Miller ps-100 User manual

June
1988
Millerfi
F~1LE
COPY
RETURN
TO
FOLDER
OWNERS
MANUAL
iMPORTANT
Read and
understand
the
entire
contents
of this
manual.
with
special emphasis
on
the
safety
material
throughout
the
manual.
Miller Electilc
Mfg.
Co.
A~L~C~at~
before
installing,
operating,
or
maintaining
this
equipment.
This
unit
and
P0. Box 1079
these
instructions
are
for
use
only
by
persons
trained
and
experienced
In
Appleton,
WI
54912 USA
the
safe
operation
of
welding equipment.
Do
not
allow
untrained
persons
Tel.
414-734-9821
to
install,
operate,
or
maintain this
unit. Contact
your
distributor
if
you
do
not
fully
understand these instructions.
FORM:F2544B
Effective
With
Serial
No.
JJ393769
MODEL
ps-100
PRINTED
IN
U.S.A.
ACOITIONAL
COPY
PRCE
70
CENTS

EFFECTIVE:
FEBRUARY
16.
1988
This
warranty
supersedes
all
previous
MILLER
warranties and
is
exclusive with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
-
Subject
to
the
terms
and
condi-
In
the
case
at
Millers breech
of
warranty
or
any
other
duty
dons
hereof,
Miller Electric
Mfg.
Co.,
Appleton,
Wisconsin
with
respect
to the
quality
of
any goods,
the exclusive
rwi~diemi
warrants to
its
Distributor/Dealer
that
all
new
and
unused
therefore shall
be,
at
Millers
option
(1)
repair
or
(2)
replacement
Equipment
furnished
by
Miller
is
free from
defect
in
workman-
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
ship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
the
reasonable
coat
of
repair
or
replacement
at
an authorized
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
Miller
service
station
or
(4)
pa~mant
of
or
credit
for
the
purchase
accessories
or
other items manufactured
by
others.
Such
pnce
(lees
reasonable
depreciation
based
upon
actual
use)
upon
engines,
trade
accessories
and other items
are
sold
subject
to
return
of the
goode
at
Customers
risk
and
expense.
MILLERs
the warranties of their
respective manufacturers,
if
any
.
All
option
of
repair
or
replacement
will be
F.O.B.,
Factory,
at
engines
are
warranted
by
their
manufacturer
for
one
year
from
Appleton, Weconsin,
or
F.O.B.,
at
a
MILLER
authorized
service
date
of
original
purchase,
except
Tecurnseh
engines
which
facility,
therefore,
no
compensation
for
transportation
costs
of
have
a
two
year
warranty.
any
kind
will
be
allowed.
Upon receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
insmact
the
claimant
on
the
warranty
Except
as
specified below,
Millers
warranty
does
not
apply
claim
procedures
to
be
followed.
to
components
having
normal
useful life
of
lees
then
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
MILLERMATIC
parts
that
come
in
contact
with the
welding
ANY
EXPRESS WARRANTY
NOT PROViDED
HEREIN
AND
wire
including
nozzles and
nozzle
insulators
where
failure
dose
ANY
IMPUED
WARRANTY.
GUARANTY
OR
REPRESENTA
~
not
result
from
defect
in
workmanship
or
material.
liON AS TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH OF CONTRACT
WHICH,
BUT FOR ThIS
PROVISION,
~
Miller
shall
be
required
to
honor
warranty
claims
on
war-
MIGHT
ARISE BY
IMPUCA11ON,
OPERATION
OF
LAW,
~
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
CUSTOM
OF
TRADE
OR
COURSE
OF
DEAUNG.
INCLUDING
~
within
the
following
periods
from
the
date of
delivery
of
Equip-
ANY
IMPUED WARRANTY
OF MERCHANTABIUTY
OR
OF
merit
to
the
original
user:
FITNESS
FOR
PARTICULAR
PURPOSE,
WITh
RESPECT
TO
ANY
AND
AU.
EQUIPMENT
FURNISHED
BY MILLER IS
EX
~.f
1. Arc
weldais,
p~re~irces,
robots,
and
c
,or~nts
.
1
yeer
CLUDED AND
DISCLAIMED BY MILLER.
2. Loadbanks
1
year
j
3.
Original
main
power
rectifiers
3
years
(labor
-
1
year
only)
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
~
4. All
welding
guns,
feeder/gun,
and
torches 90
days
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
r1~
5. All
other
Millermatic
Feeders
1
year
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
~
6.
Replacement
or
repair
parts,
exclusive
of labor
..
60
days
USERS
AND
FOR
OPERATION
BY
PERSONS TRAINED
AND
ij(
7.
Batteries
6
months
EXPERIENCED
IN
ThE USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
~
provided
that
Miller
i.
notified
in
writing
within
thirty
(30)
days
CONSUMER
USE.
MILLERS WARRANTIES
DO
NOT
EXTEND
!~
of
the
date
of
such
failure.
TO,
AND
NO
RESELLER
IS AUTHORIZED
TO
EXTEND
.~
As
a
matter
of
general
policy only,
Miller
cay
honor
dims
MILLERS WARRANTIES
TO,
ANY
CONSUMER.
by
the
original
user
within
die
foreyoing
periods

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
Welding
4
1-4.
Standards
Booklet Index
6
SECTiON
2-INTRODUCTION
2-1.
Vott-Ampere
Curves
8
2-2.
Duty
Cycle
8
2-3.
General
Information
And
Safety
8
2-4.
Receiving-Handling
8
2-5.
Description
9
SECTION
3
INSTALLATION
3-1.
Location
9
3-2. Weld
Output
Connections
9
3-3.
Control
Module
Receptacle
Information
And
Connection
10
3-4.
Electrical
Input
Connections
11
SECTION
4-
OPERATOR CONTROLS
4-1.
PilotLight
13
4-2.
Circuit
Breaker
13
4-3.
Control
Module
Receptacle
13
SECTION
5-
SEQUENCE
OF OPERATiON
5-1.
Operation
13
5-2.
Shutting
Down
13
SECTION
6-
MAINTENANCE
&
TROUBLESHOOTING
6-1.
Routine
Maintenance
14
6-2.
Fan
Motor
14
6-3.
Overload
Protection
14
6-4.
Troubleshooting
Chart
16

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
sale
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-General
Precautions,
common
to
arc
welding
and
cut
ting;
and 2-Arc
Welding
(and
Cutting)
(only).
Reference
standards: Published
Standards
on
safety
are
also
ava~able
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
(MSDSs)
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
cuffless
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.
Replace
cover
glass
when
broken,
pitted,
or
spattered.
See
1
-3A.2.
Avoid
oily
or
greasy
clothing.
A
spark
may
ignite
them.
Hot
metal such
as
electrode
stubs and
workpieces
should
never
be
handled without
gloves.
Medical
first
aid
and
eye
treatment.
First
aid facilities
and
a
qualified
first
aid
person
should
be
available
for
each shift
unless
medical facilities
are
close
by
for
im
mediate
treatment
of
flash burns of
the
eyes
and
skin
burns.
Ear
plugs
should be
worn
when
working
on
overhead
or
in
a
confined
space.
A
hard
hat
should
be
worn
when
others
work
overhead.
Flammable hair
preparations
should
not
be
used
by
per
sons
intending
to
weld
or
cut.
B.
Toxic
Fume
Prevention
Severe
discomfort,
illness
or
death
can
result
from
fumes,
vapors,
heat,
or
oxygen
enrichment
or
depletion
that
welding
(or
cutting)
may
produce.
Prevent
them
with
adequate
ventilation
as
described
in
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
it
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
F2544
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
perchioroethylene.
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,
verdi
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 be
protected
by
heat-resistant
covers or
shields.
Fire
watcher
must
be
standing by
with
suitable
fire extin
guishing
equipment
during
and for
some
time afterweld
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
orvisible)
In
floors orwalls
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
corrtustibles,
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
orwaterwashing, 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
ii
in
Standards
Index.
i.
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
1
-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.
F2544
Pace
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,
stings,
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
(1-203).
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
soui~es
of
ignition.
Wiper
with
a
clean
lintiess
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
regulatordesigned
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
fue
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
sale 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
Stag lng~Support
Rope
staging-support
should
not
be
used for
welding
or
cutting
operation;
rope
may
burn.
Trademark
of Proctor &
Gamble:
F2544
Page
3

1-3.
ARC
WELDING
Comply
with
precautions
in
1-1,
1-2,
and
this section.
Arc
Welding,
properly
done,
is
a
sale
process,
but
a
careless
operator
invites
trouble. The
equipment
cames
high
currents
at
significant
voltages.
The
arc
is
very
bright
and
hot.
Sparks
fly,
fumes
rise,
ultraviolet
and
in
frared
energy
radiates,
weidments
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
light-colored
surfaces,
and burn the skin and
eyes.
Skin
bums 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 fire-re
sistant
leggings.
Avoid
outer
garments
of
untreated
cot
ton.
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
am.
Protect filter
plate
with
a
clear
cover
plate.
Cracked
or
broken helmet
or
shield
should NOT
be
worn;
radiation
can
pass
through
to
cause
bums.
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 bum 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
kilt.
J. Fire and
Explosion
Prevention
Comply
with
precautions
in
1-2C.
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
rup
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
mat
when
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
usafety
In
Welding
And
Cut
ting,
a
voltage
may
exist
between the
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 oft.
When
installing,
connect
the frames of each
unit such
as
welding
power
source,
control,
work
table,
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
ortlammable
liquid
such
as
oil
or
fuel.
F2544 Pace
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/off
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
contactor)
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.
off.
7.
Safety
Devices
Safety
devices
such
as
Interlocks
and
circuit
breakers
should
not
be
disconnected
or
shunted out.
Before
installation,
inspection,
or
service,
of
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
bums,
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
theirdoctor
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
Ad,
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
Amen
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.
F2544
Page
5

7.
AWS
Standard
A6.0,
WELDING
AND
CUTTiNG
CONTAINERS
WHICH
HAVE HELD
COMBUS
TIBLES obtainable
horn
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,
Batterymamh
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 Jet-
ferson
Davis
Highway,
Suite
501,
Atlington,
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
Ad, 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
Rated
Welding
Amperes
100%
Duty Cycle
Range
Max.
Open-
Circuit
Voltage
Amperes Input
At
Rated Load
Output
KW

Dimensions
Weight
60
Hz
Three-Phase

200V 230V
460V 575V


~ss
~o 160
128
KVA
Net
Ship
1200A@
80V
20-1500
Amperes
.
ioov~c 128
104
Height:37in.
(940mm)
Width:271n.
(686 mm)
Length:
27in
(686mm)
1155
lbs.
(524
kg)
1370 lbs.
(621
kg)
8
B-i
16
834
FIgure
21.
SpecificatIons
X ~PS
Figure
2-2.
Volt-Ampere
Curves
F2544
Pape
6

2-1.
VOLT-AMPERE
CURVES
(Figure
2-2)
The
volt-ampere
curves
show
the
voltage
and
amper
age
output
capabilities
of
the
welding
power
source.
2-2.
DUTY CYCLE
(FIgure 2-3)
The
duty
cycle
of
a
welding
power
source
is
the
percent
age
of
a
ten
minute
period
that
a
welding
power
source
can
be
operated
at
a
given
output
without
causing
over
heating
and
damage
to
the unit. This
welding
power
source
is rated
at
100
percent duty
cycle.
This
means
that
the
welding
power
source
can
be
operated
at
rated
load
continuously
without
causing
overheating
and
damage
to
the
unit.
Figure
2-3
enables
the
operator
to
determine
the
output
of
the
welding
power
source
at
various
duty
cycles.
a
CAUTION:
EXCEEDING
DUTY
CYCLE
RAT
ING
will
damage
the
welding
power
source.

Do
not
exceed
indicated
duty cycles.
2-3.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this manual
and
on
various
la
bels,
tags,
and
plates
on
the
unit
pertains
to
equipment
design,
installation,
operation,
maintenance,
and
troubleshooting
which
should
be
read,
understood,
and
followed
forthe
safe and
effective
use
of this
equipment.
B.
Safety
The
installation,
operation,
maintenance,
and
troubleshooting
of
arc
welding equipment
requires
prac
tices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
Is
to
be
installed,
operated,
and
maintained
only
by
qualified
persons
in
accordance with
this
annual and
all
applica
ble
codes such
as,
but
not limited
to,
those
listed
at
the
end of
Section
1,
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source.
Safety
instructions
specifically
pertaining
to
this
unit
ap
pear
throughout
this
manual
highlighted
by
the
signal
words
WARNING
and
CAUTION
which
identify
differ-S
ent
levels
of
hazard.
WARNING
statements
include
installation,
operation,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
serious
personal
injury
or
loss of
life.
CAUTION
statements
include
installation,
operation,
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.
2-4.
RECEIVING-HANDLING
Before
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
claim
for
loss
or
damage
that
may
have
occurred
in
tran
sit
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
tile
claim
arises.
When
requesting
Information
concerning
this
equip
ment.
it
is essential
that Model
Description
and
Serial
Number
of
the
equipment
be
supplied.
2-5.
DESCRIPTION
This
unit
is
a
three-phase,
constant
current
dc
welding
power
source
with
solid-state
control.
The
dc
output
is
designed
for
use
with
spray
arc
equipment.
A
separate
control
module
is
required
for
setting output
parameters.
3000
2500
in
2000
8
500
1000

1550
A
200
A
 IOOZ
5
20 25 30
40
50 60 70
50 90 00
~
~JTY
CYCLE
FIgure
2-3.
Duty
Cycle
Chart
8-118
833
F2544
Pac~e
7

SECTION
3-
INSTALLA11ON
3.1.
LOCATION
a
WARNiNG: FALLING
EQUIPMENT
can
cause
serious
personal
Injury
and
equip
ment
damage.

Use
lifting
eye
to
lift
unit
only,
NOT
running
gear,
gas
cylinders,
trailer,
or
any
other
heavy
options,
accessories,
or
devices.

Use
equipment
of
adequate capacitytoliftthe
unit.

If
using
lift forks
to
handle this
unit,
be
sure
the
lift
forks
are
long
enough
to
extend
out
of the
op
posite
side
of the
base.
Using
lift forks
too
short
will
expose
internal
components
to
damage
should the
tips
of
the
lift
forks
penetrate
the bottom
of
the
unit.
RESTRICTED
AIR
FLOW
causes
overheat
Ing
and
possible damage
to
Internal
parts.

Maintain
at
least
18
inches
(457mm)
of
unre
stricted
space
on
all
sides
of
unit,
and
keep
un
derside free of obstructions.

Do
not
place
any
filtering
device
over
the
in
take
air
passages
of this
welding
power
source.
Warranty
Is
void
If
any
type
of
filtering
device Is
used.
This
welding
power
source
has
a
lifting
device
for
mov
ing
the unit
and
holes
in
the
base for
mounting
purposes.
The
location should
allow sufficient
room
to
remove
the
top
cover
and
side
panels
for
installation,
maintenance,
and
repair
procedures.
IMPORTANT:
The
welding
power
source
must
be
lo
cated
so
that the
Control
Module
cord
can
reach
the
welding
power
source.
The
control
module
may
be
in
stalled
into
a
control
console.
The
service
life
and
operating
efficiency
of this
unit
are
reduced when the
unit
Is
subjected
to
high
levels
of
dust,
dirt, moisture,
corrosive
vapors,
and
extreme
heat.
3-2.
WELD
OUTPUT
CONNECTIONS
OUTPUT
To obtain
the full
rated
output
from
this
unit,
It is
neces
sary
to
select,
install,
and
maintain
proper
welding
ca
bles.
Failure
to
comply
in
any
of
these
areas
may
result
in
less than
satisfactory
welding
performance.
A.
Welding
Cables
If
welding
cables
were
not
ordered with
this
unit,
the
steps
listed
should be
followed to
ensure
the best weld
ing
performance:
1.
Keep
cables
as
short
as
possible,
and
place
cables
close
together.
Excessive
cable
length
adds
resis
tance
which
may
reduce
output
or
cause
overload
ing
of
the
unit.
2. Select
adequate
size
welding
cable
for the
antici
pated
maximum weld
current.
Use
total
length
of
welding
cable
in
the
circuit
to
determine
cable
size.
For
example:
lithe
cable
to
spray gun
is 25 feet
(7.5
mm)
long
and
work
cable
is
25 feet
(7.5 mm)
long,
select the size
cable
recommended
in
Table
3i
for
50
feet
(15
m).
Table 3-1.
WeldIng
Cable
Size
WELDING
AMPERES
TOTA LLEN GTH OF
CABLE
(COPPERHN
WELD
CIPC%JIT
50
100
150 200
250
300
350 400
100
4 4
2
2 2
1
1/0
1/0
150
2 2
2
1
1/0
2/0
3/0
3/0
200
1 1
1
1/0
2/0
3/0
4/0
4/0
260
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
3/0
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
2-210
2-2(0
2-2/0
2-3/0 3-2/0
24/0
3-3/0
3-4/0
700
2-3/0 2-310
2-3/0
24/0
3-3/0
3-4/0
44/0
4-4/0
600
2-3/0 2-3/0 2-3/0
24/0
3-3/0 3-4/0
4-4/0
4-4/0
900
3-2/0 3-2/0 24/0
3-3/0
34/0
4-4/0 4.4/0
1000 24/0 24/0 24/0
24/0
4-3/0
4-4/0
1250
3-3/0 3-3/0
3-3/0
4-3/0 4-4/0
1500
3-4/0
3-4/0
3-4/0
44/0
A~2 623
NOTE:
A.
SOFEETOR
LESS.
B.
CABLE
SIZE
IS
BASED ON DIRECT CURRENT
(DC).
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
4OCV)
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.
Do
not
use
damaged
or
frayed
cables.
A-002
623
-
4.
Install
correct
size
lugs
of
adequate
amperage
ca
pacity
onto
ends
of
both cables for
connecting
to
work
clanp,
spray
gun,
and weld
output
terminals.
5.
Install
spray gun
onto
cable
following
manufactur
ers
instructions.
An
insulated
spray
gun
must
be
used
to
ensure
operator safety.
6.
Install work
clamp
onto
cable.
.~
~

WARNING:
ELECTRIC
SHOCK
can
kill.

Do
not
touch IWe
elect
rica!
parts.

Shut
down unit
and disconnect
input
power
employing
lockout/tagging
procedures
before
making welding
cable
connections.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
posi
tion,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit breaker
or
other dis
connecting
device.
1.
Connect
end
of
spray
gun
cable
to
POSITIVE
(+)
weld
output
terminal.
2. Connect
one
end of work
cable
to
NEGATIVE
()
weld
output
terminal
and
remaining
end
to
workpiece.
IMPORTANT: For
Electrode
Negat
We/Straight Polarity
connections,
reverse
cable
connections
to
weld
output
terminals;
electrode becomes
negative.
3-3.
CONTROL
MODULE RECEPTACLE
INFOR
MAT1ON
AND
CONNECTiON
(Figure
3.1)
The
1
7-socket
Amphenol receptacle
RC2
provides
a
connection
point
for the
Control
Module. To
make
con
nections,
align keyway,
insert
Control
Module
plug fully
into
receptacle,
and
rotate
threaded collar
fully
clock
wise.
A
properly
connected
Control
Module
is
neces
sary
for
unit
operation.
The
command
signals required
and
the
output
signals
available
at
the
sockets
of
receptacle
RC2
are
as
fol
lows:
Socket
A:
Reference
voltage
for
output
command;
+l0vdc
Socket
B:
Output
command
signal.
Socket
C:
Not
used.
Socket
D:
Output
contactor
control.
Socket
E:
Output
current
signal;
1
volt
per
150
amperes.
Socket
F:
Control
circuit
common.
Socket G:
Not
used.
Socket
H:
+24
volts
dc
unregulated;
fused
at
1
ampere.
Socket
J: 115 volts
applied
from
external circuit
for
input
contactor
control.
Designed
for
use
with
a
normally-open,
momentary
contact
switch.
Socket
K:
115
volts
applied
from
external
circuitfor
input
contactor
control.
Designed
for
use
with
a
normally-closed,
momentary
contact
switch.
Socket
L:
24
volts dc
unregulated;
fused
at
1
Socket
M:
Output
voltage signal;
I
volt
per
10
volts.
Socket
N:
+15
volts dc
rectifier
caution
signal.
Present
when
rectifier
is
overheated
or
there
is
unbalanced
output.
Socket
P:
Transformer caution
signal.
Normally-open
relay
activates
to
potential
of
pin
F
(control
circuit
common)
when
the
transformer
is
overheating.
Socket
A:
Fan
motor
signal.
Normally-open,
relay
activates
to
potential
of
pin
F
(control
circuit
common)
when
the fan
motor
is
operating.
TA.1Il
059
Figure
3-1. Front VIew
Of
17-Socket
Amphenol
Receptacle
With
Socket
LocatIons
3-4.
ELECTRICAL
INPUT
CONNECTIONS
INPUT
A.
ElectrIcal
Input
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
electrical
input
voltages
shown
on
the
nameplate.
Con
sult 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.
installation
POSITIVE
NEGATIVE
+
ampere.
SocketS:
Socket
T:
Chassis
common.
115
vac
return
for
Input
contactor control.
F2544 Pacie
9

B.
Matching
The
Welding
Power
Source
To
The
Available
Input
Voltage
a
WARNING:
ELECTRIC
SHOCK can
kill.

Do
not
touch
live
electrical
parts.

Shut
down
unit
and
disconnect
input
power
employing
lockout/Tagging
procedures
before
inspecting
or
seivicing.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
posi
tion,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit breaker or
other
dis
connecting
device.
This
unit
is
equipped
with
input
voltage jumper
links
either installed
or
in
a
bag
on
the
input
terminal board
to
allow
operation
from
different line
voltages.
If
installed,
the
jumper
links
are
positioned
for
the
highest voltage
stated
on
the
nameplate
or
input
data label.
II in
a
bag,
proper
installation is
necessary
before
operation.
a
WARNING:
ELECTRIC SHOCK
can
kill.

Do not touch live electrical
parts.

Install
a
fusible
line
disconnect
switch
in
the
input
circuit
to
the
welding
power
source.
This
provides
a
sate and convenient
means
to
completely
remove
all electrical
power
from
the
welding
power
source
whenever
It
Is
necessary
to
inspect
or
service
the
unit.

Employ
lockoutiTagging
procedures
on
in
put
line
before
making
input
connections
to
the
welding
power
source.
Lockout/tagging procedures
consist of
padlocking
line
disconnect switch
in
open
posi
tion,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit breaker
or
other
dis
connecting
device.

When
making input
power
connections,
work
from
the
welding
power
source
to
deenergized
line
disconnect switch.
Always
work
on
deener
gized
circuits when
making
input
powerconnec
tions.
Remove
the
top
cover
and
reposition
or
Install,
If
appli
cable,
the
jumper
links
onto
the terminal
board
to
match
the
available
line
voltage positions
shown
on the
input
voltage
label.
C.
Input
Conductor Connections
Table
3-2
provides
guidelines
for
selecting
the
propet
size
input
conductors and
line fuses.
The
input
conduc
tor
should
be
covered
with
an
insulating
material that
complies
with
national,
state,
and local electrical
codes.
Table
3.2.
Input
Conductor
And
Fuse
Size
Input
Conductor
Size
-
AWG
Fuse
Size
In
Amperes
200V
I
230V
1460V1575V
500MCML~MCM~
110 1
(1)
(2)
(4)
(6)
200VI230V
I~0%hI
575V
600
500 300
200
lnputconckictor
sizes
are
based
on
National
Electrical
Code
specifi
caflons
for
allowable
ampacWesof
insulated
copper
conductors,
hav
ing
a
temperature
rating
of
75
degrees
C.
with
not
more
than
three
conductors
in
a
racoway
or
cable.
Numbers
in
( )
are
equipment
ground
onductor
sizes.
Install
terminal
tugs
of
adequate
amperage
capacity
and
correct
stud
size
onto
the
Input
and
ground
conductors.
a
WARNING: ELECTRIC
SHOCK
can
kill.

Do
not connect
an
input
conductor to
the
ground
terminal
in
the unit.

Do
not
connect
the
ground
conductor
to
an
in
put
line
terminal.
Install
and
connect
Input
and
ground
conductors
as
fol
lows:
1.
Obtain
and Install
a
proper
strain relief connector
into
rear
panel
access
hole
(
hole
accepts
standard
conduit
fittings).
2.
insert
input
conductors
and
ground
conductor
through
rear
panel
access
hole
and
route
conduc
tors
to contactor.
3.
Connect
input
conductors
to
line
terminals
on
con
tactor.
4. Connect
ground
conductor to
ground
terminal
next
to
contactor.
5.
Connect
remaining
end
of
ground
conductor
to
a
proper
ground.
Use
a
grounding
method that
is
ac
ceptable
to
the
local
electrical
Inspection
authority.
6.
Reinstall and
secure
top
cover
onto
unit.
F2544
Page
10

SECTION
4-
OPERATOR
CONTROLS
4-1.
PILOT LIGHT
The
pilot
light,
when
Iffliminated,
Indicates
that the
weld-
ing
power
source
primary
contactor
is
energized.
from overload.
If
CB1
opens,
correct
the
problem
and
manually
reset
CBI.
4-3.
CONTROL MODULE
RECEPTACLE
4.2.
CIRCUIT
BREAKER
Circuit breaker
CB1
functions
as
the
unit ON/OFF
switch.
CB1
also
protects
the
primary
contactor
circuitry
The
Control
Module
receptacle
RC2
provides
a
connec
tion
point
forthe
remote
control module.
See
Section
3-3
for connection
information.
SECTION
5
SEQUENCE
OF
OPERATION
5-1.
OPERATION
1.
Install
and
connect
unit
according
to
Section
3.
a
WARNING:
ELECTRIC
SHOCK
can
kIlI
2.
Install
and
connect Control
Module
as
instructed
in
MOVING PARTS
can cause
serious
iniury;
Section
301 this
manual and
control console Own-
IMPROPER
AIR
FLOW
AND
EXPOSURE
TO
ers
Manual.
ENVIRONMENT
can
damage
Internal
parts.

Do
not
touch live
electrical
parts.
3.
Prepare
any
remaining equipment
for
the
applica
tion.

Keep
all
covers
and
panels
in
place
while
op
erating.
5. Turn
on
power
to
welding
power
source
contactor
Warranty
Is void
if
the
welding
power
source
is
and
begin operation.
operated
with
any
portion
of the
outer
enclosure
5-2.
SHUTTING DOWN
removed.
1.
Stop
operation.
ARC
RAYS, SPARKS,
AND
HOT
SURFACES
can
burn
eyes
and
skin;
NOISE
can
damage
2.
Turn off
power
to
welding
power
source
contactor.
hearing.
3.
Turn off all
auxiliary
equipment.

Wear
con-ect
eye,
ear,
and
body
protection.
FUMES
AND
GASES
can
seriously
harm
your
health.

Ventilate
to
keep
from
breathing
fumes
and
gases.

If
ventilation is
inadequate,
use
approved
breathing
device.
HOT
METAL,
SPATTER
AND
SLAG
can
cause
fire
and
bums.

Watch
for
fie.

Have
a
fire
extinguisher nearby,
and know
howto
use
it.

Allow work
and
equipment
to
cool
be
fore han
dling.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.

Wearers should
consult
with
their doctors
be
fore
going
near arc
welding,
gouging,
or
spot
welding operations.
See
Section
1

Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source
for basic
welding
safety
information.
F2544
Pa~:1e
11

SECTION
6
-
MAINTENANCE
&
TROUBLESHOOTING
6-1.
ROUTINE
MAINTENANCE
IMPORTANT:
Every
six
months
inspect
the
labels
on
this
unit
for
legibility.
All
precautionary
labels
rrvst
be
maintained
in
a
clearly
readable
state
and
replaced
when
necessary.
See
Parts List
for
part
number
of
pre
cautionary
labels.
WARNING:
ELECTRIC SHOCK
can
kill.

Do
not
touch
live
electrical
parts.

Shut
down
unit
arid
disconnect
input
power
employing
lockout/tagging
procedures
before
inspecting,
maintaining,
or
servicing.
Lockout/tagging
procedures
consist
of
padlocking
line disconnect
switch
in
open
posi
tion,
removing
fuses
from fuse
box,
or
shutting
off and
red-tagging
circuit
breaker
or
other dis
connecting
device.
HOT
SURFACES
can
cause
severe
burns.

Allow
cooling
period
before
servicing.
Troubleshooting
of internal
parts
to
be
per
formed
only by
qualified
person.
Table 6-1.
MaIntenance
Schedule
FREQUENCY
MAINTENANCE
.
Every
Month
Units
in
heavy
service
environment
Check
weld
cables,
check
labels,
clean
internal
parts.
Every
3
Months
Check
weld cables
(see
Section
6-lA).
Every
6
Months
Check
all
labels
(see
IMPORTANT
block,
Section
6-1).
Yearly
Clean
internal
parts
(see
Section
6-18).
A.
Weld
Cables
Every
three months
inspect
cables for
breaks
in
insula
tion.
Repair
or
replace
cables
if
insulation breaks
are
present.
Clean
and
tighten
connections at
each
inspec
tion.
B.
Internal
CleanIng
Blow
out
or
vacuum
dust and
dirt
from
around the inter
nal
con~onents.
Do this
annually
depending
on
the lo
cation of
the
unit
and
the
amount
of dust and dirt
in
the
atmosphere.
If
dirty
or
dusty
conditions
are
present,
clean
unit
monthly.
The
power
source
outer
enclosure
should be
removed,
and
a
clean
dry
airstream
or
vac
uum
suction should be
used
for
this
cleaning
operation.
6-2.
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.
6-3.
OVERLOAD PROTECTiON
a
WARNING: ELECTRIC
SHOCK
can
kill.

Do
not
touch live
electrical
parts.

Shut
down unit and disconnect
input
power
employing
lockout/tagging
procedures
before
inspecting, maintaining,
or
servicing.
Lockout/tagging
procedures
consist of
padlocking
line disconnect
switch
in
open
posi
tion,
removing
fuses from fuse
box,
or
shutting
off
and
red-tagging
circuit breaker
or
other dis
connecting
device.
a
CAUTION: IMPROPER
FUSES
can
damage
unit

Be
sure
replacement
fuses
are same
size,
type,
and
rating
(see
Parts
List).
A.
Transformer
And Rectifier ProtectIon
The main
transformer
and rectifier
assembly
are
pro
tected
from overload
by
three
normally-closed
thermo
stats
TP1,
TP2,
and
TP3.
TPI
and
TP2
are
located
in
the main
transformer,
and
TP3 is located
in
the rectifier
assembly.
If
overheating
of the transformer and/or recti
fier
occurs,
the associated
thermostat(s)
will
open
deenergizing
the
output
contactor.
The
welding
power
source
signals
the
control
console
and weld
output
ceases.
If
this condition
occurs,
allow
a
cooling
period
before
resuming
operation.
B.
Circuit
Board
ProtectIon
(FIgure
6-1)
Fuses
Fl
and
F2
protect
both the
+
and
24
volts cir
cuits.
If Fl
opens,
24 volts dc
is
not
available
from
PCi
to
receptacle
RC2.
If
F2
open,
+24
volts dc is not
avail
able from
PCi
to
receptacle
RC2. The
fuses
are
located
on
the
rear
of the circuit
board
mounting
bracket
inside
the unit. It Is
necessary
to
remove
the unit
top
cover
to
gain
access
to
the fuses.
C.
Fan Protection
Fuse
F4
open
when fan
motor
FM
stalls
or
draws
exces
sive
current
from the
main
transformer.
F4
is located
on
the
rear
panel
under the windtunnel
by
the
input
conduc
tor
strain
relief.
It is
necessary
to
remove
the
nght
side
panel
to
gain
access
to
this fuse.
F2544
Pa~~
12

Figure
6-1.
Component
Locations
(A)
Circuit
Board
P~3
Terminal
Strip
And
Control
R.ctifi.r
Mount
maid.
IS.s
Parts
Ust)
Ru.:
TA-090
925-A
6-4.
TROUBLESHOOTING
CHART
a
WARNING:
ELECTRIC SHOCK
can
kill.

DO
not
touch
live electrical
parts.

Shut
down unit arid disconnect
input
power
employing
lockoutiTagging
procedures
before
inspecting, maintaining,
or
servicing.
Lockout/tagging
procedures
consist
of
padlocking
line disconnect
switch
in
open
posi
tion,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
dis
connecting
device.
MOVING
PARTS
can cause
serious
Injury.

Keep
clear
of
moving
parts.
HOT
SURFACES
can cause severe
burns.

Allow
cooling
pericd
before
servicing.
Troubleshooting
of
internal
parts
to
be
per
formed
only
by qualified
persons.
It
is assumed that the unit
was
properly
Installed
and
connected
according
to
Section
3
of this
manual,
the
op
erator
is familiar with
the
function
of
controls,
the weld
ing
power
source was
working
properly,
and
the
trouble
is
not
process
related.
The
following
chart is
designed
to
diagnose
and
provide
remedies
for
some
of the troubles
that
may
develop
in
this
welding
power
source.
Use this
chart
in
conjunction
with
the
circuit
diagram
while
performing troubleshooting
procedures.
If
the
trouble
is
not
remedied after
performing
these
proce
dures,
contact
the
nearest
Factory
Authorized Service
Station.
In
all
cases
of
equipment
malfunction,
the
manufacturers
recommendations
should be
strictly
fol
lowed.
Component
Access
Compartment
Board PCi
Block
Gate
Connectors
With Red
And Whits
Wy.
Circuit BOard
Pc2
F?544
P2c:e
1~3

Table 6-2.
TroubleshootIng
TROUBLE
PROBABLE CAUSE
REMEDY
No
weld
output;
unit
completely
inoperative
Une
disconnect
switch
in
the
OFF
position.
Place
line
disconnect
switch
in
the
ON
position.
Line
fuse(s)
open.
Replace
line
fuse(s).
Improper
electrical
input
connections.
See
Section
3-4
for
proper
input
connections.
Input voltage
jumper
links
not
in
proper
position.
See
Section
3-4
B for
proper
jumper
link
position.
Main transformer
Ti
and/or main
rectifier
SRI
and
SR2
assembly
overheating
(thermal
shutdown).
Allow
the
unit
to
cool down
(see
Section
6-3).
Erratic
weld
output
Poor and/or
in~roper
input
and/or
output
connections.
See
Sections
3-2
and
3-4
for
proper
input
and
output
connections.
No
24
volts
control
circuits.
Fuse(s)
Fl and/or F2.
Replace
Fuse(s)
(see
Section
6-3).
Fan
does
not
run.
Fuse
F4
Replace
fuse
(see
Section
6-3).
F2544
Pa~~
14

/
to
to to
to
to to
to
to
0
Figure
6-2.
CIrcuit
Diagram
Circuit
Diagram
No.
D-122
253

Dia.
Part
Mkgs.
No.
Descnptuon
Quantity
Complete
Assembly
CB1
053
283
CIRCUIT
BREAKER,
manual
reset
1
pole
15
amp
250 volts
1
090
476
CAPACITOR
(consisting
of)
1
Cl
4,15
000 859
CAPACITOR,
electrolyte
220 UI
35
volts dc
2
R4
601 394
RESISTOR,
carbon
2
watt
10K ohm
1
Cl
7,18
083
332
CAPACITOR,
ceramic 0.003
UI
3000 volts
2
094
206
CAPACITOR,
(consisting
of)
1
C21
,24
097 749
CAPACITOR,
ceramic
0.05 Ut 500 volts dc
2
CR12.4
059
266
RELAY,
enclosed 120 volts
ac
DPDT
3
CR3
106
462
RELAY,
enclosed
24
volts
dc
DPDT
1
Dl
115 325
DIODE,
1
amp
400 volts
SP
1
FM
032 633
MOTOR,
1/4
hp
230
volts
ac
1625
rpm
(consisting
of)
1
011 850
SWITCH,
motor
1
032 617
BLADE,
fan
50
hz
20 inch
3
wing
24
deg
1
059
585
WINDTUNNEL,
20 inch
1
114425
BAR,
support,
windtunnel
2
Fl
,2
012 643
FUSE,
miniature
glass
sb
blo
1
amp
1
098
376
HOLDER,
fuse
1
F4
012639
FUSE,
cartridge
30
amp
600 volts
1
070 404
HOLDER,
fuse
1
HAl
,2
093
342
SENSOR,
current
2
PCI
115185
CIRCUIT
CARD,
control
(pg
20)
I
PC2,3
106
585
CIRCUIT
CARD,
SCR
firing
(pg 22)
2
115149
ENCLOSU
RE,
circuit caids
1
110375
STAND-OFF,
support
12
PL1
027645
LIGHT,
indicator
red lens
125 volts
ac
1
PLG51
,56,57
090
469
HOUSING,
terminal header 10
pin
3
PLG52,53
072 566
HOUSING,
terminal header
8
pin
2
PLG
50 081 379
HOUSING,
terminal
header
12
pin
1
POS,NEG
115397 TERMINAL
ASSEMBLY,
power
output (consisting
of)
1
115148
TERMINAL
BOARD
1
038847
BUSBAR 2
601 840
NUT,
brass-hex
jam
1/2-13
8
601
839
NUT,
brass-hex
jam
1/2-13
4
038900
STUD,
brass 1/2-13
x
2-1/4
4
602247
WASHER,
flat-SAE
1/2
4
605787
WASHER,
lock-internal
tooth
1/2
4
RC2 097
869
RECEPTACLE,
17
socket
MS-3102A-20-29S
1
R5
039
210
RESISTOR,
WW
fixed
375
watt
1.2
ohm
1
SRi
115
429
RECTIFIER,
SCR
main
(consisting
of)
1
SCR1-12
109091
THYRISTOR,
SCR
865
amp
300 volts
12
C1-12
048420
CAPACITOR,
ceramic
0.01 UI 500 volts dc
12
TP3
012
786
THERMOSTAT,
NC
1
086
354
CLAMP,
diode/rectifier
4
025
248
STAND-OFF,
1/4-20
x
1-1/4 8
028516
PIN,springl/8x1/4
24
SR3
035
914
RECTIFIER,
integrated
30
amp
400
volts
1
TEl
114
545
TERMINAL
ASSEMBLY,
pn
(consisting
of)
1
038669
TERMINAL
BOARD
1
038
621
BLOCK,
terminal 30
amp
4
pole
1
038652
LINK,
jumper
6
026754
INSULATION
12
038 620
LINK,
jumper
2
F2544
Page
16