Miller M-180 User manual

October
1969
FORM:
IOM-
114A
Effective
with
serial
No.
N295574
MODEL
STOCK
NO.
M-180
900001
M-180P
900010
M-225
900019
M-225P
900
028
1
Astallation
IfiperatioN
~
E~1
aioteoance
Manual
mIIcr
ELECTRIC
MIGU
CO.
APPLETON,
WISCONSIN,
U.S.A.
54911
-
-
USt.
NWSA
CODE
NO.
4579

SECTION
1-
SAFETY
RULES
FOR
OPERATION
OF
ARC WELDING MACHINE
1.1.
GENERAL
DA.
These
rules
apply
to
ac
and
dc
welding
generators,
ac
transformer
and
ac/dc
welding
machines,
and
dc
transformer
rectifier
welding
machines.
DB.
In
arcwelding
operations,
where
electrically
en
ergized
parts
are
exposed,
observe
the
following
safety
rules
to
insure
maximum
personal
safety
and
protect
nearby
persons.
DC.
Failure
to
observe these
safety
precautions
may
expose
not
only
you,
but
fellow
workers
as
well,
to serious
injuries.
Once
these
rules
are
learned
and
kept
in
mind,
proceed
with maximum
assurance.
WELDING
MACHINE
ciA.
Never
use
welding
cables
at currents
in
excess
of
their
rated
capacity.
It
will
cause
overheating
and
rapid
deterioration
of
the
insulation.
It is
also
uneconomical.
DONT
use worn or
poorly
connected
cables.
DB.
Inspect
the cables
frequently. Immediately
repair
all breaks in the
insulation with rubber and
friction
tapes.
Tighten
all
cable
connections
and
adequately

insulate
any
joints
where
a
connector
may
have
an
exposed
conductive
part.
In addition
to
the
potential
hazard
to
life,
a
hazard
occurs
when
exposed

sections
of
cable
come
in
contact
with
grounded
metallic
objects,
causing
an
arc.
Unprotected
eyes
may
be
injured
and
fire
may
result
if
combustible
materials
such
as
oil
or
grease
are
in the
vicinity.

The
efficiency
and
quality
of
welding
will
be
im
proved
by
elimination
of
these
dangerous
grounds,
and
by keeping
connections
tight.
1.3.
ELECTRODE
HOLDER
DONT
use
electrode
holders with
defective
jaws.
ciA.
Keep
the
jaws
of
the
electrode
holder
tight
and
the
gripping
surfaces
in
good
condition
to
provide
close
contact
with
the
electrodes.
Defective
jaws
will
permit
the
electrode
to
wobble,
making
control
of
the
welding
operations
difficult.
DONT
use
electrode holder
with
loose
cablecon
nections.
Keep
the
connections
of
the
electrode lead to
the
holder
tight
at
all
times.
Use
only fully
insulated
electrode holders
(and
with
out
protruding
screwheads.)
Never
touch
two
electrode
holders
from
two
separate
welding
machines at
the
same
time.
1.4. CODE CONFORMANCE
ciA.
The machine
and its
equipment
must
be
installed
and
maintained in
accordance
with the National
Electrical Code
and
local
requirements.
1.5.
PARALLEL
CONNECTIONS
ciA.
See
diagrams
in
the
instruction manual
applying
to
the
welding
machine
used.
1.6.
POWER
DISCONNECT
SWITCH
DA.
If
the
welding
machine does
not
include
a
power
disconnect
switch,
install
one
at
or
near
the
machine.
1.7. POLARITY
SWITCH
DONT
operate
the
polarity
switch
under
load.
ciA.
The
polarity
switch
(when
supplied)
is
provided
for
changing
the electrode lead
from
positive (reverse
polarity)
to
negative (straight polarity).
Never
move
it while
under the load
of
a
welding
current.
Operate
this switch
only
while the
machine is
idling
and
the
welding
circuit is
open.
The
potential
dangers
of
opening
the
circuit
while
carrying high
current
are:
0(1)
An
arc
will
form
between
the
contact
surfaces
of
the
switch
and
severely
burn
them.
0(2)
The
person
throwing
the switch
may
receive
a
severe
burn
from
this
arcing.
1.8.
RANGE
SWITCH
DONT
operate
the
range
switch
under
load.
ciA.
The
range
switch
(when
supplied)
is
provided
for
obtaining
required
current
settings.
It
must
never
be
operated
while the
machine
is under
the
load of
welding
current.
Operate
the
range
switch
only
while
the machine
is
idling
and
the
welding
circuit
is
open.
Thepotenialdangerofswitchingthe
circuit
while
carrying
high
current
is
the
formation of
an
arc
between
the
contact
surface
which
will
severely
burn
them.
Repeated
occurrences
of
this
arcing
will
eventually
prevent operation
of the
contacts.
1.9.
EXHAUST
GASES
DONT
use
gas
engine
units
in
confined
spaces
without
venting
the exhaust
gases.
ciA.
If
gasoline
or
other fuel
driven
welding
machines
are
operated indoors,
provide
means
to
pipe
the
exhaust
gases
to
the
outside air to
avoid carbon
monoxide
poisoning.
1.2.
WELDING
CABLES
DONT
overload
cables.
DB.
DC.
DD.
I
~1/
,-- I..
-
IOM-114A-
Page
1

DONT
use
welding
machine
without
grounding
frame
or
case.
I
_
I
DA.
Ground the
ground
cable
of
every
power
circuit
to
prevent
accidental
shock
by stray
current.
The
potential
danger
is
that
development
of
a
stray
cur
rent
may
give
a
fatal
shock
should
a
person,
for
example,
place
one
hand
on
thewelding
machine
and
the other
on
the
switch
box,
or
other
grounded
equipment.
Do
not
ground
to
pipelines
carrying
gases
or
flammable
liquids
and
conduits
carrying
electrical
conductors.
Be
sure
conductors
can
safely
carry
the
ground
current.
When
con
necting
the
welding
machine,
properly ground
the
machine
frame
or
case.
WELDING
OPERATIONS
1.11.
CONTAINERS
WHICH
HELD COMBUSTIBLES
DONT
weld
on
containers
which
have held
com
bustible
or
flammable
materials
or
materials
which,
when
heated,
give
off flammable
or
toxic
vapors
without
proper
cleaning,
purging,
or
inerting.
DA.
Welding
on
containers
which
have
heldflammable or
combustible
materials
may
be
extremely
danger
ous.
To
prevent
afireorexplosionof
the
container,
follow
the
recommendations
of
the
American
Weld
ing
Society
Pamphlet
A6.O
Welding
or
Cutting
Con
tainers
Which
Have Held
Combustibles.
DONT
depend
on
your
eyes
or
nose
to
decide
if
it is
safe
to
weld
on a
closed
container.
DB.
Find
out
what
was
in
the
container
or use
an
explosimeter.
A
very
small
amount
of
residual
flammable
gas
or
liquid
can cause
a
serious
explosion.
NEVER
use
oxygen
to
ventilate
a
container.
DC.
When
you
know
the
container
held
a
gas
or
liquid
which
will
readily
dissolve
in water:
D(1)
Flush
out
with water
several
times
and
then
fill
with
water
as
far
as
work
permits,
posi
tioning
container
to
permit
introduction
of
as
much water
as
possible.
D(2)
Before
welding
be
sure
there
is
a
vent
or
opening
to
provide
for release
of
air
pressure.
EW.
When
you
know
the
container
held
a
gas
or
liquid
which
will
not
readily
dissolve
in
water.
D(1)
Clean
out
thoroughly
with steam
or a
cleans
ing
agent
and
purge
all air
or
inert
with
a
gas
such
as
carbon dioxide
or
nitrogen
before
re
pairing.
Carbon dioxide
is
heavier
than
air
and
will
tend
to
remain
in the container
if
the
open
ing
is
at
the
top.
D(2)
Use steam
to
clean
out
light
material.
D(3)
Use
a
strong
caustic
soda
solution
to
clean
out
heavy
oils
or
grease.
0(4)
Be
sure
to
purge
all air
or
inert
with
a
gas,
such
as
nitrogen
or
carbon
dioxide,
no
matter
how
well
you
have
cleaned.
There
may
still
be
traces
of
oil,
grease,
or
other
readily
oxidizable
material under
the
seams.
DE.
Be
careful
when
cleaning
with steam
or
caustic
soda
wear
goggles
and
gloves.
DONT clean
where
there
is
poor
ventilation.
OF.
Ventilation
is
necessary
to
carry
away
harmful
or
explosive
vapors.
DONT clean where there
are
open
flames.
0G.
When
scraping
or
hammering
to
remove
heavy
sludge
or
scale,
use
a
spark
resistivetool
and
keep
it wet to
avoid
sparks.
OH.
Keep
your
head and
arms as
far
away
from
your
work
as
possible.
1.12.
HOLLOW CASTINGS
DONT
weld
on
hollow
(cored)
castings
that have
not
been
properly
vented.
The
casting
may
explode.
NEVER
weld
in
or
near
explosive
atmospheres,
Such
atmospheres
can
be created
by
flammable
gas
leaks
or
by
vapors
from
flammable
liquids
(gasoline,
alcohol,
etc.)
or
by
combustible
dusts.
1.14.
VENTILATION
DONT
weld
in
confined
spaces
without
adequate
ventilation.
DA.
When
welding
in
confined
spaces,
provide
ventilation
in accordance
with
United States
of
America Stand
ard
Z49.1,
1967.
Always
provide
adequate
ventila
tion
by
blowers,
air
lines,
or
other
acceptable
means.
Never
use
compressed
oxygen.
The
depletion
of
the
oxygen
supply,
the
heat
of
welding,
and
the
fumes
given
off
may
cause
severe
dis
comfort
or a
serious
illness.
OB.
When
toxic
fumes from
lead
or
cadmium
bearing
materials
or
any
other
substances
are
present
in
harmful
concentrations,
always
use
an
air
supplied
respirator.
L
--

J
--
1.10.
POWER
CIRCUIT GROUND
1
_--I
1.13.
EXPLOSION
HAZARDS
Page
2

1.15.
SOLVENTS
DA.
Do
not
weld
where
chlorinated
hydrocarbon
vapors
from
degreasing, cleaning,
or
spraying
may
reach
or
he
drawn
into air
surrounding
the
welding
operation.
The
heat
of
the
arc can
decompose
solvent
vapors
to
form
phosgene,
a
highly
toxic
gas
and other
irritating
decomposition products.
OB.
Do
not weld
where
ultraviolet
lightfrom
the
electric
arc
can
penetrate
air
containing
even
minute
amounts
of
vapors
from
solvents
such
as
trichlo
roethylene
or
perchloroethylene.
Ultraviolet
light
can
decompose
the
vapors
to
form
phosgene,
a
highly
toxic
gas,
and
other
irritating
products.
1.16.
FIRE
HAZARDS
DONT
weld
near
flammable
or
combustible
materials.
DA.
Fires
can
be caused
by
the
arc,
by
contact with
the heated
metal,
by
slag,
or
sparks. Keep
com
bustibles
at
least 35
feet from
the
arc
or
suitably
protected.
If
welding
must
be
done
in
a
particular
area,
move
the combustibles
away.
If
they
cannot
be
moved,
cover
them
completely
with
fire
resistive
screens.
Cover
cracks
or
openings
in
floors
or
walls;
sweep
floor
free
of
combustibles
and wet
down,
if
wood,
being
sure
welder
wears
insulation
shoe
coverings.
Avoid
welding
on
partition
walls
in contact
with
combustibles.
Heated metal
on
the
other side
of
partition
wall
being
welded
upon
can
ignite
combustibles
in contact
with the
partition.
Where
other
than
a
minor
fire
might develop,
have
a
fire
watcher
stand
by
with suitable fire
extin
guishing
equipment
for
at
least
one-half
hour
after
the
welding
is
completed.
1.17.
ELECTRICAL
SHOCK-VOLTAGE
OPEN
power
circuits
before
checking
machines.
DA.
Before
working
on
the
wiring,
switches,
controls,
etc.,
open
the
power
line
disconnect
switch.
In
most
welding
shops
the
power
supply
used
for
arc
welding
machines
is
230
or
460
volts.
Open
circuit
voltages
are
usually
less
than
100 volts
and
welding
or arc
voltage
drops
are
still
lower.
How
ever,
all
of
these
voltages
are
capable
of
developing
a
harmful
or
fatal current
to
the
body.
DONT
touch
electrically
hot
parts.
DB.
Never
touch
any
exposed
or
non-insulated
part
of
the
cables,
cable
connectors,
clamps,
electrode
holders,
electrodes~
or
the
power
supply
equipment
to
prevent
harmful
or
fatal
electric
shock
or
burns.
1.18.
ELECTR
ICAL
SHOCK-DAMPNESS
NEVER
work
in
a
damp
area
without
suitable
in
sulation
against
shock.
Keep
hands,
feet,
and
clothing
dry
at all
times.
DA.
To
pievent
harmful
body
shocks,
keep
hands,
feet
and
clothing
dry.
Never
stand
or
lie
in
puddles
of
water,
damp
ground,
or
against grounded
metal
when
welding
without
suitable insulation
against
shock.
Always
find
a
dry
board
or
rubber
mat
to stand
on
when
water,
moisture,
or
perspiration
cannot
be
avoided.
Dampness
between
the
body
and
an
en
ergized
or
grounded
metallic
part
lowers
the
resistance
to
the
passage
of
current to
the
body
which
may
produce
a
harmful
or
fatal
shock.
Salt
in
perspiration
or
sea
water
dangerously
1ower~
contact
resistances.
1.19. STARTING
UNDER LOAD
DONT
leave
an
uninsulated
electrode
holder,
or
a
live
electrode
on
the
table
topor
in
contact
with
a
grounded
metallic
surface.
When
it is
not
in
use,
never
place
an
electrode
holder
in
contact
with the
table
top
or
other
metallic
surface
in
contact
with
welding
ground.
Provide
an
insulated
hook
or
holder
for
the
electrode
holder.
A
potential
danger
is
that
a
holder
in contact
with
the
ground
circuit
provides
a
dead
short
circuit
on
the
welding
machine.
If
the
machine
should
be
started
up,
this
short
circuit
would
cause
an ex
cessive
load
on
the
machine
and
may
damage
the
insulation.
1.20.
FACE
PROTECTION
DONT
use
cracked
or
defective
helmets
or
shields.
Keep
the
helmet,
hand
shields,
or
face
shield
in
good
condition,
If
cracks
occur
in
the
fibre
material,
replace
the
shield,
since
the
leakage
of
arc
rays
may
cause
serious
burns.
1.21.
EYE
PROTECTION
NEVER
under
any
circumstances,
look
at
an
electric
arc
without
eye
protection.
CAUTION
Make
sure
that
flash
goggles
are
used
under
the

welding
helmet
at
all
times,
particularly
while
gas
shielded-arc
welding.
DA.
In
some
type
of
arc
welding,
such
as
gas
shielded-
arc
welding.ultraviolet
and
infrared
radiation
from
the
arc
is
particularly
intense
and
requires
constant
attention
to
avoid
arc
flashes
to
the
welder
when
striking
an
arc
and
to
avoid
exposure
to
other
welders.
NEVEB
strike
an
arc
without
ascertaining
that
nearby
persons
either
have
the
necessary
pro
tective
equipment
or
are
looking
in
the
opposite
direction.
DB.
For
welding
operations
in
open
areas,
provide
portable,
nonreflecting
screens
to
shield
persons
nearby
from the
rays
of
the
arc.
Eye
burns
from
the
arc, though
not
generally
permanent
injuries,
are
exceedingly
painful.
Such
burns
frequently
referred
to
as
flashes,
feel
like hot
sand
In
the
eye.
For
eye
burns
consult
your
first
aid
station
or doctor.
IOM-114A-Page
3

N EVER
use
cracked,
ill-fitting,
or
defective
plates.
EC.
The
filter
glass
plate
provided
in
the
helmets
and
shields
must be
of
reputable
manufacture
conform
ing
to
the latest USA
Standard
Z2.1.
Replace
cracked
or
ill-fitting
filter
plates
promptly.
NEVER
use
filter
plates
without
a
protecting
cover
glass.
ED.
Keep
a clean
cover
glass
in
front
of
the
filter
plate
for
the
protection
thereof.
Frequent
renewal
of
these
cover
glasses
is
necessary,
since
they
become
covered
with
spatter,
reducing
vision.
1.22. CLOTHING
NEVER
use
poor,
inadequate,
or
worn-out
cloth
ing.
Wear
heavy shoes,
tightly
laced.
Keep
clothing
dry.
EA.
Proper
and
dry,
oil-free
clothing
is
essential
for
the
welders
protection.
Clothing
must
not
only
keep
off
the
spatter
and molten
particles,
but
must
also
abstruct
the
rays
of
the
arc
and,
when
nec
essary,
insulate the
body
from
harmful
electrical
currents.
EB.
Wear
leather
or
asbestos
gloves
at
all
times
to
protect
the hands
and
wrists.
Dark
colored
shirts
are
preferred
to
light
ones
because
light
ones
reflect
arc
rays
to
exposed
parts
of
the
body.
In
the
case
of
gas
shieldedarc
welding,
light
colors
are
more
reflective
and
may
cause
eye
burns
due
to
the
intense
ultraviolet
rays
given
off
by
the
process.
Avoid
cotton
fabrics
when
gas
shielded
arc
welding.
EC.
An
arc
burn
on
the skin
resembles
a
sunburn,
except
that
it is
usually
more
severe.
Clothing
can
be
made
flame
resistant
by
treatment
with
a
solution
of
3/4
pound
of
sodium
stannate in
1
gal
lon
of
water,
then
wrung
out
and
dipped
in
a
solution of
1/4
pound
ammonium
sulphate
per gal
lon
of
water.
Dont
wash
clothing
so
prepared
in
water,
but
dry
clean.
ED.
When
welding
operations
are
to
be
performed
in
vertical
and
overhead
positions,
leather
sleevelets,
aprons,
and
in
some cases
leggings
and
ear
plugs
should
be
used to
prevent
severe
burns
from
spatter
and molten
metal.
1.23. HOT
METAL
BURNS
NEVER
pick
up
hot
objects.
EA.
Never
pick
up
pieces
of
metal
which
welded
or
heated,
or
the
stub
ends
which
have
been
discarded.
1.24.
GRINDING
AND
CHIPPING
EA.
Whenever
it is
necessary
to
grind
or
chip
metal,
wear
protective
goggles
specifically
designed
for
this
purpose.
Serious
eye
injuries
may
result
from
failure
to
wear
protective
goggles.
NEVER
do
any chipping
or
grinding
without
pro
tective
goggles.
1.25.
COMPRESSED
GAS
CYLINDERS
NEVER
strike
an arc on
compressed
gas
cylin
ders.
EJA.
Avoid
accidental
contact
of
the
electrodes,
electrode
holder,
or
other
electrically
energized
parts
with
a
compressed
gas
cylinder
or
any
other
pressure
vessel.
Serious
accidents
or
fires
may
result.
EB.
Use
I.C.C.
cylinders.
They
are
manufactured
and
maintained
in
accordance with
I.C.C.
requirements
and
are
safe
so
long
as
they
are
properly
handled.
Dont
drop cylinders.
EC.
Identify
gas
content
by
the
name
marked
on
the
cylinder.
If
the
cylinder
is
unmarked,
do not
use
it.
Return
it
to
the
supplier.
Do
not
rely
on
color
code.
ED.
Never
use
a
cylinder
or
its
contents
for
other
than
intended
purposes.
EE.
Keep
oil
and
grease
away
from
oxygen
cylinders
and
cylinder
valves.
EF.
Keep
cylinders
away
from
exposure
to
sparks,
hot
slag,
open
flame
and all
possible
sources
of
ignition
or
excessive
heat.
EG.
Be
careful
that
cylinders
are
not
placed
so
as
to
become
a
part
of
an
electrical
circuit.
Avoid
third
rails,
wires and
electric
welding
circuits.
EH.
When
transporting
cylinders by
crane,
use
cradle,
platform
or
other suitable
support.
El.
Never
lift
the
cylinders by
slings,
by
the
caps
or
by
electric
magnets.
EJ.
Never
use
cylinders
as
supports
or
rollers.
EK.
Never
try
to mix
any
gases
in
a
cylinder.
EL.
Never
try
to
refill
a
cylinder.
EM.
Mark
empty cylinders
Empty
or
MT.
EN.
Send
Emptys
back
to
the
supplier
promptly.
EO.
Keep
Emptys
and Fulls
separate.
EP.
Never
tamper
with
or
alter
cylinder
numbers
or
other
markings.
This
is
not
only
foolish
but
may
be
illegal.
EQ.
Do
not
tamper
with
or
change
fittings
on
cylinders.
ER.
If
valves
cannot be
opened
by
hand,
do
not
use
hammer
or
wrench.
Notify
supplier.
ES.
Protect
cylinder
valves
from
bumps,
falls,
falling
objects,
and
from
weather.
Keep
them
covered
with
cylinder
caps
when
moving
cylinders.
LIT.
Keep
valves closed
on
empty
cylinders.
EU.
See
that
your
cylinders
are
clear
of
passageways
and active
work
areas
and
that
they
are
secured
against
falling.
LIV.
If
adapter
is
required
between
cylinder
an~l
reg
ulator,
always
use
a
standard
adapter.
These
may
be
obtained from
your
supplier.
Where
right
and
left
hand
threads
are
used
on
adapter,
use
two
wrenches to
insure leak
proof
connections.
EW.
Do
not
store
cylinders
in
unventilated
areas.
1/
~
have
just
been
of
electrodes
Page
4

SECTION
2-
INTRODUCTION
2-1.
GENERAL
This
manual
has
been
prepared
especially
for
use
in
familiarizing
personnel
with
the
design,
in
stallation,
operation
and
maintenance
ofthewelding
machine.
In
some
cases,
the contents
of
this
pub
lication
are
generalized.
All
information
presented
in
this
manual
should
be
given
careful
consideration
to
assure
optimum performance
and
service
of
the
equipment.
Process
information
is
available
by
contacting
your
welding
distributor.
2-2.
RECEIVING-HANDLING
To
prepare
the
welding
machine
for
installation,
several
items
should
be
checked.
Clean
all
packing
material
from
around the
unit
and
carefully
inspect
for
damage
that
may
have
been
caused
by
shipping.
Any
claims
for
loss
or
damage
that
may
have
oc
curred in
transit must be
filed
by
the
buyer
with the
carrier.
Copy
of bill of
lading
and
freight
bill
will
be
furnished
on
request
ifoccasiontofileclaimarises.
Be
sure
to
read
all the
instructions
before
at
tempting
to
operate
the
welding
machine.
When
requesting
information
concerning
the
weld
ing
machine,
be
sure,
to
furnish
serial and model
numbers.
2-3. DESCRIPTION
This
welding
machine
is
designed
for
use
in
light
industrial
plants,
metal
fabrication
shops,
auto
motive
repair
shops
and
for
general
light
welding
applications.
Two
welding
current
ranges
are
available.
The
high
range
provides
ample
normal
open
circuit volt
age
for
average
electrode
sizes.
The
low
range
pro
vides
maximum
open
circuit to
permit
the
use
of
smaller
electrode
sizes.
The
180
amp
machine
uses
natural
updraft
cooling
and
the
225
amp
machine
uses
a
fan,
both
which
help
ensure
that
the
internal
components
are
kept
below the
critical
operating
temperatures, pro
viding
the
duty
cycle
ratings
are
not
exceeded.
2-4. SAFETY
Before
attempting
to
make
primary
or
secondary
connections,
change
parts
or
make
repairs,
be
sure
the
welding
machine
is
completely
disconnected
from
the
main
power
line.
Before
the
welding
machine
is
put
into
operation,
read the
complete
safety
section
at
the
front of
this
manual.
This will
help
avoid
any
possible
injury
due
to
misuse
or
improper
welding
applications.
SECTION
3
-
INSTALLATION
3-1.
LOCATION
(Figure
3-1)
Proper component
operating
temperatures
on
the
225
amp
model
are
maintained
by
the air stream
produced
by
thefan
assembly.
On
the
180
amp
model
air
cooling
is
provided
by
means
of
natural
updraft
through
the
vented
bottom.
Therefore
the
air
passages
in
the front and bottom of
the
welding
ma
chine
must be
kept
open.
The
rear
of
the
welding
machine
should
be
kept
a
minimum
distance of 18
inches
from
the wall to
help
ensure
proper
cooling.
The
location
should
be such
that
a
minimum
amount
of
dust
and dirt
will
be
drawn
into
the air
stream.
Preventive
maintenance
consists
of
re
moving
the
wrapper
and
blowing
out the
dust
ac
cumulation
inside the
welding
machine,
For
this
reason
it is
desirable
to
locate
the unit
so
that
the
wrapper
can
be
removed without
any
difficulty.
Four
mounting
holes
are
provided
in the
welding
machine base
for
machines that
require
mounting.
Figure
3-1
gives
overall dimensions
and the
base
mounting
hole
layout
for
console
installation
or
other installations that
may
require
this
infor
mation.
3-2.
PRIMARY
CONNECTIONS
(Figure
3-2
&
3-3)
Most
rural and
residental
power
systems
are
of
the
115/230
volt,
single
phase
type.
This
ac arc
welding
machine is
a
single
phase
unit
and
must
be
connected
to
a
single
phase
power
line.
Consult
the
local
power
and
light
company
if
there
is
any
question
about
type
of
system
used
locally
or
the
proper
connection
to
obtain
single
phase
power
service
to
the
welding
machine.
All
models
are
ordinarily
supplied
with
an
attach
ed three conductor
cable.
Models
requiring
208
or
230
volt
primary
input
are
equipped
with
a three
prong
polarized
plug
and
wall
receptacle.
The
wall
receptacle
should be
installed
in
a
con
venient
location
by
a
competent
electrician.
The
wall
receptacle
should be
installed
with the
grounding
MODEL
WELDING
CURRENT
RANGE
AMPERES
RATED
CURRENTOUTPUT
AT25
VOLTS.
20%
DUTY
CYCLE
CURRENT
OUTPUT
AT3OVOLTS.
20%
DUTY
CYCLE
OPEN
CIRCUIT
VOLTS
POWER INPUT AT
RATED
LOAD
50/60
Hz.
AMPERES


23OVOLTS
SINGLE
PHASE
kw
kva
DIMENSIONS
OVERALL WEIGHT
HEIGHT WIDTH DEPTH
NET SHIPPING
180
Amp.
180
Amp.
*
225
Amp.
225
Amp.
*
20-180
20-180
30-225
30-225
180
180
225
225
200
200
55180
55/80
55/80
55/80
37
30
44.4
38.5
5.4
5.4
7.2
7.2
8.5
6.9
10.2
8.8
17
12-1/2 20-1/2
130
Lbs.
138 Lbs.
17
12-1/2~~ 20-1/2~
135
Lbs.
142
Lbs.
17
12-1/2 20-1/2
135
Lbs.
142 Lbs.
17
12-1/2~ 20-1/2~~
140
Lbs.
147
Lbs.
~With
Power
Factor
Correction.
Figure
2-1.
Specifications
Figure
3-1.
Dimensional
Drawing
AA-500
001-1
IOM-114A-
Page
5

terminal
at
the
top
as
this
then
permits
the
power
cord
to
hang
downward
without undue
bending
or
twisting.
Models with
other than
230
volt
only
primary
input
voltages,
are
equipped
with
a
voltage changeover
terminal
strip
and two
jumper
links.
This
terminal
strip
is
accessible
by
opening
the
access
door
on
the
rear
panel.
The
terminal
strip
is
located
at
the
rear
of
the
welding
machine
base.
If
the
welding
machine
is
furnished
with
a
pri
mary
voltage
changeover
terminal
strip,
connect
the
jumper
links
to
the
indicated
voltage
terminals
to
match the
primary
input
voltage.
Whenever
only
one
jumper
link
connection is
necessary
for
the
proper
input
voltage,
connect both
jumper
links
across
the
same
two
terminals.
This will
help
prevent
losing
the
second
jumper
link.
Refer
to
Figure
3-2
for
proper
jumper
link
connections.
Welding
machines
are
shipped,
unless otherwise
ordered,
with
the
jumper
links
connected
in
the
highest
voltage
position.
This
welding
machine
should
be
operated
from
a
separately
fused
or
circuit
breaker
protected
cir
cuit.
The maximum
capacity
of
the
welding
machine
is
affected
by
the line
voltage
and
if the circuit
is
overloaded,
the
performance
of
the
welding
machine
will
be
impaired.
Install
a
cable
of
two
primary
wires
plus
one
ground
wire
(see
Table 3-1
for
proper
wire
and
fuse
sizes)
from
the
line
disconnect
switch
or
circuit
breaker
to the
WALL
RECEPTACLE.
See
Figure
33.
For
models
without
a
three
prong
plug,
a
60
am
pere plug
may
be
installed
to
the
welding
machine
primary
input
cable
and
the
receptacle
to
the
line
disconnect
switch.
A
grounding
wire must be
run
to
a
suitable
ground
ing
medium such
as
the
electrical
conduit
system,
the water
system
or
a
regular
driven
ground
rod.
Check
with
the local
inspection
authority
if
there
is
any
question
as
to
an
accepted
grounding
method.
Models with
a
three
prongpolarizedplug,plugin
to the
wall
receptacle.
For
models without
a
three
prong
plug,
connect
the
No.
10
green
wire
to
the
ground
wire
or
connection in the line
disconnect
switch
and
the two
No.
8 wires
to
the
power
leads.
3-3. SECONDARY
(WELDING)
CONNECTIONS
It
is
recommended that the
welding
cables
be
kept
as
short
as
possible,
placed
close
together
and be
of
adequate
current
carrying
capacity.
The
resistance
of the
welding
cables
and
connections
cause
a
volt
age
drop
which is
added
to the
voltage
of
the
arc.
Excessive cable resistance
may
result
in
over
loading
as
well
as
reducing
the
maximum
current
output
of
which
the
welding
machine
is
capable.
When
welding
with
ac, longer
cables
if
coiled
up,
will
generate
a
magnetic
field that
can
reduce
the
output
of
the
welding
machine.
The
welding
cables
from
the work and
electrode holder
to
the
welding
machine should
be
taped
together
at
short
intervals.
The
proper
operation
of
any
arc
welding
machine
is
to
a
great
extent
dependent
on
the
use
of
welding
cables
and
connections
that
are
in
good
condition
Table 3-2.
Secondary
Welding
Cable
Size
WELDING
AMPERES
TOT
AL
LENGTH
OF
CABLE)
COPPER)
IN
WELD CIRCUIT
50
100 150
200
250
300
100 2
2
1
1/0
2/0
3/0
150
2
1
2/0 3/0 4/0
200
2
1/0
3/0 4/0
250
2
2/0 4/0
300 1
3/0
NOTE:
A.
50
FEETOR
LESS
B.
CABLE SIZE
IS
BASED
ON DIRECT CURRENT
(DC),
20%
DUTY
CYCLE
AND
EITHER
A 4
VOLTS
OR
LESS
DROP
OR
A
CURRENT
DENSITY
OP
NOT
OVER
300 CIRCULAR
MILS
PER
AMP.
C.
WELD
CABLE INSULATION
WITH A
VOLTAGE
RATING
TO WITH
STAND THE OPEN
CIRCUIT
VOLTAGE
IO.C.V.)
OF
THE
WELD
ING MACHINE MUST
BE USED. WHILE MOST
WELDING
MA
CHINES
HAVE AN OPEN
CIRCUIT VOLTAGE OP
LESS
THAN
100
VOLTS,
SOME WELDING MACHINES OF
SPECIAL DESIGN
MAY
HAVE HIGHER OPEN CIRCUIT VOLTAGE.
~~1
Table
3-1.
Recommended
Primary
Wire And Fuse
Sizes
MODEL
PRIMARY WIRE
SIZE
(From
source
to
line
disconnect switch)
FUSE SIZE
(AMPERES)
115V
208V 230V
460V
575V
115V 208V 230V
460V
575V
180
Amp
Model
Without P.F.C.
180
Amp
Model
With P.F.C.*
225
Amp
Model
Without P.F.C.
225
Amp
Model
With
P.F.C.
No. 2
(No. 6)
No.4
(No.6)
No. 2
(No.
6)
No.3
(No.6)
No.
6
(No.
8)
No.8
(No.8)
No.
6
(No.
8)
No.6
(No.8)
No.
8
(No. 8)
No.
10
(No.
10)
No.
6
(No.
8)
No.8
(No.
8)
No. 12
(No.
12)
ND.
14
(No.
14)
No. 10
(No.
10)
No. 12
(No.
12)
No.
14
(No.
14)
No. 14
(No.
14)
No.
12
(No. 12)
No.
12
(No.
14)
150
110
175
150
80
70
100
80
70
60
90
75
35
30
45
35
30
25
35
30
Numbers
in
I
4
are
ground
mire
sizes.
Pomer Factor
Correction.
AA-900 B23-9
Figure
3-3.
Primary
Connections
iee
SzS voits
ate
voLts
373
VOLtS
:
A-BOO g23-e
Figure
3-2.
Primary
Voltage
Link
Arrangement
Page
6

and
of
adequate
size.
Electrode
holder and
ground
clamp
should
be
at least 200
ampere capacity
and
securely
connected
to
the
welding
cables.
An
in
sulated electrode
holder
must be
used
to
ensure
operators safety.
Select
the
proper
size
welding
cable
from
Table
3-2.
A.
Jack
Plug
Installation
(Figure
3-4)
Two
jack
plugs,
enclosed
in
a
cloth
bag,
are
fur
nished with
the
welding
machine.
Follow instruc
tions
carefully
for
proper
installation
of
the
jack
plugs
to
the
welding
cables.
See Table 32
for
proper
welding
cable
sizeS
Standard
jack
plugs
furnished
with unit
will
accommodate
cable sizes
ranging
from
6
to
1.
1.
Remove
3/4
inch
of
insulation from
one
end of
each
welding
cable.
2.
Clamp
the
welding
cable
in
a
vise
with
the
un
insulated end
protruding
upward
out
of
the vise
approximately
1-3/4
inches.
3.
Place the
steel tie wire
(A)
approximately
1/4
inch
from
the end
of
the
insulation.
4.
Make
a
half
turn around
the cable
bringing
the
looped
ends of
the
tie wire
together.
5.
Insert a rod
of
approximately
3/8
inch diameter
through
the two
looped
ends
of
the tie
wireS
6.
Twist
the
tie
wire
(B)
until
the
entire
tie wire is
twisted
and
is
tight
around
the
insulation
of
the
welding
cable.
7.
Clip
off
the
looped
ends
of
the tie
wireS
8.
Bend
the twisted tie wire
over
alongthe
side
(C)
of
the
uninsulated
portion
of
the
welding
cable.
9.
Wrap
the
strip
of
copper
foil
tightly
around the
uninsulated
end
of
the
welding
cable and the twist
ed
tie
wire
(D).
10.
Place
the
jack
plug
on
the
end of
the
welding
cable
and
push
it
onto
the
welding
cable
over
the
copper
foil
(E).
11.
Insert
the
1/4-20
allen
set
screws
into the center
CAUTION
cfl~
Figure
3-4.
Jack
Plug
Installation
and
upper
holes
in the
jack
plug
and
tighten.
12.
Remove
the
welding
cable
from
the vise
and
in
sert
the
jack
plug
into the
fiber
sleeve.
Slide
the
fiber sleeve
over
the
jack
plugandweldingcahle
until
the
hole
in
the
fiber
sleeve
lines
up
with the
8/32
hole
in
the
jack
plug
(F).
13.
Insert the
8/32
self
tapping
screw
through
the
hole
in the
fiber
sleeve into
the
jack
plug.
Tighten
the
screw
with
a
screw
driver.
Connect
a
Work
Clamp
to
one
of
the
unused
ends
of
one
of
the
cables.
Connect
an
Electrode Holder
to
the unused
end
of
the
other
welding
cable.
The
method
of
connecting
the
cables
to
the
work
clamp
and
electrode
holder
will
depend
on
the
manu
facturers
design.
SECTION
4
-
OPERATION
I
Never,
under
any
circumstances,
operate
the
weld
ing
machine with
the
cover removed.
In addition to
a
safety
hazard,
improper
cooling
may
result
in
damage
to the
welding
transformer and
the
welding
machine
components.
Be
sure
to
read the
complete
safety
section
at
the
front
of
the
manual before
oper
ating
the
welding
machine.
20
30
40
50
60
7080
100
%
DUTY
CYCLE
A-101
391A
Figure
4-1.
Duty
Cycle
Chart
4-1.
DUTY CYCLE
(Figure
4-1)
The
duty cycle
of
a
welding
machine
is
the
percentage
of
a
ten
minute
period
that the
welding
machine
can
operate
safely
at
a
given
output.
This
welding
machine
is
rated
at
a
20
percent
duty
cycle.
This
means
that
the
welding
ma
chine
can
operate
safely
at
rated
load if
the
ma
chine
is
on
for
no
more
than
two minutes and
off for
eight
minutes.
If
the
output
is
increased above
rated
load,
the
duty
cycle
must
be
reduced.
Figure
4-1
shows
the
percent
duty
cycle
compared
to
output.
This chart
should
be
used
for
reference
by
the
operator
to de
termine
the
operating
limits
or
ON
time
of
the
weld
ing
machine
if
it is
operated
above
rated
output.
4-2.
OPEN
CIRCUIT
VOLTAGE
This
welding
machine
provides
80
volts
open
circuit
on
the
ac
LOW
range
and
55
volts
open
cir
cuit
on
the
ac
HIGH current
range.
Open
circuit
voltage
is
the
voltage
present
between
the electrode
and
work
before
an
arc
has
been
struck.
4-3.
ARC
VOLTAGE
Arc
voltage
is
the
voltage
between
the electrode
and work while
a
welding
arc
is
being
maintained.
Two
open
circuit
voltages
permit
the
use
of
larger
electrodes
demanding
high
welding
amperages
with
minimum
power
requirements.
The
higher
open
cir
cuit
voltage
enables the
welder
to
use
small
dia
meter
electrodes,
stainless
steel,
low
hydrogen
and
other
hard
to
run
electrodes
with
complete
satis
faction.
I I
FPL ~jI
AA-901
024-4
i/
U)
a
Li
cc
Li
£
0
C
U
Lii
I
225
200
175
150
125
100
go
80
0
IOM-114A-
Page
7

90
80
70
60
(#1
-J
0
40
C
30
20
10
0
cuit
voltage
to
reduce
power
demand.
The
LOW
ampere
range
utilizes a
high open
cir
cuit
voltage
to
assure
arc
flexibility
and
it
is
always
recommended
that the
LOW
range
be
used
for
hard
surfacing,
alloy
application,
and
small electrodes
where the
average
current
used
is
155
or
less.
4-6.
FINE
CURRENT
CONTROL
Select
the
desired
welding
current within the
range
by rotating
the
Fine
Current
Adjustment
Control
on
the
front
of
the
welding
machine.
A
current
indicator
on
the
upper
left
part
of
the
control
panel
shows
the
current
in
accordance
with
thecurrentrangeinuse.
4-7.
ON-OFF POWER
SWITCH
The Power switch
controls
the
primary
line
power
to
the
welding
transformer.
When
the switch
is
placed
in
the
ON
position,
open
circuit
voltage
will
be
impressed
across
the
Work and Electrode
re
ceptacles.
4-8.
SHIELDED
METAL-ARC
(SMAW)
WELDING
(Figure
4-3)
This
welding
machine
will
handle all
good
quality
mild
steel,
ac
and ac/dc
electrodes
from
5/64 to
3/16
diameter
with
the
exception
of
low
hydrogen
and
iron
powder
coated
electrodes.
Iron
powder
coating
requires
higher
arc
voltages
for
the
given
current.
The
use
of
iron
powder
coated
electrodes
in
the
excess
of
5/32
diameter
is not
recommended
for
this
model
welding
machine.
The
high open
circuit
voltage
of
80
volts
available
on
the
low
ac
current
range
of
this
welding
machine
makes
it
possible
to
use some
of the so-called
hard
to
run
electrodes
such
as
stainless steel
and
low
hydrogen
up
to
3/32
and
possibly
1/8 diameter.
4-4.
VOLT-AMPERE CURVES
(Figure
4-2)
The
volt-ampere
curves
show the
output
volt
age
available
at
any
given
output
current
within the
limits
of
the
minimum
and
maximum current
control
setting
on
each
range.
With the
use
of
the
volt-am
pere
curves,
it
is
possible
to
determine
the
am
perage
required
for
a
particular
load
voltage.
In
metallic
arc
or
coated
electrode
welding,
it is
impossible
for
the
operator
to
hold
an
arc
length
which
does
not
vary.
This
varyingarc
length
causes
arc
voltage
to
vary
which
in
turn
produces
core
sponding changes
in
welding
current.
The
steeper
the
slope
of
the
volt-ampere
curve
within the weld
ing
range,
the
lower
the
current
change
for
a
given
voltage
change.
4-5.
CURRENT
RANGES
The
HIGH
ampere
range
utilizes
a
low
open
cir
1,
Insert the
jack
plug
from
the
Work
Welding
Cable
into
the
WORK
receptacle
and
clamp
the
opposite
end
of the
Work Cable
to
the
work-
piece.
2.
Insert the
Electrode
Holder
welding
cable
jack
plug
into either
the
Electrode
LOW
or
HIGH
receptacle.
A
slight
twist
while
inserting
the
jack
plugs
into
the
receptacles
will
ensure
a
tight
connection.
If the
required
current
is in
both
ranges,
use
the
LOW
range
receptacle
as
this
will
provide
better
current
control.
3.
Turn
the
Fine
Current
Adjustment
Control
to
the
desired
welding
current.
4.
Place the
Power
switch
In
the
ON
position.
5.
Place
an
electrode
of
proper
type
and size
into
the
Electrode
Holder and
commence
welding.
6.
Readjust
the
current control
if
necessary.
7.
After
the
welding
job
is
completed,
break
the
arc
and
place
the
Power switch
in
the
OFF
position.
4-9.
ARC
TORCH
OPERATION
A
carbon
arc
torch
may
be usedwith
this
welding
machine.
With
a
carbon
arc
torch
it is
possible
to
weld
and braze
metals
that
ordinarily
are
considered
weldable
only
by
the
oxyacetylene
method.
Itis
es
pecially
adaptable
for
brazing,
soldering, pre
heating
and hard
surfacing.
A
carbon
arc
torch
maintains
a
high
temperature
arc
between
two
car
bons.
Welds
produced
with
this
type
of
torch
are
sound,
strong,
and
free
from
porosity.
The
parent
metal
or
welding
rod
is used
as a
filler.
25
50
75 100
125 150
175 200
225
AC
AMPERES
180
AMP
MODEL
96-900
001-1
90
80
70
60
~
50
-a
0
>
40
U
C
30
20
10
0
50
100
150
200
250
300
AC
AMPERES
225 AMP MODEL
EB-900 019-1
Figure
4-2.
Volt-Ampere
Curves
AA-900
001-2
Figure
4-3.
AC
Welding
Connections
4
Page
8