Miller ARC PAK 350 User manual

Miller
September
1989
FORM:
OM-126853A
Effective
With
Serial
No.
JJ401061..
MODEL:
ARC
PAKIM
350
Manufactured
For
Chicago
Bridge
&
Iron
OWNERS
MANUAL
IMPORTANT:
Read and
understand
the
entire
contents
of this
manual,
with
special
emphasis
on
the
safety
material
throughout
the
manual,
before
MILLER
ELECTRIC
MfcI.
Co.
AMrnGfG(O~OLtd.CO~Y
-
installing,
operating,
or
maintaIning
this
equipment.
This unit
and
these
instructions
are
for
use
only by
persons
trained
and
experienced
In
the
safe
P0 Box
1079
.Appleton,
WI
54912 USA
operation
of
welding
equipment.
Do
not
allow
untrained
persons
to
install,
Tel.
414-734-9821
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand these
instructions.
PRINT~D
IN
U.S.A

I
-J
LIMITED
WARRANTY
EFFEC1IVE:
MARCH
15,
1989
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
conditions
hereof,
Miller Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
to
its Distributor/Dealer
that
all
new
and
unused
Equipment
fur
nishedby
Miller is
free from defect
in
workmanship
and
material
as
of
the time
and
place
of
delivery by
Miller.
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade accessories
or
other
items
manufactured
by
others. Such
engines,
trade
ac
cessories
and other
items
are
sold
subject
to
the warranties
of
their
respective
manufacturers,
if
any.
All
engines
are
war
ranted
by
their
manufacturer
for
one
year from
date of
original
purchase,
except
Tecumseh
and
Onan
engines
which
have
a
two
year
warranty.
Except
as
specified
below,
Millers
warranty
does
not
apply
to
components
having
normal
useful
life of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
MILLER-,
5MA11C
parts
that
come
in
contact
with the
welding
wire includ
ing
nozzles
and
nozzle insulators
where
failure
does
not
result
from defect
in
workmanship
or
material.
Miller
shall
be
required
to
honor
warranty
claims
on
warranted
Equipment
in the
event
of failure
resulting
from
a
defect
within
the
following
periods
from
the
date of
delivery
of
Equipment
to
the
original
user:
1.
Arc
welders,
power
sources,
robots,
and
1
year
components
2.
Load
banks
1
year
3.
Original
main
power
rectifiers
3
years
(labor

1
year
only)
4.
All
welding
guns,
feeder/guns
and
torches
90
days
5.
All
other Millermatic
Feeders
1
year
6.
Replacement
or
repair
parts,
exclusive of labor
60
days
7.
Batteries
6
months
provided
that Miller
is
notified in
writing
within
thirty
(30)
days
of
the
date
of such
failure.
As
a matter
of
general
policy
only,
MiHer
may
honor
daims
submitted
by
the
original
user
within
the
foregoing
periods.
In the
case
of
Millers
breach of
warranty
or
any
other
duty
with
respect
to the
quality
of
any
goods,
the
excluswe
remedies
therefore
shall
be,
at
Millers
option
(1) repair
or
(2)
replacement
or,
where
authorized in
writing by
Miller
in
appropriate
cases,
(3)
the reasonable
cost
of
repair
or
replacement
at
an
authorized
Miller
service
station
or(4)
payment
of
or
credit
for the
purchase
price
(less
reasonable
depreaation
based
upon
actual
use)
upon
return
of
the
goods
at
Customers
risk and
expense.
MILLERsoption
of
repairorreplacenientwill
be
F.O.B..
Factory
at
Appleton,
Wisconsin,
or
FOB.
ata
MILLER authorized
serv
ice
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind
will
be allowed.
Upon
receipt
of notice
of
apparent
defect
or
failure,
Miller
shall instruct
the claimant
on
the
war
ranty
claim
procedures
to be
followed.
ANY EXPRESS WARRANTY
NOT PROVIDED HEREIN
AND ANY IMPLIED
WARRANTV
GUARANTY OR REPRE.
SENTAT1ON
AS TO
PERFORMANCE,
AND ANY REMEDY
FOR BREACH
OF
CONTRACT
WHICH,
BUT
FOR THIS
PRO
VISION,
MIGHT ARISE BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPUED WARRANTY
OF MERCHAN
TABILITY
OR OF FITNESS FOR PARTICULAR
PURPOSE,
WiTH
RESPECT
TO
ANY
AND ALL
EQUIPMENT FUR
NISHED
BY MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER
EXCEPT
AS
EXPRESSLY PROVIDED
BY
MILLER
IN
WRITING,
MILLER PRODUCTS
ARE
INTENDED
FOR
ULTI
MATE
PURCHASE
BY COMMERCIAL/INDUSTRIAL USERS
AND
FOR OPERATION
BY
PERSONS TRAINED
AND
EXPE
RIENCED
IN
THE USE AND MAINTENANCE OF
WELDING
EQUIPMENT
AND NOT FOR CONSUMERS OR
CON
SUMER
USE.
MILLERS
WARRANTIES
DO
NOT EXTEND
TO,
AND
NO
RESELLER IS AUTHORIZED TO
EXTEND
MILLERS WARRANTIES
TO.
ANY
CONSUMER.
I

OM-126853A9/89
RECEiVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam-
Use the
following
spaces
to
record the
Model
Design
a-
age
that
may
have occurred
during
shipment.
File
any
tion
and
Serial
or
Style
Number
of
your
unit.
The
infcr
claims for loss
or
damage
with the
delivering
carrier.
mation
is located
on
the
data
card
or
the
nameplate.
Assistance
for
filing
or
settling
claims
may
be
obtained
from the
distributor and/or the
eq~iipment
manufactur-
Model
_______________________________
ers
Transportation Department.
Senal
or
Style
No.
____________________
When
requesting
information
about this
equipment,
al
ways
provide
the
Model
Description
and
Serial
or
Style
Dateof
Purchase
_____________________
Number.
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
Boo
k~et Index
5
SECTION
2SAFETY
PRECAUTIONS
AND
SIGNAL WORDS
2-1.
General
Information
And
Safety
6
2-2.
Safety
Alert
Symbol
And
Signal
Words
6
SECTION
3SPECIFICATIONS
3-1.
Volt-Ampere
Curves
8
3-2.
Duty Cycle
8
3-3.
Description
8
SECTION
4-INSTALLATION
OR
RELOCATION
4-1.
Site
Selection
8
4-2.
Transporting
Methods
9
4-3.
Weld
Output
Connections
9
4-4.
Electrical
Input
Connections
10
SECTION
5-OPERATOR
CONTROLS
5-1.
PowerSwitch
12
5-2.
Pilot
Light
12
5-3.
Output
Control
12
5-4.
Arc
Control/Inductance
Control
12
5-5.
Contactor
Switch
13
5-6.
Output
Control
Switch
13
5-7.
CV/CC
Switch
14

Section
No.
Page
No.
SECTION
6
SEQUENCE
OF OPERATION
6-1.
Gas
Metal
Arc
(GMAW)
And
Flux Cored
Arc
Welding
(FCAW)
14
6-2.
Tungsten
Arc
Welding
(GTAW)
14
6-3.
Shielded
Metal Ait
Welding
(SMAW)
15
6-4.
SubmergedArc
Welding
(SAW)
15
6-5.
Air
Carbon Arc
Cutting
And
Gouging
(ACA)
15
6-6.
Shutting
Down
15
SECTION
7
MAINTENANCE
&
TROUBLESHOOTING
7-1.
Routine Maintenance
16
7-2.
Overload
Protection
16
7-3. Thermal
Protection
17
7-4.
Circuit
Board
Indicator
Lights
17
7-5.
Circuit
Board
Handling
Procedures
18
7-6.
Troubleshooting
18
SECTION
8
ELECTRICAL
DIAGRAMS
Diagram
8-1.
Circuit
Diagram
21
Diagram
8-2.
Circuit
Diagram
For Control
Circuit
Board
PCI
22
Diagram
8-3.
Circuit
Diagram
For Base Drive
Circuit Boards
PC2
And
PC3
24
Diagram
8-4.
Circuit
Diagram
For
Snubber Circuit
Board
PC4
24
Diagram
8-5.
Circuit
Diagram
For Balance
Circuit
Board
PC5
25
SECTION
9-
PARTS LIST
Figure
9-1.
Main
Assembly
26
Figure
9-2.
Panel,
Front
W/Components
28
Figure
9-3.
Baffle,
Center
W/Components
30
Figure
9-4.
Transistor
Assembly,
Main
32
Figure
9-5.
Module,
Diode
34
LIST
OF CHARTS
AND
TABLES
Table
3-1.
Specifications
7
Chart
3-1.
Volt-Ampere
Curves
7
Chart
3-2.
Duty Cycle
8
Table
4-1.
Weld
Cable Size
9
Table
4-2.
Input
Conductor
And Fuse Size
11
Table
7-1.
Maintenance Schedule
16
Table 7-2.
Troubleshooting
18

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
oth
ers
teach
you.
Safe
practices
developed
from
experience
in
the
use
of
welding
and
cutting
are
described
in
this manual. Re
search~
development,
and field
experience
have
evolved reliable
equipment
and
safe
installation,
opera
tion,
and
servicing practices.
Accidents
occur
when
equipment
is
improperly
used
or
maintained.
The
rea
son
for
the safe
practices
may
not
always
be
given.
Some
are
based
on common
sense,
others
may
require
technical volumes
to
explain.
It
is
wiser
to
follow the
rules.
Read
and
understand
these safe
practices
before
at
tempting
to
install,
operate,
or
service
the
equipment.
Comply
with
these
procedures
as
applicable
to
the
par
ticular
equipment
used and
their instruction
manuals,
for
personal
safety
and for the
safety
of
others.
Failure
to
observe
these
safe
practices
may
cause
seri
ous
injury
or
death. When
safety
becomes
a
habit,
the
equipment
can
be
used
with
confidence.
These
safe
practices
are
divided
into
two
Sections:
1-General
Precautions,
common
to
arc
welding
and
cut
ting;
and
2-Arc
Welding
(and
Cutting)
(only).
Reference
standards:
Published
Standards
on
safety
are
also
available for
additional and
more
complete
pro
cedures than
those
given
in this
manual.
They
are
listed
in
the
Standards
Index
in
this
manual.
ANSI
Z49.1
is
the
most
complete.
The
National
Electrical
Code,
Occupational
Safety
and
Health
Administration,
local
industrial
codes,
and
local
inspection
requirements
also
provide
a
basis
for
equip
ment
installation,
use,
and
service.
12.
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
manu
facturers
Material
Safety
Data
Sheets
(MSDSs)
for
specific
technical
data
and
precautionary
measures
concerning
their
material.
A. Burn
Prevention
Wear
protective
clothing-gauntlet
gloves
designed
for
use
in
welding,
hat,
and
high
safety-toe
shoes.
Button
shirt
collar
and
pocket
flaps,
and
wear
cuff
less
trousers
to
avoid
entry
of
sparks
and
slag.
Wear
helmet
with
safety
goggles
and
glasses
with side
shields
underneath,
appropriate
filter
lenses
or
plates
(protected
by
clear
cover
glass).
This
is
a
MUST
for
welding
or
cutting, (and
chipping)
to
protect
the
eyes
from radiant
energy
and
flying
metal.
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 immediate
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
Standard
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
orcontaining
materials
that
emit
toxic
fumes
should
not
be
heated unless
coating
is
removed
from
the
work
surface,
the
area
is well
ventilated
and,
if
necessary,
while
wearing
an
air-supplied
respirator.
Work
in
a
confined
space
only
while it is
being
ventilated
and,
if
necessary,
while
wearing
an
air-supplied
respira
tor.
Gas
leaks in
a
confined
space
should
be avoided.
Leaked
gas
in
large
quantities
can
change
oxygen
con
centration
dangerously.
Do
not
bring
gas
cylinders
into
a
confined
space.
Leaving
confined
space,
shut
OFF
gas
supply
at
source
to
prevent
possible
accumulation
of
gases
in
the
space
if
downstream
valves
have
been
accidentally
opened
or
left
open.
Check
to
be
sure
that
the
space
is
safe
before
re-entering
it.
Vapors
from
chlorinated
solvents
can
be
decomposed
by
the
heat
of the
arc
(or flame)
to
form
PHOSGENE,
a
highly
toxic
gas,
and
other
lung
and
eye irritating
prod
ucts.
The
ultraviolet
(radiant)
energy
of
the
arc
can
also
decompose
trichloroethylene
and
perchloroethylene
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
OM-126
853
Page
1

to
atmospheres
containing
even
minute
amounts
of
trichloroethylene
or
perchloroethylene~
C. Fire
and
Explosion
Prevention
-
Causes
of fire and
explosion
are:
combustibles
reached
by
the
arc,
flame,
flying sparks,
hot
slag
or
heated
mate
rial;
misuse of
compressed
gases
and
cylinders;
and
short
circuits.
BE
AWARE THAT
flying sparks
or
falling slag
can
pass
through
cracks,
along
pipes,
throughwindows
ordoors,
and
through
wall
or
floor
openings,
out
of
sight
of the
goggled
operator.
Sparks
and
slag
can
fly
35
feet.
To
prevent
fires and
explosion:
Keep
equipment
clean and
operable,
free
of
oil,
grease,
and
(in
electrical
parts)
of
metallic
particles
that
can
cause
short circuits.
If
combustibles
are
in
area,
do
NOT weld
or
cut.
Move
the
work
if
practicable,
to
an area
free
of combustibles.
Avoid
paint
spray
rooms,
dip
tanks,
storage
areas,
venti
lators.
If
the
work
cannot
be
moved,
move
combustibles
at
least
35
feet
away
out
of reach of
sparks
and
heat;
or
protect
against
ignition
with suitable and
snug-fitting,
fire-resistant
covers
or
shields.
Walls
touching
combustibles
on
opposite
sides should
not
be welded
on
(or
cut).
Walls,
ceilings,
and floor
near
work should 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
thatadequate
precautions
have
been taken.
After
work is
done,
check
that
area
is free
of
sparks,
glowing
embers,
and
flames.
An
empty
container
that held
combustibles,
or
that
can
produce
flammable
or
toxic
vapors
when
heated,
must
never
be
welded
on or
cut,
unless container
has
first
been
cleaned
as
described
in
AWS
Standard
A6.O,
listed
7
in
Standards
Index.
This
includes:
athorough
steam
or
caustic
cleaning
(or
a
solvent
or
water
washing,
depending
on
the
combusti
bles
solubility)
followed
by
purging
and
inerting
with
ni
trogen
or
carbon
dioxide,
and
using
protective
equip-
ment
as
recommended
in
A6.O.
Waterfilling
just
below
working
level
may
substitute
for
inerting.
A
container
with unknown
contents
should
be cleaned
(see preceding paragraph).
Do
NOT
depend
on
sense
of
smell
or
sight
to
determine
if
it is
safe
to
weld
or
cut.
Hollow
castings
or
containers
must
be
vented
before
welding
or
cutting. They
can
explode.
Explosive
atmospheres.
Never weld
or
cut
where the
air
may
contain
flammable
dust,
gas,
or
liquid
vapors
(such
as
gasoline).
D.
Compressed
Gas
EquIpment
Standard
precautions.
Comply
with
precautions
in this
manual,
and
those detailed
in
CGA
Standard
P-i,
SAFE
HANDLING OF
COMPRESSED GASES
IN
CYLIN
DERS,
listed
11
in
Standards
Index.
1.
Pressure
Regulators
Regulator
relief valve
is-designed
to
protect
only
the
regulator
from
overpressure;
it is
not
intended
to
protect
any
downstream
equipment.
Provide
such
protection
with
one or more
relief devices.
Never
connect
a
regulator
to
a
cylinder
containing
gas
other than that for which the
regulator
was
designed.
Remove
faulty
regulatorfrom
service
immediately
for
re
pair
(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
pointerdoes
not
move
off
stop
pin
when
pressurized,
nor
returns
to
stop
pin
after
pressure
release.
Repair.
Do NOT
attempt
to
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
cittuit
contact
with
cylinders
including
third
rails,
electrical
wires,
or
welding
circuits.
They
can
produce
short circuit
arcs
that
may
lead
to
a
serious
acci
dent.
(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.
Empties:
Keep
valves
closed,
replace
caps
securely;
mark
MT;
keep
them
separate
from
FULLS
and
return
promptly.
OM-126
853
Page
2

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
mag~nets.
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
orwrench
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.
Cylinderfittings
should
never
be modified
orexchanged.
3. Hose
Prohibited
use.
Never
use
hose
otherthan
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
ordi
nary
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;
bubbles
in
dicate
leaks.
Repair
leaky
orwom
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
sources
of
ignition.
Wipe
with
a
clean
lintless
cloth.
Match
regulator
to
cylinder.
Before
connecting,
check
that
the
regulator
label
and
cylinder
marking
area,
and
thatthe
regulator
inlet
and
cylinderoutlet
match.
N
EVER
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.
usetwowrenchestotighten
adaptermarked
RIGHTand
LEFT
HAND
threads.
Regulatoroutlet
(or
hose)
connections
may
be identified
by right
hand threads for
oxygen
and
left
hand
threads
(with grooved
hex
on
nut
or
shank)
for
fuel
gas.
5.
Pressurizing
Steps:
Drain
regulator
of residual
gas
through
suitable
vent
be
fore
opening cylinder
(or
manifold
valve)
by
turning
ad
justing
screw
in
(clockwise). Draining
prevents
exces
sive
compression
heat
at
high
pressure
seat
by allowing
seat
to
open
on
pressurization.
Leave
adjusting
screw
engaged
slightly
on
single-stage
regulators.
Stand
to side
of
regulator
while
opening
cylinder
valve.
Open cylinder
valve
slowly
so
that
regulator
pressure
in
creases
slowly.
When
gauge
is
pressurized
(gauge
reaches
regulator
maximum)
leave
cylinder
valve
in
fol
lowing
position:
For
oxygen,
and inert
gases,
open
rully
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
regullarly
there-after.
Brush
with
soap
solution
(capfull
of
Ivory
Liq
uid*
or
equivalent
per
gallon
of
water).
Bubbles
indicate
leak.
Clean
off
soapy
water
after
test;
dried
soap
is
com
bustible.
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
Staglng.Support
Rope
staging-support
should
not
be
used for
welding
or
cutting
operation;
rope may
burn.
*Trademark
of
Proctor
&
Gamble.
OM-1
26
853
Page
3

1-3.
ARC
WELDING
Comply
with
precautions
in
1-1, 1-2,
and
this section.
Arc
Welding,
properly
done,
is
a
safe
process,
but
a
careless
operator
invites trouble. The
equipment
carries
high
currents at
significant voltages.
The
arc
is
very
bright
and hot.
Sparks
fly,
fumes
rise,
ultraviolet and
in
frared
energy
radiates,
weldments
are
hot,
and
com
pressed
gases
may
be used.
The
wise
operator
avoids
unnecessary
risks
and
protects
himself and others from
accidents.
Precautions
are
described here andin
stan
dards referenced
in
index.
A.
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
burns resemble
acute
sunburn,
those from
gas-
shielded
arcs are more severe
and
painful.
DONT
GET
BURNED;
COMPLY
WITH
PRECAUTIONS.
1.
Protective
Clothing
Wear
long-sleeve
clothing (particularly
for
gas-shielded
arc)
in
addition
to
gloves,
hat,
and shoes
(1
-2A).
As
nec
essary,
use
additional
protective
clothing
such
as
leather
jacket
or
sleeves,
flame-proof
apron,
and 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
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
bums.
Cracked,
broken,
or
loose
filter
plates
must
be
replaced
IMMEDIATELY.
Replace
clear
cover
plate
when
broken,
pitted1
or
spattered.
Flash
goggles
with
side
shields MUST
be
worn
under
the
helmet
to
give
some
protection
to
the
eyes
should
the
helmet
not
be
lowered
over
the
face
before
an
arc
is
struck.
Looking
at
an arc
momentarily
with
unprotected
eyes
(particularly
a
high
intensity
gas-shielded
arc)
can
cause
a
retinal
burn
that
may
leave
a
permanent
dark
area
in
the
field
of
vision.
3.
Protection
of
Nearby
Personnel
Enclosed
welding
area.
For
production
welding,
a
sepa
rate
room or
enclosed
bay
is
best.
In
open
areas,
sur
round
the
operation
with
low-reflective,
non-combusti
ble
screens
or
panels.
Allow
for
free air
circulation,
par
ticularly
at
floor
level.
Viewing
the weld.
Provide
face shields for all
persons
who
will
be
looking
directly
at
the
weld.
Others
working
in
area.
See
that all
persons
are
wearing
flash
goggles.
-
Before
starting
to
weld,
make
sure
that
screen
flaps
or
bay
doors
are
closed.
B.
ToxIc
Fume
PreventIon
Comply
With
precautions
in
1-2B.
Generator
engine
exhaust
must
be vented
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
arcwelding
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.
D.
Compressed
Gas
Equipment
Comply
with
precautions
in
1
-2D.
E.
Shock
Prevention
Exposed
hot
conductors
or
other bare
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:
Wear
dry
insulating
gloves
and
body
protection.
Keep
body
and
clothing
dry.
Never
work
in
damp
area
without
adequate
insulation
against
electrical
shock.
Stay
on a
dry
duckboard,
or
rubber
mat
when
dampness
or
sweat
can
not
be
avoided.
Sweat,
sea
water,
or
moisture
be
tween
body
and
an
electrically
HOT
part
or
grounded
metal
reduces
the
electrical
resistance,
and could
en
able
dangerous
and
possibly
lethal
currents
to
flow
through
the
body.
A
voltage
will
exist
between
the
electrode
and
any
con
ducting
object
in
the
work
circuit.
Examples
of
conduct
ing
objects
include,
but
are
not
limited
to,
buildings,
elec
trical
tools,
work
benches,
welding
power
source
cases,
workpieces,
etc.
Never
touch
the
electrode
and
any
metal
object
unless
the
welding
power
source
is
off.
1.
Grounding
the
Equipment
Arc
welding equipment
must
be
grounded
according
to
the
National Electrical
Code,
and
the
work
must
be
grounded
according
to
ANSI
Z49.1
usafety
In
Welding
And
Cutting.
When
installing,
connect
the
frames
of
each
unit
such
as
welding
power
source,
control,
worktable,
and
water
cir
culatorto
the
building
ground.
Conductors
must
be
ade
quate
to
carry
ground
currents
safely.
Equipment
made
OM-126
853
Page
4

electrically
HOT
by
stray
current
may
shock,
possibly
I
a-
tally.
Do
NOT
GROUND
to
electrical
conduit,
orto
a
pipe
carrying
ANY
gas
or
flammable
liquid
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
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
USQ
holders
with
protruding
screws.
3.
Connectors
Fully
insulated
lock-type
connectors
should
be used
to
join
welding
cable
lengths.
4. Cables
Frequently
inspect
cables
forwear,
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
operation.
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
electri
cally
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
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.
F.
ProtectIon
For Wearers
of ElectronIc
Life
Sup
port
DevIces
(Pacemakers)
Magnetic
fields from
high
currents
can
affect
pacemaker
operation.
Persons
wearing
electronic
life
support
equipment
(pacemaker)
should
consult
with their doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
1-4.
STANDARDS
BOOKLET
INDEX
For
more
information,
referto
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
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
5.
ANSI
Standad
Z41.1,
STANDARD FOR
MENS
SAFETY-TOE
FOOTWEAR
obtainable
from
the
American National
Standards
Institute,
1430 Broad
way,
New
York,
NY
10018.
6.
ANSI Standard
Z49.2,
FIRE
PREVENTION
IN
THE
USE OF
CUTTING
AND
WELDING
PROCESSES
OM-
126 853
Page
5

obtainable from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
7.
AWS Standard
A6.0,
WELDING
AND~
CUTTING
CONTAINERS
WHICH
HAVE
HELD
COMBUS
TIBLES
obtainable
from
the
American
Welding
So
ciety,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126.
8.
NFPA
Standard
51,
OXYGEN-FUEL
GAS
SYS
TEMS
FOR
WELDING,
CUTTING,
AND
ALLIED
PROCESSES
obtainable
from
the
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
9.
NF?A
Standard
70,
NATIONAL
ELECTRICAL
CODE
obtainable
from
the
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
10.
NFPA
Standard
51B,
CUTTING
AND
WELDING
PROCESSES
obtainable
from
the National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
ii. CGA
Pamphlet
P-i,
SAFE HANDLING OF
COM
PRESSED
GASES
IN
CYLINDERS
obtainable
from
the
Compressed
Gas
Association,
1235
Jeffer
son
Davis
Highway,
Suite
501,
Arlington,
VA
22202.
12.
CSA
Standard
W117.2,
CODE
FOR
SAFETY
IN
WELDING
AND
CUTTING obtainable
from
the
Ca
nadian
Standards
Association,
Standards
Sales,
178 Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W1R3.
13.
NWSA
booklet,
WELDING
SAFETY
BIBLIOGRA
PHY.obtainable
from
the
National
Welding
Supply
Association,
1900
Arch
Street,
Philadelphia,
PA
19103.
14.
American
Welding
Society
Standard
AWSF4.1,
RECOMMENDED
SAFE PRACTICES
FOR THE
PREPARATION
FOR
WELDING
AND
CUTTING
OF
CONTAINERS
AND
PIPING THAT HAVE
HELD
HAZARDOUS
SUBSTANCES,
obtainable
from
the
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126.
15. ANSI
Standard
Z88.2,
PRACTICE FOR
RESPIRA
TORY
PROTECTION,
obtainable
from
the
Ameri
can
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
SECTION
2
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
2.1.
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.
The
nameplate
of this unit
uses
international
symbols
for
labeling
the front
panel
controls.
The
symbols
also
ap
pear
at
the
appropriate
section
in
the
text.
B
.
Safety
The
installation,
operation,
maintenance,
and trouble
shooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of others.
Therefore,
this
equipment
is
to
be
in
stalled,
operated,
and
maintained
only by qualified
per
Sons
in
accordance with this
manual
and
all
applicable
codes
Such
as,
but
not
limited
to,
those listed
at
the
end
of
Section
1

Safety
Rules For
Operation
Of
Arc
Weld
ing
Power
Source.
2-2.
SAFETY
ALERT
SYMBOL
AND
SIGNAL
WORDS
The
following
safety
alert
symbol
and
signal
words
are
used
throughout this
manual
to
call
attention
to
and iden
tify
different levels of hazard
and
special
instructions.
a
a
This
safety
alert
symbolis
used with the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
WARNING
statements
identify
procedures
or
practices
which
must
be followed
to
avoid
seri
ous
personal
injury
or
loss
of
life.
a
CAUTION
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
statements
identify
special
instructions
necessary
for
the
most
efficient
operation
of
this
equip
ment.
OM-126
853
Pages

SECTION
3-
SPECIFICATIONS
Table
3-1.
SpecifIcations
Input
Power
Rated
Output
At 100%
Duty Cycle
Voltage-
Range
in
CV Mode
Amperage
Range
in
CC
Mode
~
Max.
Open-Circuit
Voltage
in
CC
Mode
input
At
Rated
Load
Output
50/60
Hz_
kw
Weight
Amperes
At

230V
460V kva Net
Ship
Three-
Phase
350
Amperes
At 34
Volts
DC
10-35
Volts
5-350
Amperes
70
Volts DC
42
21
16.7
14.3
13.8
150
lbs.
(68
kg)
164
lbs.
(74 kg)
60
30
10
Single-
Phase
275
Amperes
31
Volts
DC
TC-131
955
Base
Meunting
Hole
Layout
inches Millimeters
A
1-9/16
39.7
B
13 330.2
C
23
584.2
0 25.13/32
645.3
E
25/32
19.8
F
3/4
19.0
G
11-1/2 292.1
H
13 330.2
J
23 584.2
K
26-1/4
666.8
B holes
are
3/8 In.
(9.5
mm)
Die.
(4
hole,)
C
holes
are
14/32 in.
(13.5
mm)
DIe.
(4
holes)
Figure
3-1.
Overall
Dimensions
And Base
Mounting
Hole
Layout
Chart
3-1.
Volt-Ampere
Curves
Volt-Ampere
Curves
For
CV
Mode
(With
3-Phase,
60 Hz
Input)
Volt-Ampere
Curves
For
CC
Mode
(With
3-Phase,
60
Hz
Input)
K
J
N
N
N
0
U
N
I
0
I.
U.
U.
DC AMPERE5
U. U. U.
u~.
8-099012
N
IN IN ZN
ZOO ZOO
DC
AMPE~E3
e-ogct
013
OM-126
853
Page
7

3-1.
VOLT-AMPERE
CURVES
(Chart
3-1)
RATED
OUTPUT
The
volt-ampere
curves
show
the
voltage
and
amper
age
output
capabilities
of
the
welding
power
source.
Curves
of other
settings
fall between
the
curves
shown.
With the
use
of
the
volt-ampere
curves,
it is
possible
to
determine
the
weld
amperage
at
any
particular
load
volt
age.
3-2.
DUTY
CYCLE
(Chart
3-2)
Chart
3-2.
Duty
Cycle
:ury CyCLE
C
The
duty cycle
is
the
percentage
of
a
ten
minute
period
that
a
welding
power
source
can
be
operated
at
a
given
output
without
overheating
and
damaging
the
unit.
This
welding
power
source
is rated
at
100%
duty
cycle.
The
unit
can
be
operated
at
rated
load
continuously,
If
the
welding
amperes
increase
beyond
rated
output,
the
duty
cycle
decreases.
Refer
to
the
Duty
Cycle
chart
(Chart
3-2)
to
determine
the
Output
of
the
welding
power
source
at
various
duty
cycles.
a
CAUTION:
EXCEEDING
DUTY
CYCLE
RATiNGS
will
damage
the
welding
power
source.

Do
not
exceed
indicated
duty cycles.
3-3.
DESCRIPTION
This unit is
a
three-phase,
or
single-phase
if
derated,
dc,
arc
welding
power
source
having
constant
voltage
(CV)
and
constant
current
(CC)
output
characteristics
for
multi-process
capability.
The
unit
produces
dc
weld
out
put
and
is
designed
for-use
with
Shielded
Metal Arc
(SMAW),
Gas
Metal Arc
(GMAW),
Gas
Tungsten
Arc
(GTAW),
Flux
Cored
Arc
(FCAW),
Submerged
Arc
(SAW),
and
Air
Carbon
Arc
(ACA)
cutting
and
gouging
welding
processes.
The
solid-state,
electronic
components
of
this
unit
are
lo
cated
in
sealed
areas
unexposed
to
airflow and
asso
ciated
contaminants.
The fan
motors
cool
only
the
heat
sinks
and main transformer.
SECTION 4- INSTALLATION
OR
RELOCATION
4.1.
SITE SELECTION
Select
an
installation
site which
provides
the
following:
1. Correct
input
power
supply
(see
unit
nameplate)
2.
Shielding
gas
supply (if
applicable)
3.
Water
supply
(if
applicable)
4.
Adequate
ventilation
and
fresh air
supply
5. No
flammables
6.
A
clean and
dry
area
7.
Proper
temperature
that
avoids
extremes
of
heat
or
cold
8.
Proper
airflow
around unit
9.
Adequate
space
for
removing
top
cover
and
outer
panels
for
installation, maintenance,
and
repair
functions.
Base
mounting
holes
provide
the
capability
to
install
and
secure
the
unit
on a
running
gearor
in
a
permanent
loca
tion. Figure
3-1
gives
overall
dimensions
and
base
mounting
hole
layout.
4A
WARNING:
FIRE
OR EXPLOSION
can
result
from
placing
unit
on
or over
combustible
surfaces;
RESTRICTED AIRFLOW
can
cause
overheating
and
possible
damage
to
Internal
parts.

Do
not
locate unit
over
combustible
surfaces.

Maintain
at
least
6
inches
(152
mm)
of
unrest
ricted
space
on
tight
side
of
unit,
and
keep
underside free
of obstructions,

Do
not
place
any
filtering
device
over
the
in
take air
passages
that
pro
vide
airflow
forcoollng
this unit.
Warranty
is
void
if
any
type
of
filtering
device
is
used
at
intake
air
passages.
300
2~0
200
350~,
___________________________________
This unit is
capable
of both
pulsed
and
no
npuised
opera-
.5
20
2~
30
40
50
60
0
Sc
90 00
tion. The
welding
power
source
compensates
for
line
a-ia
983
voltage
fluctuation
of –10%.
OM-1
26 853
Pages

4-2~
TRANSPORTiNG
METHODS
-
This
welding
power
source
has
space
underneath
it
for
lift
forks.
a
WARNING:
ELECTRIC
SHOCK
can
kill.
~
Do
not
touch
live
electrical
parts.

Disconnect
input
power
conductors
from
deenergized
supply
line
BEFORE
moving
weld
ing
power
source.
FALLING
EQUIPMENT can cause
serious
personal
injury
and
equipment
damage.

Use
equipmentof
adequate
capacity
to
lift the
unit.

If
lifting
or
moving
this unit
with lift forks
under
the
base,
be
sure
that
lift
folks
are
long
enough
to
extend
beyond
opposite
side of
the
base.
Using
lift
forks
too
short
can
damage
internal
parts
if
tips
of
the
lift forks
penetrate
the
unit
base,
or
may
cause
personal
injury
and/or
equipment
damage
if
unit
falls off the
lift forks.
4-3.
WELD
OUTPUT
CONNECTIONS
(Figure
5-1)
RATED
OUTPUT
To
obtain
full
rated
output
from
this
unit,
it
is
necessary
to
select,
prepare,
and
install
properwØld
cables.
Failure
to
comply
in
any
of these
areas
may
result
in
unsatisfactory
welding
performance.
A. Weld
Cable SelectIon
Use the
following guidelines
to
select
weld
cables:
1.
Use
the
shortest
possible
cables,
and
place
cables
close
together.
Excessive cable
lengths
may
reduce
output
or
cause
unit
overload due
to
added
resis
tance.
2.
Use
weld
cable
with
an
insulation
voltage
rating
equal
to
or
greater
than
the
maximum
open-circuit
voltage
(ocv)
of
the
welding
power
source
(see
Table
3-1
for
unit
maximum
ocv
rating).
3.
Select
welding
cable
size
according
to
maximuim
weld
output
and
total
length
of
connecting
cables
in
weld
circuit.
For
example,
if
a
25 foot
(7.5
m)
wi~re
feeder
or
electrode
holder cable
is used
with
a
25
foot
~7.5
m)
work
cable,
select
the
cable
size
recom
mended
in
Table
4-1
for
50
feet
(15
m).
4.
Do
not
use
damaged
or
frayed
cables.
B.
Weld
Cable
Preparation
1.
Installterminallugs
of
adequate
amperage
capacity
and
correct
stud
size
onto
cables
that
connect
to
the
work
clamp,
wire
feeder
or
electrode
holder,
and
weld
output
terminals.
2.
If
installing
an
electrode
holder,
follow
manufactur
ers
installation
instructions.
Always
use an
insu
lated
electrode
holder
to
ensure
operator
safety.
3.
Install
work
clamp
onto
cable.
C. Weld
Cable
Connections
To
Welding
Povier
Source
(Figure
5-1)
NEGATIVE
POSITIVE
+
a
WARNING:
ELECTRIC SHOCK
can
kill.

Do
not
touch live electrical
parts.

Shutdown
welding
powersource,
and discon
nect
input
power
employing
lockout/tagging
procedures
before
inspecting
or
installing.
Lockout/tagging procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removun~
fuses from
fuse
box,
or
shutting
off
and
red-tagging
circuit breaker
or
other
disconnect
ing
device.
Table
4-1.
Weld
Cable
Size
Total
Cable
(Copper) Length
In
Weld Circuit
Not
Exceeding
100
ft.
Or
Less
150 ft.
200 ft.
1
250
ft. 300 ft.
350
ft. 400 ft.
(30
m)
(45
m)
(60
m)
j
(70 m)
(90 m)
(105
m)
(120 m)
10
To 60%
60
Thru
100%
10 Thru 100%
Duty
Cycle
Duty
Cycle Duty
Cycle
4
3
3
2
1
1/0
1/0
2/0
3/0
4
3
2
1
1/0
2/0
2/0
3/0
4/0
4
2
1
1/0
2/0
3/0
3/0
4/0
2-2/0
3
1
1/0
2/0
3/0
4/0
4/0
2-2/0
2-3/0
2
1/0
2/0
3/0
4/0
2-2/0
2-2/0
2-3/0
2-4/0
1
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
3-3/0
1/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
3-3/0
3-4/0
1/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
3-3/0
3-4/0
weld cable
size
(AWG)
is based
on
either
a
4
volts
or
less
drop
or a
current
density
of
more
than 300 circular
mils
per ampere.
S.0007/8.88
OM-126
853
Page
9

1.
For
Shielded
Metal Arc
Welding
(SMAW)
(Electrode
Positive/Reverse
Polanty)
a.
Connect
end of electrode holder cable
to POSI
TIVE
(+)
weld
output
terminal.
b.
Connect
one
end of work cable
to
NEGATIVE
()
weld
output
terminal and
remaining
end
to
workpiece.
-
IMPORTANT:
For Electrode
Negative/Straight
Polarity
connections,
reverse
cable connections
to
weld
output
terminals;
electrode
becomes
negative.
2.
Fo~
Gas Metal
Arc
Welding
(GMAW),
Flux Cored
Arc
Welding
(FCAW),
and
Submerged
Arc
Welding
(SAW)
(Electrode
Positive/Reverse
Polarity)
a.
Connectneendofweldcableto
POSITIVE(+)
weld
output
terminal and
remaining
end
to ter
minal
on
drive
housing
of wire
feeder
(see
wire
feeder
Owners
Manual for
location).
b.
Connect
one
end of work cable
to
NEGATIVE
()
weld
output
terminal
and
remaining
end
to
workpiece.
IMPORTANT: For Electrode
Negative/Straight
Polarity
connections,
reverse
cable connections
to
weld
output
terminals;
electrode becomes
negative.
3.
For Gas
Tungsten
Arc
Welding (GTAW)
(Electrode
Negative/Straight
Polarity)
a.
Connect
torch cable
or
connector to
NEGA
TIVE
()
weld
output
terminal.
b.
Connect
one
end of work
cable
to
POSITIVE
(+)
weld
output
terminal
and
remaining
end
to
work-
piece.
IMPORTANT:
For
Electrode
Positive/Reverse
Polarity
connections,
reverse
cable
connections
to
weld
output
terminals;
electrode
(torch)
becomes
positive.
4.
For
Air
Carbon
Arc
Cutting
And
Gouging
(ACA)
(Electrode
Positive/Reverse
Polarity)
a.
Connect
torch
cable
to POSITIVE
(+)
weld
out
put
terminal.
b.
Connect
one
end of
work
cable
to
NEGATIVE
()
weld
output
terminal
and
remaining
end
to
workpiece.
IMPORTANT:
For
Electrode
Negative/Straight
Polarity
connections,
reverse
cable
connections
to
weld
output
terminals;
electrode
(torch)
becomes
negative.
4.4.
ELECTRICAL
INPUT
CONNECTIONS
INPUT
AA
WARNING:
ELECTRIC
SHOCK
can
kIll.

Do
not
touch live
electrical
parts.

Shutdown
welding
powersource,
and
discon
nect
input
power employing
lockout/tagging
procedures
before
inspecting
or
installing.
Lockout/tagging procedures
consist
of
pad
locking
line disconnect
switch
in
open
position,
removing
fuses from
fuse
box,
or
shutting
off and
red-tagging
circuit
breaker
or
other disconnect-

ing
device.
A.
ElectrIcal
Input
Requirements
Operate
the
welding
power
source
from
a
three-phase,
or
single-phase
if
derated,
50/60
Hertz,
ac
power
supply.
The
input
voltage
must
match
one
of the
electrical
input
voltages
shown
on
the
input
data label
on
the unit
name
plate.
Contact
the local electric
utility
for information
about
the
type
of electrical service
available,
how
proper
connections
should be
made,
and
inspection
required.
B.
Jumper
Link
InstallatIon
(FIgure
4-1)
a
WARNING:
Read and follow
safety
Info
rma
tlon
at
beginning
of entire
SectIon
4-4
before
proceedIng.
Jumper
links
are
used
to
allow the
equipment
to
operate
from
different
line
voltages.
The
jumper
links
may
be in
a
bag
attached
to
the
input
terminal
board and
terminal
strip
11
or
installed for
the
highest
voltage
shown
on
the
input voltage
label.
1.
Remove
top
cover
and
left
side
panel.
2.
Compare
position
of
jumper
links
on
the
input
termi
nal board and
terminal
strip
1
T
to
the
voltage
link
ar
rangement
shown
on
input
voltage
label.
a
CAUTION:
INCORRECT
INPUT
VOLTAGE
JUMPER LINK
PLACEMENT
can
damage
unit.

Position
jumper
links
as
shown
on
the
input
voltage
label
(see
Figure
4-1).

Store
unused
jumper
links
across
linked
terminals.
3.
Install
jumper
links
onto
the
input
terminal
board
and
terminal
strip
iT
to
match
the
available
input
line
voltage.
4
Reinstall
and
secure
left
side
panel
and
top
cover
onto
unit.
C.
Welding
Power
Source
Input
Power
Connec
tions
(Figure
4-1)
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.

Connect
input
conductors
to
the
welding
power
source
before
connecting
to
single-
phase
or
three-phase
input
power.

Read
and follow
safety
information
at
be
gin-
fling
of
entire
Section
4-4
before
proceeding.
The
line
disconnect
switch
provides
a
safe
and
convenient
means
to
completely
remove
all
electrical
power
from
the
welding
power
source
whenever
it
is
necessary
to
inspect
or service
the
unit.
OM-126
853
Page
10

1.
Use Table
4-2
as
a
guide
to
select
input
conductors
for
the
installation.
The
input
conductors
should be
covered with
an
insulating
material
that
complies
with
national,
state,
and local
electrical
codes.
2.
Install
terminal
Iugs
of
adequate
amperage
capacity
and
correct
stud
size
onto
the
input
and
ground
con
ductors.
A~
WARNING:
ELECTRIC SHOCK
can
kill.

Do
not
(ouch
live
electrical
parts.

Do
not
connect
an
input
conductor to
the
ground
terminal
in
the
unit.

Do
not
connect
the
ground
conductor
to an
input
line
terminal.
Incorrect
input
connections
can
result
in
an
electrically
energized welding
power
source
chassis. The
ground
terminal
is
connected
to
the
welding
power
source
chassis
and
is for
grounding
purposes
only.
Remove
cover
plate
from
rear
panel.
Obtain
and
install astandard conduit strain
relief
connector
into
access
hole
in
cover
plate.
5.
Insert conductors
through
strain
relief installed
in
Step
4.
Route
conductors
to
input
terminals.
6.
For
three-phase
input
supply:
Connect
input
con
ductors to line
terminals,
L2,
and L3.
For
single-phase
input
supply:
Connect
input
con
ductors
to
the
top
Li
and bottom
L3 terminals.
7.
Connect
the
ground
conductor
to
the
ground
termi
nal
(see
Fig~ire
4-1).
8.
Reinstallcover
plate
onto
rear
panel,
and
secure
in
put
cable
in
strain
relief
connector.
9.
Connect
remaining
end
of
ground
conductor
to
a
suitable
ground.
Use
a
grounding
method
that
com
plies
with
all
applicable
electrical
codes.
10.
Connect
remaining
ends
of
input
conductors
to
a
deenergized
line
disconnect
switch.
11.
Use
Table
4-2
as a
guide
to
select
line
fuses for the
disconnect
switch. Obtain and install
proper
fuses.
Table
4.2.
Input
Conductor
And Fuse
Slze*
Input
Power
Input
Voltage
Input
Conductor
Size
(AWG)
Ground
Conductor
Size
(AWG)
Fuse
Size
In
Amperes
Three-
Phase
230
8 10 60
460
1-0
10 30
Single-
Phase
230
~
6
10
60
460
8
10 40
tConductor
size
is
based
on
the 1987 Edition of
the National
Electrical Code
(NEC)
specifications
for
allowable
am
pacities
of
insulated
copper
conductors,
having
a
tempera
ture
rating
of 167F
(75C),
with
not
more
than
three
single
current-carrying
conductors
in
a
raceway
(Article
310
of
NEC). (The
ground
conductor is not
counted
as
a
current-
carrying
conductor.)
tFuse
size is
based
on not
more
than
200
percent
of the
rated
input
amperage
of
the
welding
power
source
(Article
630
of
NEC).
s-oogeił-aa
Terminal
Strip
11
With
Jumper
Links
Line
Disconnect Switch:
Three-Phase
System
Shown
Piinel
3
4.
Ground
Conductor
Center
Panel
Contactor
Fuse
Fl
Input
Voltage
Route
To
Unit:
Rear
Panel
Access
Hole
Is
1-3/8
in.
(34.9
mm)
In Diameter
Input
Terminal
Board With
Jumper
Unks
18-096
967-A
FIgure
4-1.
Component
Locations And
Input
Conductor
ConnectIons
OM-126
853
Page
11

SECTION
5-
OPERATOR
CONTROLS
Output
Control
Switch
Circuit
Breaker
CB1
Positive
(+)
Weld
Output
Terminal
Negative ()
Weld
Output
Terminal
Power
Switch
ON
Push
Button
TC-131
955
Figure
5-1.
Front Panel
View
POWER
-e
5-2.
PILOT
LIGHT
(Figure
5.1)
ON
Q
OFF
CV/CC
Switch
Output
Control
Power
Switch
OFF
Pilot
Ught
Push
Button
5-1.
POWER
SWITCH
(Figure
5-1)
Depressing
the
POWER
switch
ON
push
button
ener
gizes
the
welding
power
source.
Depressing
the
POW
ER
switch
OFF
push
button
shuts down
the
welding
power
source.
IMPORTANT:
After
any
interruption
of
input
power.
the
POWER
switch
ON
push
button
must
be
depressed
to
reenergize
the
welding
power
source.
5-3
OUTPUT
CONTROL
(FIgure
5-1)
The
OUTPUT
control
provides
a
means
of
selecting
the
desired
output
within
the entire
range
of
the
welding
power
source.
The
control
adjusts
the
voltage
level(V)
in
the
CV
mode and the
amperage
level
(A)
in
the
CC
mode
from
minimum
to
maximum
of
power
source
capability.
Rotating
the
control
clockwise
increases
weld
output,
and
rotating
the
control
counterclockwise
decreases
weld
output.
IMPORTANT:
The
OUTPUT
control
may
be
adjusted
while
welding.
5-4.
ARC
CONTROL/INDUCTANCE
CONTROL
(FIgure
5.1)
The ARC
CONTROL/INDUCTANCE
control
functions
as
an
arc
control
in
the
constant
current
(CC)
mode
and
as
an
inductance
control
in the
constant
voltage (CV)
mode.
IMPORTANT:
The
ARC
CONTROL/INDUCTANCE
control
may
be
adjusted
while
welding.
The
control
should
be
set at
0
(zero)
for
Gas
Tungsten
Arc
Welding
(GTAVV9.
The
pilot
light
comes
on
when
the POWER
switch
ON
button
is
depressed
and
indicates
that the
unit
is
ener
gized.
OM-126
853
Page
12

A.
Arc
Control
(Used
in
CC
Mode
For
Shielded
Metal
Arc
Welding
(SMAW)
And
Air
Carbon
Arc
Cut
ting
And
Gouging
(ACA)
Processes)
IMPORTANT:
The
maximum
ARC
CONTROL
current
available
is
150
amperes
above the
ampere
value
Se
lectedon
the
OUTPUTcontro!.
However,
unit
output,
in
cluding
ARC
CONTROL
amperes,
cannot
exceed the
rated
output
of the
welding
power-
source.
(See
volt-
ampere
curves
for
CC
mode.)
The
ARC
CONTROL
provides
variable
selection
of
short-circuit
current
to
suit
individual
welding
conditions.
Rotating
this
control
clockwise
causes
the
current to
in
crease as
the
short-circuit
condition
is
approached.
When
the control
is
set at
100,
the
short-circuit
current
is
higher
(upto
150
amperes)
than
normal
welding
current.
(See
volt-ampere
curve
for
CC
mode
and
IMPORTANT
block
at
beginning
of
this
Subsection.)
The
increased
current
enables
arc
starting
in
out-of-position
welds,
and
it
provides
the
momentary
overcurrents
necessary
for
certain
types
of
electrodes.
When the control
is
set
at
0
(zero),
short-circuit
current
is
the
same
as
the
welding
current.
When
the
control is
set at
50,
short-circuit
current
is
ap
proximately
halt
that of
the
100
position,
but
still
higher
than
normal
welding
current.
The 50
position
provides
a
moderate
current
increase
necessary
for
arc
starting
certain
applications
and
types
of electrodes.
Select
a
setting
best suited
for
the
application
and
type
of
electrode.
B.
lnductanc~Control
(Used
For
Constant
Voltage
(CV)
Operations
Only)
Rotating
this control clockwise
electronically
increases
inductance.
As
the level
of
inductance
increases,
the
rate
of
current
change
or
speed
of
response
slows down.
The slower
response
time
produces
a
softer
arc,
more
fluid
welding puddle,
and
flatter,
smoother
bead.
The 0
(zero)
setting
gives
minimum
inductance;
for
ex
ample,
a
stiff,
fast-responding
arc,
and
a
small,
fast-
freezing puddle.
The
100
setting gives
maximum induc
tance
characteristics;
for
example,
a
soft,
slow-respond
ing,
low
spatter
arc,
and
high
weld
puddle fluidity.
Select
a
setting
best
suited for
the
application.
5-5.
CONTACTOR
SWITCH
(Figure
5-1)
A~
WARNING:
ELECTRIC SHOCK
can
kill.

Do
not
touch
live electrical
parts.

Do
not
touch
the
weld
output
terminals
or
any
metal
pails
of the
welding
circuit
when
the
contactor
is
energized.
If
CONTACTOR
switch
Si
is in
the
ON
posi
tion
and
Output
Control
switch
(PANEL!
REMOTE)
S3
is
in
the
PANEL
position,
open-circuit
voltage
is
present
at
the
output
terminals
whenever the
welding
power
source
is
energized.
a
.
Do
not
touch
gun
wire
and work
clamp
at
the
same
time.

Place
CONTACTOR
switch
in
OFF!
REMOTE
position
when
using
wire
feeder
or
remote
control
device
to
control
contactor.
If
CONTACTOR
switch is
in
ON
position
arid
-
wire feeder
or
remote
control
device
is
con
nected
to
terminal
strip
lOT,
weld
output
(ocv)
will
be
present
whenever the
weldi
rig
power
source
is
energized.
IMPORTANT:
Although
the
term
CONTACTOR
is
used
on
the
nameplate,
the
output
is
not
switched
on
or
off
by
a
physical
output
contactor;
rather,
the
output
is
Con
trolled
by
relay
action
andsolid-state
components
on
cir
cuit
boards.
When
the
CONTACTOR
switch is
in
the ON
position,
open-circuit
voltage
(ocv)
is
present
at
the weld
output
terminals
whenever
the
welding
power
source
is
erier
gized.
When
the switch is
in the
OFF/REMOTE
position,
no
voltage
is
available
at
the
output
terminals
ocv
goes
to
0
(zero)
volts.
If
awire
feeder
or
remote
control
device is
controlling
the
contactor,
place
the
CONTACTOR
switch
in
the
OFF/
REMOTE
position.
Open-circuit
voltage
will
be
present
at
the
weld
output
terminals
whenever
the
gun
trigger
or
remote
control
device is closed.
The
CONTACTOR
switch is
normally placed
in the
OFF!
REMOTE
position
with
the
Gas
Tungsten
Arc
Welding
(GTAW)
process
and
all
wire
feeding
processes
--
Gas
Metal
Arc
Welding
(GMAW),
Flux Cored
Arc
Welding
(FCAW),
and
Submerged
Arc
Welding
(SAW).
The
switch
is
normally
placed
in
the
ON
position
for
the
Shielded Metal
Arc
Welding
(SMAW)
and
the
Air
Carbon
Arc
(ACA)
cutting
and
gouging
processes.
5-6.
OUTPUT CONTROL
SWITCH
(Figure
5-1)
4A
WARNING:
ELECTRIC SHOCK
can
kill.

Do
not
touch live
electrical
parts.

Do
not
touch
the
weld
output
terminals
or
any
metal
parts
of the
welding
circuit
when
the
contactor
is
energized.
if
the
CONTACTOR
switch
Si
is
in
the
ON
position
and
Output
Control
switch
(PANEL!
REMOTE)
is
in
the PANEL
position,
open-
circuit
voltage
is
present
at
the
output
termi
nals
whenever
the
welding
power
source
is
energized.

Do
not
touch
gun
wire
and
work
clamp
at
the
same
time.
If
remote contactor
control
is
desired,
make
proper
con
nections
to
terminal
strip
1
OT,
and
place
the
Output
Con
trol
switch
in
the
REMOTE
position. Open-circuit
voltage
(ocv)
will
be
present
at
the weld
output
terminals when
ever
the
remote
control device
is closed.
If
remote contactor
control is
not
desired,
place
the
Out
put
Control
switch
in
the
PANEL
position. Open-circuit
voltage (ocv)
will
be
present
at
the
output
terminals
whenever
the
welding
power
source
is
energized.
OM-126
853
Paie
13

5-7.
CVICC SWITCH
(Figure
5-1)
The
CV/CC
switch
provides
a
means
of
selecting
weld
output
characteristics
for
the
desired
process.
When the
switch
is
in
the
CV
(constant
voltage)
position,
the
unit
provides
a
constant
voltage
output
specifically
designed
for
wire
feeding
applications
--
Gas
Metal Arc
Welding
(GMAW),
Flux
Cored
Arc
Welding
(FCAW),
and
Shielded
Metal Arc
Welding
(SAW).
When
the
switch is
in
the
CC
(constant
current) position,
the
unit provides
a
constant
current
output
specifically
designed
for
Shielded
Metal Arc
Welding
(SMAW)
and
Gas
Tungsten
Arc
Welding
(GTAW).
The
CC
position
is
also
used for
the
Air
Carbon
Arc
(ACA) cutting
and
gouging
process.
SECTION
6
SEQUENCE
OF
OPERATION
a
WARNING:
ELECTRIC
SHOCK
can
kill;
MOVING
PARTS
can
cause
serious
injury;
IMPROPER
AIRFLOW
AND
EXPOSURE
TO
ENVIRONMENT
can
damage
Internal
parts.

Do
not
touch
live electrical
parts.

Keep
all
covers
and
panels
in
place
while
operating.
Warranty
is
void
if
the
welding
power
source
is
operated
with
any
portion
of
the outer
enclosure
removed.
ARC
RAYS,
SPARKS,
AND
HOT SURFACES
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.

Wear
correct
eye,
ear,
and
body
protection.
FUMES
AND
GASES
can
seriously
harm
your
health.

Keep
your
head
out
of the
fumes.

Ventilate
to
keep
from
breathing
fumes and
gases.

If
ventilation
is
inadequate,
use
approved
breathing
device.
WELDING
WIRE
can
cause
puncture
wounds.

Do
not
point
gun
toward
any
part
of
the
body,
any
conductive
surface,
or
other
personneL
HOT
METAL,
SPATrER,
AND
SLAG
can
cause
tire
and
burns.

Watch
for
fire.

Keep
a
fire
extinguisher nearby,
and know
how
to
use
it.

Do
not
use
near
flammable
material.

Allow
work
and
equipment
to
cool
before
handling.
MAGNETIC FIELDS
FROM
HIGH
CURRENTS
can affect
pacemaker operation.

Wearers
should
consult
their
doctor before
going
neararc
welding,
gouging,
orspot
welding
operations.
See
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source
for
basic
welding
safety
information.
6.1.
GAS
METAL
ARC
(GMAW)
AND FLUX
CORED
ARC
WELDING
(FCAW)
a
WARNING:
Read
and
follow
safety
Informa
tIon
at
beginning
of
entire
SectIon
6 before
proceeding.
1.
Install
and
connect
unit
according
to Section 4.
2.
Install and
prepare
wire feeder
according
to
its
Own
ers
Manual.
3.
Place
the
CONTACTOR
switch
in
the OFF/
REMOTE
position.
4.
Place
the
CV/CC
switch
in
the
CV
position.
5.
Place
the
applicable
Output
Control switch
in
the
desired
position (see
Section
5-6).
6.
Rotate
the
applicable
OUTPUT
Control
(panel
or re
mote)
to
the desired
position
(see
Section
5-3).
7.
Rotate
the
INDUCTANCE
control
to
the desired

position
(see
Section
5-4B).
8.
Wear
dry insulating gloves
and
clothing,
and
wear
welding
helmet with
proper
filter lens
according
to
ANSI Z49.1.
9.
Prepare
for
welding
as
follows:
a.
Connect work
clamp
to
clean,
bare
metal
at
workpiece.
b.
Select
and obtain
proper
welding
wire,
and
thread
as
instructed
in
wire
feeder
Owners
Manual.
10.
Turn
on
shielding
gas
supply
if
applicable.
11.
Press
the
POWER
switch
ON
button.
12.
Begin welding.
5-2.
TUNGSTEN
ARC WELDING
(GTAW)
a
WARNING:
Read and follow
safety
Informa
tion
at
beginning
of
entIre Section
6
before
proceeding.
1.
Install
and
connect unit
according
to
Section 4.
2.
Install
and
connect
the
High-Frequency
unit
accord
ing
to
its
Owners
manual
if
applicable.
Scratch
start
Gas
Tungsten-Arc
Welding
does
not
require
the
use
of
external
high
frequency.
3.
Place the
CONTACTOR
switch
in
the OFF/
REMOTE
position.
4.
Place
the CV/CC
switch
in
the
CC
position.
5. Place the
Output
Control
switch
in
the
desired
posi
tion
(see
Section
5-6).
6.
Rotate
the
applicable
OUTPUT
Control
(panel
or
remote)
to
the
desired
position (see
Section
5-3).
7.
Rotate
the
ARC CONTROL
to
the
zero.
8.
Wear
dry
insulating
gloves
and
clothing,
and
wear
welding
helmet
with
proper
filter
lens
according
to
ANSI Z49.1.
OM-126
853
Page
14

9.
Prepare
for
welding
as
follows:
-
a.
Connect
work
clamp
to
clean,
bare
metal
at
workpiece.
b.
Select
and
obtain
proper
tungsten
electrode.
c.
Prepare
tungsten
electrode
and
insert
into
torch.
10.
Turn
on
shielding
gas
and
water
supplies
as
appli
cable.
11.
Press the
POWER
switch
ON button.
12.
Begin
welding.
6-3.
SHIELDED
METAL
ARC
WELDING
(SMAW)
a
WARNING:
Read
and
follow
safety
Informa
tion
at
beginning
of
entire
Section
6 before
proceeding.
1. Install
and
connect
unit
according
to
Section 4.
2.
Place the
CONTACTOR
switch
in
the
ON
position.
3.
Place
the
CV/CC switch
in
the
CC
position.
4.
Place
the
Output
Control
switch
in
the
desired
posi
tion
(see
Section
5-6).
5. Rotate
the
applicable
OUTPUT
Control
(panel
or
remote)
to
the
desired
position
(see
Section
5-3).
6.
Rotate
the
ARC
CONTROL to
the
desired
position
(see
Section
5-4A).
7. Wear
dry
insulating gloves
and
clothing,
and
wear
welding
helmet
with
proper
fllter
lens
according
to
ANSI
Z49.1.
8.
Prepare
for
welding
as
follows:
a;
Connect
work
clamp
to
clean,
bare metal
at
workpiece.
b.
Select and
obtain
proper
electrode,
and
insert
into
electrode
holder.
9.
Press the
POWER
switch
ON
button.
10.
Beginwelding.
6-4.
SUBMERGED
ARC WELDING
(SAW)
a
WARNING:
Read
and
follow
safety
informa
tion
at
beginning
of entire
SectIon
6before
proceeding.
1.
Install and
connect
unit
according
to Section
4.
2.
Install
and
prepare
wire
feeding
system
according
to
its
Owners
Manual.
3.
Install flux
system
according
to
its
Owners
Manual.
4.
Place
the
CONTACTOR switch
in
the OFF/
REMOTE
position.
5. Place
the
CV/CC
switch
in the desired
position
(see
Section
5-7)..
6.
Place
the
Output
Control
switch
in
the
desired
posi
tion
(see
Section
5-6).
7.
Rotate the
applicable
OUTPUT Control
(panel
or
remote)
to
the desired
position
(see
Section
5-3).
8.
Rotate
the
ARC
CONTROL/INDUCTANCE
CON
TROL
to
the
desired
position
(see
Section
5-4).
9.
Wear
dry
insulating
gloves
and
clothing,
and
wear
safety
goggles
with
correct
filter
shade
according
to
ANSI Z49.1.
10.
Prepare
for
welding
as
follows:
a.
Connect
work
clamp
to
clean,
bare
metal
at
workpiece.
b.
Select
and
obtain
proper
welding
wire,
and
thread
as
instructed
in wire
feeder
Owners
Manual.
c.
Select
and
obtain
proper
flux,
and
put
into
flux
system.
11.
Turn
on
flux
supply
valve
as
applicable.
12.
Press
the
POWER switch
ON
button.
13.
Begin
welding.
6-5.
AIR
CARBON
ARC
CUTTING
AND
-GOUGING
(ACA)
4A
WARNING:
Read
and
follow
safety
Informa
tion
at
beginning
of entire
SectIon
6
before
proceeding.
1.
Install
and
connect
unit
according
to
Section
4.
2.
Connect
compressed
air
supply
to
torch
air
hose.
3.
Place
the
CV/CC
switch
in
the
desired
position
(see
Section
5-7)..
4.
Place
the
Output
Control
switch
in the
desired
posi
tion
(see
Section
5-6).
5.
Rotate the
applicable
OUTPUT Control
(panel
or
remote)
to
the
desired
position
(see
Section
5-3).
6.
Rotate the
ARC
CONTROL/INDUCTANCE
CON
TROL to
the
desired
position
(see
Section
5-4)~.
7.
Place
the
CONTACTOR
switch
in
the
ON
positi~on.
8.
Wear
dry
insulating gloves
and
clothing,
and
wear
welding
helmet
with
proper
filter
lens
according
to
ANSI Z49.1.
9.
Prepare
for
cutting
or
gouging
as
follows:
a.
Connect
work
clamp
to
clean,
bare
metal
at
workpiece.
b.
Select
and
obtain
proper
carbon
electrode,
and
insert
into torch.
10.
Press the
POWER switch
ON
button.
11.
Begin operation.
6-6.
SHUTTiNG
DOWN
1.
Stop
welding
or
cutting.
2.
Press the
welding
power
source
POWER
switch
OFF
button.
3.
Turnoff
the
shielding
gas
and
water
supplies
if
appli
cable.
a
WARNING: HIGH CONCENTRATION
OF
SHIELDING
GAS
can
harm health
or
kIll..
S
Shut
off
gas
supply
when
not
in
use.
4.
Turn
off
flux
supply
and
compressed
air
supply
if
applicable.
OM-126
853
Page
15

SECTION
7.- MAINTENANCE
&
TROUBLESHOOTING
7-1.
ROUTINE
MAINTENANCE
(Table
7-1)
IMPORTANT:
Every
six
months
inspect
the
labels
on
this
unit
for
legibility.
All
precautionary
labels
must
be
maintained
in
a
clearly
readable
state
and
replaced
when
necessary.
See
Parts
List for
part
number of
precautionary
labels.
WARNING:
ELECTRIC SHOCK
can
kill.

Do
not
touch live
electrical
parts.

Shutdown
welding
po
wersource,
and discon
nect
input
power
employing
locko
ut/tagging
pro
cedures
before
inspecting,
maintaining,
orserv
icing.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off and
red-tagging
circuit breaker
or
other
disconnect
ing
device.
MOVING
PARTS
can
cause
serious
Injury.

Keep
away
from
moving
parts.
HOT SURFACES
can
cause
severe
burns.
. Allow
cooling period
before
servicing.
Maintenance
to
be
performed
only
by qualified
persons.
Table
7-1.
MaIntenance Schedule
Frequency
Maintenance
Every
month.
Units
in
heavy
service
environ
ments:
Check
labels,
weld
cables,
clean
internal
parts.
Every
3
months.
Check
weld
cables
(see
Section
7-1B).
Every
6
months.
Check
all labels
(see
IMPORT
ANT
block,
Section
7-1).
Clean
internal
parts
(see
Section7-1
C).
Frequency
of
service
is
based
on
units
operated
40
hours
per
week,
Increase
frequency
of
maim
enance
if
usage
exceeds
40 hours
per
week.
A.
Fan
Motors
This
unit is
equipped
with
two
exhaust
fans
and
relies
on
forced
draft for
adequate
cooling.
The
fan
motors
are
manufactured
with
lifetime
sealed
bearings
and
require
no
maintenance.
B.
Weld
Cables
a
WARNING:
Read
and
follow
safety
Informa
tlon
at
beginning
of entire
SectIon
7-1
before
proceeding.
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.
C.
Internal
Cleaning
a
WARNING:
Read
and
follow
safety
Informa
tion
at
beginnIng
of
entire
Section
7-1
before
proceeding.
Every
six months blow
out
or
vacuum
dust
and dirt
from
the
inside
of the
welding
power
source.
Do
not
remove
the
outer
enclosure,
but
blow
a
clean,
dry
airstream
through
the
cabinet
lovers.
U
dusty
or
dirty
conditions
are
present,
clean the unit
monthly.
7-2.
OVERLOAD PROTECTION
4A
WARNING:
ELECTRIC
SHOCK
can
kill.

Do
not
touch
live
electrical
parts.

Shutdown
welding
powersource,
and
discon
nect
input
power
employing
locko
ut/tagging
pro
cedures
before
inspecting, maintaining,
orseri
icing.
Lockout/tagging procedures
Consist
of
pad
locking
line
disconnect switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off and
red-tagging
circuit breaker
or
other
disconnect
ing
device.
INCORRECT FUSE
can
damage
unit.

Use
only replaceme
ntfuse
of
same
size,
type,
and
rating
(see
Parts
List).
A.
Main
Fuse
Fl
(Figure
7-1)
a
WARNING:
Read
and
follow
safety
Informa
tlon
at
beginning
of entire
Section
7-2
before
proceeding.
The unit is
protected
from overload
by
fuse
Fl
located
on
the
center
panel.
if
fuse
Fl
opens,
the
unit
will
be
com
pletely
inoperative.
To
replace
Fl,
proceed
as
follows:
1.
Remove
the
unit
top
cover.
2. Check
Fl,
and
replace
if
necessary.
3.
Reinstall unit
top
cover.
B.
Control
Circuit
Fuse
F2
(Figure
7-1)
a
WARNING:
Read
and follow
safety
informa
tion
at
beginning
of
entire
Section
7-2
before
proceeding.
The
power
source
rectifier
SRi
is
protected
from
over
load
by
fuse
F2
located
behind
the
lower left
portion
of
the
front
panel.
Should
F2
open,
the
CV/CC
and
CONTACTOR
switches would
not
work.
To
replace
F2,
proceed
as
follows:
1.
Remove left side
panel.
2.
Check
F2,
and
replace
if
necessary.
3.
Reinstall
left
side
panel.
OM-126
853
Page
16