
hole
loca
tion and size.
NOTE
It
is
recommended
that
a
terminal
lug
of
adequate
amperage
capacity
be
attached
to
the
ends
of
the
input
and
ground
conductors.
The
hole
diameter
in
the
terminal
lug
must
be
of
proper
size
to
accommo
date
the
line terminal
hardware used
on
the
primary
i
contactor.
U
I
Page
13

Open
the
right
rear
side
door
to
obtain
access
to
the
primary
contactor.
Connect the
three
input
conductors
directly
to
the
line
terminals
of
the
primary
contactor
and
connect
the
ground
conductor to
the
terminal
labeled
GROUND.
See
Fig
ure
3-2
for
input
conductor
connections.
The
remaining
end
of the
ground
conductor
should
be
connected to
a
proper
grnund.
Use
whatever
grounding
method
that is
acceptable
to
the
local
electrical
inspection
authority.
The terminal
labeled
GROUND
is
connected
to
the
welding
power
source
chassis
and
is
for
grounding
purposes
only.
Do not
connect
a
conductor
from
the
terminal
labeled
GROUND
to
any
one
of
the
line
terminals
on
the
primary
contactor
as
this
will
result
in
an
electrically
hot
welding
power
source
chassis.
C.
Matching
The
Welding
Power Source To
The Avail
able
Input
Voltage
The
input
voltage
jumper
links
provided
on
the
primary
ter
minal
board
permit
the
welding
power
source
to
be
operated
from
various
line
voltages.
The
various
voltages
from
which
this unit
may
be
operated
are
stated
on
the
nameplate
and
on
the
input voltage
label.
See
Figure
3-2 for
location
of
this
label.
The
input
voltage
jumper
links
are
positioned
for
the
highest
of
the
voltages
stated
on
the
nameplate.
If
the weld
ing
power
source
is
to
be
operated
from
a
line
voltage
which
is
lower
than the
highest
voltage
for which the
unit
was
designed,
the
jumper
links
will
have
to
be
moved
to
the
proper
positions
before
operating
the
unit.
Figure
3-3 shows
the various
positions
of
the
jumper
links
on
the standard
welding
power
source.
If
the
input
voltages
on
the
name
plate
differ
from those
shown in
Figure
3-3,
the
input
voltage
jumper
links
must
be
positioned
as
shown
on
the
input
voltage
label.
NOTE
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
to
be
used. This
will
prevent
losing
the
jumper
links
which
are
not
required
for
this
connection.
3-3.
SECONDARY
CONNECTIONS
(Figure
4-1)
The
POSITIVE
and
NEGATIVE
secondary
terminals
are
located
behind
the lower
front
access
panel.
The
access
panel
which
covers
the
secondary
terminals
is
secured
by
two
fas
teners.
To
open
the
access
panel,
rotate
the
fasteners
counler
clockwise
one
full
turn.
Likewise,
so
close
the
panel,
rotate
the
fasteners clockwise
one
full
turn.
A.
Welding
Cables
It
is recommended
that
the
welding
cables be
kept
as
short
as
possible,
placed
close
together,
and be of
adequate
current
carrying
capacity.
The
resistance
of
the
welding
cables
and
connections
cause
a
voltage
drop
which
is
added
to the volt
age
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
is
capable.
The
proper
opera
tion
of
any
arc
welding
power
source
is
to
a
great
extent
dependent
on
the
use
of
welding
cables
and
connections
that
are
in
good
condition
and of
adequate
size.
Use
Table 3-2
as
a
guide
for
selecting
the
correct
welding
cable size
for
the
anticipated
maximum weld
current
that
will
be
used. Table 3-2
takes into
account
the
total cable
length
for
the
weld
circuit.
This
means
the
length
of
the
Electrode
cable
that
connects
the
wire
feeder
to
the
welding
power
source
and
the
Work
or
ground
cable
between
the
welding
power
source
and
the work
piece.
For
example:
if
the
Elec
trode 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
recom
mended
for
100
feet.
In
a
situation where
a
maximum weld
current
of
150
amperes
is
anticipated,
No. 2
weld
cable
is
recommended
for both the Electrode and
Work cables.
WE LOIN C
*TDTA
LLEN
C
TI-I
OF
CABLE
ICOPPE RI
IN
WELD CIA
CIJIT
AMPERES
SO
too
150 200
250 300
350 400
100
4
4
2
22
1
1/0 1/0
150
2 2 2
1
1/0
2/0
3/0
3/0
200
111
1/0
2/0
3/0
4/0
4/0
250
1/0
1/0 1/0
2/0
3/0 4/0 4/0
2-2/0
300
2/0
2/0
2/0 3/0
4/0
4/0
2-2/0
2-3/0
350
3/0
3/0
2/0
4/0 4/0
2-2/0
2-3/0
2-3/0
400
3/0 3/0
3/0 4/0
2-2/0
2-3/0
3-2/0
2-4/0
500
4/0 4/0
4/0
2-2/0 2-3/0 2-3/0
2-4/0
3-3/0
600
2-2/0
2-2/0 2-2/0 2-3/0 3-2/0
2-4/0
3-3/0 3-4/0
700
2-3/0 2-3/0 2-3/0 2-4/0
3-3/0
3-4/0
4.4/0
4-4/0
800
2-3/0 2-3/0
2-3/0
2-4/0
3-3/0
3-4/0
4-4/0
4-4/0
A-002
623
NOTE:
A.
50
FEET
OR
LESS.
B
CABLE
SIZE
IS BASED
ON
DIRECT
CURRENT IDCI.
100%
DUTY CYCLE
AND
EITHER
A
4
VOLTS OR
LESS
DROP
OR
A
CURRENT
DENSITY
OF
NOT OVER
300
CIRCULAR
MILS
PER
AMP.
C. WELD
CABLE
INSULATION
WITH
A
VOLTAGE
RATING
TO WITHSTAND
THE
OPEN-CIRCUIT
VOLT
AGE
IOCVI
OF
THE
WELDING
POWER
SOURCE
MUST
BE
USED.
WHILE
MOST
WELDING
POWER
SOURCES
HAVE
AN
OPEN-CIRCUIT
VOLTAGE
OF
LESS
THAN
100
VOLTS.
SOME
WELDING
POWER
SOURCES
OF
SPECIAL
DESIGN
MAY
HAVE
HIGHER
OPEN-CIRCUIT
VOLTAGE.
3-4.
115
VOLTS
AC
RECEPTACLE
(Figure
4-1)
Two
receptacles,
both
labeled
115
VAC,
are
provided
on
the
front
panel.
The
duplex
115
VAC
receptacle
fRC4)
is
in
tended
to
be
used
for
operating
accessory
equipment.
The
three-pole
twistlock.
115
VAC
receptacle
(RC2)
is
intended
to be
used for
supplying
operating
power
to
a
control/feeder.
To
secure
the
corresponding
three-pole
plug
into
this
recep
tacle,
rotate
the
plug
as
far
as
it
will
turn
in
a clockwise
direction.
3-5.
CONTACTOR
CONTROL
CONNECTIONS
(Figure
4-1)
The
CONTACTOR
CONTROL
Receptacle
IRC3)
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
CONTAC
TOR
CONTROL
Receptacle,
insert
the
two-pole
plug
from
the
Remote
Contactor
Control
device into
the
CONTACTOR
CONTROL
Receptacle
and
rotate
the
plug
as
far
as
it
will
Line
Table
3-2.
Secondary
Cable Sizes
Figure
3-2.
Input
Conductor
Connections
Te-gol
181-2
I
I
I
I
230
VOLTS
460
VOLTS
Figure
3-3.
Input
Voltage
Jumper
Link
Arrangement
OM-254
Page
9

turn in
a
clockwise direction The
plug
will
now
be
locked
in
the
receptacle
and will
not
pull
out
under
stress.
i
p.El
1~EP9RT~~~)
r
--.
lnih 11
t~
VA.
Receptacles
and
CONTACTOR
CON
TROL
Circuitry
are
protected
by
a
15
ampere
fuse
1F21
orhich
is
located behind the
right
front
side
panel.
II
it
chould
become
necessary
to
replace
the
fuse,
rincuri
that
a
fuse
of
the
same
rating
is
used
for
a
replacement.
A
fuse
of
a
larger
raring
will
permit
over
loadinq
o~
the 115
volts
circuitry
and
thereby
cause
_~,rnage
to
the
welding
power
source.
3-6.
REMOTE
VOLTAGE
CONTROL
CONNECTIONS
(Figure
4-1)
The
VOLTAGE
CONTROL
Receptacle
(RC1),
located
on
the
hunt
panel,
is
a
three-pole,
twistlock
receptacle.
The
VOLTAGE CONTROL
Receptacle
provides
a
connection
point
between the
Remote
Voltage
Control and
the
welding
power
sourci
voltage
adjustment
circuitry.
When
utilizing
a
Remole
Voltage
Control
insert
the
plug
from
a
Remote Volt
agi
Control
fully
into
the
VOLTAGE CONTROL
Receptacle
and thnn rotate
the
plug
as
far
as
it will turn
io
a
clockwise
direction This
rotating
action
will
secure
the
plug
in
the
receptacle
and
prevent
it
from
coming
out
if
tension should
he
applied
to the
Remote
Voltage
Control cord.
37.
SLOPE
REACTOR
CONNECTIONS
Be
sure
the branch circuit
or main
disconnect
switch
is
open
or
electrical
input
circuit fuses
are
removed
befote
attempting
any
inspection
or
work
on
the
in
side of
the
welding
power
source.
Placing
the
POWER
Switch
on
the
welding
power
source
in
the
OFF
posi
tion
does
not
remove
voltage
from
the
power
ter
miritalt
inside
of
the
welding
power
source.
The
slope
reactor
)Z),
located
behind the
left
rear
tide
panel,
has three
sets
of
five
slope
reactor coil
taps.
An
increase
or
decrease
in
slope may
be deemed
necessary
with
a
particular
43
Gas
Metal-Arc
Welding
process.
An increase in
slope
results
in
lets
available short
circuit
welding
current
and
slower
welding
response.
The
slope
connections
are
positioned
for
0
turns
(OT)
slope
(no
slope),
upon
shipment.
To
change
the
slope
connections,
proceed
as
follows:
(See
Figure
3-4
for
slope
reactor
coil
tap
connections.)
1.
Open
the
left
rear
side
panel
to obtain
access
to
the
slope
reactor
coils.
2.
Disconnect
leads
43,
44,
and
45
from
the
slope
reactor
coil
taps.
3. Reconnect
leads
43,
44,
and
45
to
the
desired
slope
re
actor
coil
taps.
IMPORTANT
Ensure
that
leads
43, 44,
and
45
are
connected
to the
same
value
reactor
coil
tap.
Ensure
also
that
leads
43,
44.
and
45
are
reconnected
to
the
same
reactor
coil
from
which
these
leads
were
disconnected.
SECTION
4-FUNCTION
OF
CONTROLS
I I
I
I
4.
Close
the left
front
side
panel.
I
I
21c~
45r
TA-gol
181-5
Figure
3-4.
Slope
Reactor
Coil
Tap
Connections
44
ST
ST
Primary
Overload
Voltage
Power
Circuit Breaker
Control Switch
DC
Voltmeter
115
VAC
Duplex
Receptacle
Positive
Weld
Output
Terminal
Voltage
Control
Switch
DC
Ammeter
Contactor
Control
Switch
Circuit Breaker
115 VAC Twistlock
Receptacle
Contactor
Control
Receptacle
Negative
Weld
Output
Terminal
Figure
4-1.
Front
Panel
View
TB-gol
181-4A
Page
10

4-1.
POWER
SWITCH
(Figure
4-1)
Placing
the
POWER
Switch
in
the
ON
position
will
energize
thr
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
posi
ion
and
the
welding
power
source
is
apparently
elec
trically
shut
down,
electrical
input
power
is
still
present
on
all
circuitry
up
to
the
POWER
Switch
and
primary
contactor.
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
the
line fuses.
4-2.
VOLTAGE
CONTROL
(Figure
4-1)
The
VOLTAGE
CONTROL,
located
on
the
front
panel,
pro
vides
a
means
of
selecting
the
voltage
desired within the
load
voltage
slope
connection
range
being
used.
Rotating
the
con
trol
in
a
clockwise
direction
will
increase the load
voltage.
Whenever
a
Remote
Contactor Control
is
to be
used,
make
connections
to
she
CONTACTOR
CONTROL
Receptacle
)RC3)
on
the
welding
power
source
as
instructed
in
item
3~5.
In
order
for
a
Remote
Contactor
Control
Station
to
operate
the
contactor
in
the
welding
power
source,
the
Remote
Con
tactor
Control must
be
able
to
supply
115
volts
ac
60
Hz
power
to
the
CONTACTOR
CONTROL
Receptacle
whenever,
weld
output
is desired.
Also,
whenever
suspension
of
weld
output
is
desired,
the Remote
Station
must
be
able
to
cut-off
the
115
volts
ac
supply
to
the
receptacle
(RC3). Another
prerequisite
for
remote
control
of
the
contactor is
to
have
the
CONTACTOR CONTROL
Switch
on
the
welding
power
source
in
the
REMOTE
position.
If
this switch it left
in
he
STANDARD
position,
the
contactor will
energize
as soon
as
the
POWER
Switch is
positioned
to
ON.
The
CONTACTOR CONTROL
Circuitry
(and
115
VAC Re.
ceptaclea)
it
protected
by
a 15
ampere
fuse
)F2) which
is
located
behind
the
right
front
side
panel.
If
this
fuse
should
open,
the
contactor
coil
would
de-energize
(if
the
CON
TACTOR
CONTROL
Switch
were
in the
STANDARD
posi
don)
and
all
weld
output
would be
suspended.
Alto,
if
this
fuse
should
open,
it
will be
noted
that
115
volts
ac
would
not
be available
at
the
115
VAC
Receptacles.
IMPORT
When
replacing
fuse
F2,
ensure
that
the
fuse
being
used
as
a
replacement
is
one
of
proper
size
and
rating.
A
fuse
of
larger rating
will
permit
overloading
of
the
115
volts
circuitry
and
thereby
cause
damage
to
the
welding
power
source.
The
scale
surrounding
the
VOLTAGE
CONTROL
is cali
brated
in
percentage
and
should
not
be
misconstrued
as
an
amperage
or
voltage
reading.
It
is
recommended
that the
meters
be read whenever it
is
necessary
to
know
the
amper
age
and
voltage
output.
4-3.
REMOTE
VOLTAGE CONTROL RECEPTACLE
&
SWITCH
(Figure
4-1)
If
a
Remote
Voltage
Control
is
to
be
used,
make
Connections
from
rhe
Remote
Voltage
Control to
the
VOLTAGE CON
TROL
Receptacle
as
instructed
in
item
3-6.
When
remote
control
of
the
voltage
is
desired,
it
is
essential
that the
VOLTAGE CONTROL
Switch
be
placed
in
the RE
MOTE
position.
Likewise,
if
a
Remote
Voltage
Control
it
not
to
be
utilized,
the
switch
must
be
in
the
STANDARD
position.
When
in
the
STANDARD
position
only
the
VOLT
AGE
CONTROL
on
the
front
panel
will
control
the
voltage.
The 30
volts
control
circuitry
in
the
welding
power
source
is
protected by
a
circuit
breaker
(CR2)
which
is
located
on
the
right
side
of
the
front
panel.
If
this
circuit breaker
opens,
the weld
output
goes to
minimum
output
and
remains
there, regardless
of
the
position
of
any
of the
welding
power
source
controls.
When this
occurs,
neither
the
VOLTAGE
CONTROL,
or
Remote
Voltage
Control
will
have
any
effect
on ~ne
weld
output.
Manually
reset
the
circuit breaker
before
attempting
to
resume
operation.
This
welding
power
source
is
equipped
with
an
overload
Circuit
Breaker
(CR1)
which
will
suspend
all
weld
output
in
the
event
an
excessive overload is
placed
on
the
welding
power
source.
The Circuit Breaker
circuitry
consists
of
two
current
trans
formers
)CT1
&
CT2(
which
are
located
on
the
primary
side
of
the
main
transformer
(Ti) and
two
sets
of
contacts
which
are
wired
in
series
with
the
contactor
coil.
Should
an
over
load
occur,
the
current
sensing
transformers
would
detect the
overload
and
cause
the
Circuit
Breaker
to
trip.
When the
breaker
trips,
the
two sets
of
contacts
in
series
with
the
Con.
tactor
coil
will
open
and
thereby
cause
the
Contactor
to
de-energize
and
suspend
all
weld
output.
To
place
the
weld
ing
power
source
in
a
ready-to-weld
status
again,
it
will
be
necessary
to
manually
place
the Circuit Breaker
atms on
the
front
panel
in
the
ON
position.
46. METERS
(Figure
4-1)
This
welding
power
source
is
equipped
with
a
dc
ammeter
and
adc
voltmeter. These
meters
are
internally
connected
to
the
welding
power
source
weld
output
terminals,
The
volt.
meter
will
indicate
the
dc
voltage
at
the
secondary terminals,
but
will
not
necessarily
indicate
the
actual
voltage
at
the
welding
arc.
If the
welding
cables
are
excessively
long,
or
have
poor,
loose
connections,
the
difference
between
actual
arc
voltage
and
the
voltage
at the
welding
power
source
secondary
terminals
may
be
considerable.
The
ammeter
will
indicate
the
weld
current
output
of
the
welding
power
source.
4-7. DUTY CYCLE
(Figure
4-2)
.

c~
-
.
  -
~
I
I
U
NOTE
I I
The
contacts
of
the
VOLTAGE CONTROLareof
the
continuous
type,
thereby
making
it
possible
to
ad(ust
this
control
while
welding.
4-5. CIRCUIT BREAKER
OVERLOAD
PROTECTION
(Figure
4-1)
4-4.
CONTACTOR
CONTROL
RECEPTACLE
&
SWITCH
(Figure
4-1)

~IIuflhIlL.]jU
I
I
Whenever
the
CONTACTOR
CONTROL
Switch
is
in
the
STANDARD
position,
open.circuit
voltage
will
be
present
at
the
secondary
terminals
as
long
as
the
POWER
Switch
is
positioned
to
ON.
1000
~a
900
E
ow
ja.
800
700
U
I
30
40
50 60
708090100
%DUTY
CYCLE
DA.901
181-1
Figure
4-2.
Duty Cycle
Chart
OM-254
Page
11

Thu
dirty
cycle
of
a
welding
power
sOtrice
is
the
percentage
I
a
ten
minute
period
that
a
welding
power
tout ce
con
safely
be
operated
ni
a
given
output
ciii
ciii
-rIlirIq.
This
welding
ir~.jrr
snur cr-i
in,
nun Rt
7~ir
nhltpernv,
iflO
nirceit
duty
cyci~.
Tins
merits
the
wriidilirl
power
suurr:rn-:vIi
be
safrnly
operated
at
750
anlprrres
welrlirer
c.rrrvor
coicticununciy.
If
the
welding
current
is
increased SilO
duty cynic
viii decrease
Figure
1-2
untihies
the
oporatol
to
Irnici
nrc
the
sole
ouSuirt
hi
,~rrldi
ng
powet
source
ar
var
ir
15
ui
y
noises
~Pr~RTA~T
L ~
-~
Exceeding
the
ndieriterl
duly
C/lie
will
cause
the
t~iriirq
pointer
sourss
Na
ov-rheaS and
thereby
cause
damage
to
the
welding
power
source
components.
Tie
volt-ampere
curve
shows the
output
voltage
available at
an-c
given output
current
within
the
limits of
the minimum
and
maximum
values
of
the
VOLTAGE
CONTROL
setting.
Load
voltage
is
predetermined
to
a
large
degree by
arc
char
acteristics.
With
the
use
of
the
volt-ampere
curve,
it
is
pos
sible 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
VOLTAGE
CONTROL
for each of
the
five
slope
reactor
tap
connection
ranges.
Curves
of
other
VOLTAGE CON
TROL
settings
will
fall
between
the
maximum
and
minimum
curves
shown.
SECTION
5
-
SEQUENCE
OF OPERATION
I-
.
.1
Never,
under
any
Circumstances,
operate
the
welding
power
source
with the
outer enclosure
removed.
In
addition
to
a
safety
hazard,
improper
cooling may
re
sult
in
damage
to
the
welding
transformer
and
the
welding
power
source
components.
Warranty
is void
if
the
welding
power
source
is
operated
with the
Outer
enclosure
open
or
removed.
I
~Lu1l.]~IJ
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
result
in
serious
and/or
permanent
bodily
damage.
8. Turn
on
the
shielding
gas
supply.
5-1.
GAS
METAL-ARC
(GMAW)
WELDING
1
.
Make
Electrical
input
connections
as
outlined
in
item
3-2
-
2
Make
Secondary
connections
as
outlined in item
3-3.
3.
If
a
Remote
Contactor
Control device is
used,
make
Contactor
Control connections
as
instructed
in
item
3-5 and
place
the
CONTACTOR
CONTROL
Switch
in
the
REMOTE
position.
4.
II
a
Remote
Voltage
Control
is
to be
used,
make
con
nections
to the
VOLTAGE CONTROL
Receptacle
as
instruction
in
item
3-6
and
place
tIle
VOLTAGE
CON
TROL
Switch
in
the
REMOTE
position.
5.
If
115
volts
ac
is
required
to
operate
a control/feeder,
make
connections
to
the
three-prong,
twistlock,
115
VOLTS AC
Receptacle
as
instructed
in
item
3-4.
6.
Rotate
the
VOLTAGE
CONTROL
to
the
approximate
desired
setting.
7
Ensure
that
the Circuit
Breaker and external Line
Dis
connect
Device
are
in the
ON
position.
9. Place the
POWER Switch
to
the
ON
position
and
commence
welding.
10. The
VOLTAGE
CONTROL
may
be
rotated
while
welding.
5-2.
SHUTTING
DOWN
1. Breakthearc.
2.
Allow
the
welding
power
source
to
idle
for
3
minutes
with
no
load
applied.
3. Place
the
POWER
Switch
in the
OFF
position.
4. Turn off the
shielding
gas
at
the
shielding
gas
source.
CAUTION
I
.
-I
If
welding
is
performed
in
a
confined
area,
failure
to
turn off
the
shielding
gas
supply
could result
in
a
build
up
of
gas
fumes, thereby
endangering
personnel
re

entering
the
welding
area.
SECTION
6-
MAINTENANCE
Be
sure
the
branch
circuit
or
main
disconnect
switch
is
open
or
electrical
input
circuit
fuses
are
removed
before
attempting
any
inspection
or
work
on
the
in
side
of
the
welding
power
source.
Placing
the
POWER
Switch
on
the
welding
power
source
in
the
OFF
posi
tion
does
not
remove
voltage
from
the
power
ter
minals
inside
of
the
welding
power
source.
U
6-1.
FAN MOTOR
All
models
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.
6-2.
TRANSFORMER
Occasional
blowing
out
of
the
dust
and
dirt
from
around
the
transformer
is
recommended.
This
should
be done
periodi
cally
depending
upon
the
location
of
the
unit
and
the
I
4-8.
VOLT-AMPERE CURVE
(Figure
4-3)
I
200
300
400 500
600
700 800 900
EB-901
181-1
Figure
4-3.
Volt-Ampere
Curve
I
I
I
I
I
CAUTI9N__~
I
Page
12

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.
6-3. RECTIFIER
It
is recommended
that
the
rectifier
be
cleaned
occasionally
by
blowing
it
Out
with
compressed
air.
This
cleaning
opera
tion is
necessary
so
that
maximum
cooling
will
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
will be
necessary
to
re
move
the
outer
enclosure for
this
cleaning
operation.
6-4.
CONTROL
CIRCUIT PROTECTION
The
entire control
circuit of
the
welding
power
source
is
protected by
a
600
volts,
10
ampere, cartridge
type
fuse
(Fl).
This
fuse
is
located behind
the
right
rear
side
door.
Should this
fuse
open
the
welding
power
source
would
com
pletely
shut
down.
The
15
volts
control
circuit
is
protected
by
fuse
F3
located
on
the
center
baffle. If the
fuse
opens
control of
Output
is
avail
able
but
complete
minimum
cannot
be
obtained.
I
I
IMPORTANT
If
it
should
become
necessary
to
replace
this
fuse
or
any
other
fuse
in the
welding
power
source,
ensure
that
the
proper
size
fuse
is used
as
a
replacement.
I
I
SECTION
7
-
TROUBLESHOOTING
Hazardous
voltages
are
present
on
the
internal cir
cuitry
of the
welding power
source
as
long
as
power
is
connected
to
the
unit.
Disconnect
power
before
attempting
any
inspection
or
work
on
the
inside
Qf
the
unit.
Troubleshooting
of
internal
circuitry
should
be
performed
by
qualified personnel only.
The
following
chart is
designed
to
diagnose
and
provide
remedies
for
some
of
the troubles
that
may
develop
in this
welding
power
source.
It
is
assumed
that
proper
installation
has been
made,
according
to
Section 3
of this
manual,
and
that
the
welding
power
source
has
been
functioning
properly
until
this
trouble
developed.
Use
this chart
in
conjunction
with
the
circuit
diagram
while
performing
troubleshooting
procedures.
If the
trouble
is
not
remedied
after
performing
these
procedures,
the
nearest
Factory
Authorized
Service
Station should be
contacted.
In
all
cases
of
equipment
malfunction,
the
manufacturers
recommendations should
be
strictly
followed.
TROUBLE
PROBABLE
CAUSE
REMEDY
Limited
output
and low
open-cir-
cuit
voltage,
Operation
on
single-phase.
Open
line fuse
on one
phase.
Check
incoming
three-phase
power
for
correct
voltage
Re.
place
fuse
if
open.
Input
voltage jumper
links
con-
nected
to
wrong
terminals,
Connect
jumper
links for
input
voltage
being
used.
See
the
input
voltage
label
on
the
primary
connection
board.
Fan
runs
slow.
Input
voltage
jumper
links
on
pri-
mary
Connection board
connected
for
incorrect
voltage.
Connect
jumper
links for
input
voltage being
used.
See
Fig-
ure
3-3
and
the
input
voltage
label
on
the
primary
con-
nection
board.
Fan does
not
run.
Weld
output
available,
Fan
motor
defective.
Check fan
motor
leads
for
possible
short.
Re-insulate
fan
motor
leads,
if
shorted.
Check
fan
motor
windings
for
continuity.
If
open,
replace
the
fan
motor.
Rotate
the
fan
to
check for freedom of
rotation.
If
hard
to
rotate,
replace
the
motor.
Fan
does
not
run
and
no
weld
output.
Fuse
(Fl)
open.
~Replace
fuse
(Fl?,
,f
open.
Line
fuses
open.
Replace
line
fuses,
if
defective,
Erratic weld
current. Incorrect
welding
cable
size,
Use
proper
size
&
type
of cable.
See
item
3.3.
Loose
welding
cable
connections.
Tighten
all
welding
connections.
Incorrect drive
gear
for wire size
on
the
feeder.
See
wire
feeder
instruction
manual
troubleshooting
guide.
Fan
runs
but
no
weld
output
or
115
VAC
output.
Fuse
(F2)
open.
Replace
fuse
(F2),
if
open.
Fan
runs,
115
VAC
available,
but
no
weld
output.
Circuit breaker
(CB
1)
tripped.
Reset
circuit breaker
(CB
1).
if
tripped.
Centrifugal
switch (FMS)
open.

Replace
centrifugal
(FMS)
switch.
Fan
runs,
115
VAC
available,
but
low
weld
output.
Circuit breaker
(CB2)
open.
Manually
reset
circuit breaker
(CB2).
1f
it becomes
necessary
to
replace
any
fuse
in
the
welding
power
source,
ensure
that
a
fuse
of
the
proper
size
is
used,
OM.254
Page
13

REMOrE CONTROL
CPT~ONA1 ~EXTRA)
Figure
7-1.
Circuit
Diagram
Circuit
Diagram
No.
B-087
120
Paqe
14

July
1982
FORM:
OM-254B
PARTS
LIST
Effective
With
Serial
No.
JC600199

Item
Dia.
Part
No.
Mkgs.
No.
Description Quantity
Figure
A
Main
Assembly
BE
SURE
TO PROVIDE
MODEL
AND SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT PARTS.
OM-254
Page
1
1
1
1
1
2
2
1
1
3
1
1
1
1
003 107
COVER,
top
2
3
4
SRi
037 354
Figure
D
053
445
RECTIFIER,
silicon
diode
(Fig
B
Pg
2)
BAFFLE,
center
-
w/components
(Pg 3)
BASE
5
6
T2
026 627
036 646
GASKET,
lifting
eye
cover
TRANSFORMER,
kva
2
7
8
9
Z
~
036 697
008519
003
110
REACTOR,
slope
PANEL,side-top
PANEL,
side
10
11
12
Ti
Figure
E
Figure
G
101 811
PANEL,
rear-w/components
(Pg
4)
TRANSFORMER,
power
(Pg
7)
BUS
BAR,
accontrol
13
14
15
MA1,3
MA2
036
270
036
230
Figure
F
AMPLIFIER,
magnetic
(FigCPg2)
AMPLIFIER,
magnetic
(Fig
C
Pg
2)
PANEL,
front
-
w/components
(Pg
6)
Fig
F
Figure
A
-
Main
Assembly
I
TD-901 181-B
Fig
C