Miller PS-1005 User manual

BAY
STATE
ABRASIVES
February
1996 FORM:
OM-123
516B
Effective
With
Serial
No.
KC304130
MODEL:
PS-1005
PS-2000
~RJ~
~
OWNERS
MANUAL
IMPORTANT:
Read and understand
the
entire
contents
of
this
manual,
with
special
emphasis
on
the
safety
material
throughout
the
manual,
before
Instaiiing,
operating,
or
maintaining
this
equipment.
This
unit
and these
instructions
are
for
use
only by
persons
trained and
experienced
in the safe
operation
of
welding
equipment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
If
you
do
not
fully
understand
these
Instructions.
PRINTED
IN
U.S.A.

(

OM.123
516B

6/93
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1

SAFETY
RULES FOR OPERATION OF
ARC WELDING
POWER
SOURCE
1-1.
Introduction
I
1-2.
General
Precautions
1
1-3.
Arc
Welding
4
1-4.
Standards
Booklet
Index
5
SECTION 2-INTRODUCTION
2-1.
General
Information
And
Safety
7
2-2.
Receiving-Handling
7
2-3.
Description
7
SECTION
3-
INSTALLATION
3-1.
Location 8
3-2.
Secondary
Connections
8
3-3.
Open-Circuit
Voltage
Connections
9
3-4.
Remote
Control Connections
9
3-5.
Electrical
Input
Connections
10
SECTION
4
OPERATOR CONTROLS
4-1.
Pilot
Light
11
4-2.
Volt-Ampere
Curves
11
4-3.
Duty
Cycle
11
4-4.
115 Volts
AC
Duplex
Receptacle
11
4-5.
Overload
Protection
11
SECTION
5SEQUENCE
OF
OPERATION
12
SECTION
6
MAINTENANCE
6-1.
Fan Motor
12
6-2.
Internal
Cleaning
12
6-3.
Spark Gaps
12
SECTION
7TROUBLESHOOTING
13
SECTION
8
PARTS
LIST
Figure
8-1.
Left
Side
View
18
Figure
8-2.
Left
Side
View 20

C

SECTION
1

SAFETY RULES
FOR
OPERATION
OF ARC WELDING
POWER
SOURCE
1-1.
INTRODUCTION
We
learn
by
experience.
Learning
safety through
per
sonal
experience,
like
a
child
touching
a
hot
stove
is
harmful,
wasteful,
and
unwise. Let
the
experience
of
others teach
you.
Safe
practices
developed
from
experience
in
the
use
of
welding
and
cutting
are
described
in
this manual.
Re
search,
development,
and field
experience
have
evolved
reliable
equipment
and
safe
installation,
opera
tion,
and
servicing
practices.
Accidents
occur
when
equipment
is
improperly
used
or
maintained. The
rea
son
for
the safe
practices
may
not
always
be
given.
Some
are
based
on
common
sense,
others
may
require
technical
volumes
to
explain.
It
is
wiser
to
follow the
rules.
Read
and
understand
these safe
practices
beforQ
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.
1-2.
GENERAL PRECAUTIONS
Different
arc
welding
processes,
electrode
alloys,
and
fluxes
can
produce
different
fumes,
gases,
and
radIation levels.
in
addition
to
the Information
In
this
manual,
be
sure
to
consult flux
and electrode
manufacturers
Material
Safety
Data
Sheets
(MSDSs)
for
specific
technical
data and
precaution
ary
measures
concernIng
their
materIal.
A.
Burn
PreventIon
Wear
protective
clothing-gauntlet gloves
designed
for
use
in
welding,
hat,
and
high safety-toe
shoes.
Button
shirt
collar and
pocket
flaps,
and
wear
cuff less
trousers
to
avoid
entry
of
sparks
and
slag.
Wear
helmet
with
safety goggles
and
glasses
with
side
shieids
underneath,
appropriate
filter
lenses
or
plates
(protected
by
clear
cover
glass).
This is
a
MUST
for
welding
or
cutting,
(and chipping)
to
prctect
the
eyes
from
radiant
energy
and
flying
metal.
Replace
cover
glass
when
broken,
pitted,
or
spattered.
See
1
-3A.2.
Avoid
oily
or
greasy
clothing.
A
spark
may
ignite
them.
Hot
metal
such
as
electrode
stubs and
workpieces
should
never
be
handled without
gloves.
Medical first aid
and
eye
treatment.
First
aid
facilities
and
a
qualified
first
aid
person
should
be
available
for
each
shift
unless
medical
facilities
are
close
by
for
im
mediate
treatment
of flash
burns of
the
eyes
and
skin
burns.
Ear
plugs
should be
worn
when
working
on
overhead
or
in
a
confined
space.
A
hard
hat should
be
worn
when
others
work overhead.
Flammable
hair
preparations
should
not
be used
by
per
sons
intending
to
weid
or
cut.
B.
ToxIc Fume Prevention
Severe
discomfort,
illness
or
death
can
result
from
fumes,
vapors,
heat,
or
oxygen
enrichment
or
depletion
that
welding
(or
cutting)
may
produce.
Prevent
them
with
adequate
ventilation
as
described
in
ANSI Stan
dard
Z49.1
listed in
Standards
Index.
NEVER
ventilate
with
oxygen.
Lead
-,
cadmium-, zinc-,
mercury
-,and
beryllium-bear
ing
and
similar
materials,
when
welded
(or cut)
may
pro
duce
harmful
concentrations of toxic
fumes.
Adequate
local
exhaust ventilation
must
be
used,
or
each
person
in
the
area
as
well
as
the
operator
must
wear
an
air-sup
plied respirator.
For
beryllium,
both
must
be
used.
Metals coated
with
or
containing
materials
that emit
toxic
fumes should
not
be
heated
unless
coating
is
re
moved
from the
work
surface,
the
area
is well
ventilated
and,
if
necessary,
while
wearing
an
air-supplied
respira
tor.
Work
in
a
confined
space
only
while
it is
being
ventilated
and,
if
necessary,
while
wearing
an
air-supplied
respira
tor.
Gas leaks
in
a
confined
space
should be
avoided.
Leaked
gas
in
large
quantities
can
change
oxygen
con
centration
dangerously.
Do
not
bring
gas
cylinders
into
a
confined
space.
Leaving
confined
space,
shut
OFF
gas
supply
at
source
to
prevent
possible
accumulation of
gases
in
the
space
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
123516
Page
1

atmosphere
or
where the radiant
energy
can
penetrate
to
atmospheres
containing
even
minute
amounts
of
trichloroeth~lene
or
perchloroethylene.
C.
FIre
and
Explosion
Prevention
Causes
of
fire
and
explosion
are:
combustibles
reached
by
the
arc,flame,f
lying
sparks,
hot
slag
or
heated mate
rial;
misuse
of
compressed
gases
and
cylinders;
and
short
circuits.
BE
AWARE THAT
flying
sparks
or
falling slag
can
pass
through
cracks,
along pipes,
through
windows
or
doors,
and
through
wall
or
floor
openings,
out
of
sight
of the
goggled
operator.
Sparks
and
slag
can
fly
35
feet.
To
prevent
fires
and
explosion:
Keep
equipment
clean and
operable,
free
of
oil,
grease,
and
(in
electrical
parts)
of metallic
particles
that
can
cause
short
circuits.
If
combustibles
are
in
area,
do
NOT weld
or
cut.
Move
the
work
if
practicable,
to
an area
free
of
combustibles.
Avoid
paint
spray
rooms,
dip
tanks,
storage
areas,
venti
lators. lithe
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).
Wails,
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
after weld
ing
or
cutting
if:
a.
appreciable
combustibles
(including
building
construction)
are
within
35
feet
b.
appreciable
combustibles
are
further
than
35
feet
but
can
be
ignited by
sparks
c.
openings (concealed orvisible)
in
floors
orwalls
within 35 feet
may expose
combustibles
to
sparks
d.
combustibles
adjacent
to
walls,
ceilings,
roofs,
or
metal
partitions
can
be
ignited by
radiant
or
conducted
heat.
Hot
work
permit
should be obtained before
operation
to
ensure
supervisors
approval
that
adequate
precautions
have
been
taken.
After
work
is
done,
check that
area
is tree of
sparks,
glowing
embers,
and flames.
An
empty
container
that
held
combustibles,
or
that
can
produce
flammable
or
toxic
vapors
when
heated,
must
never
be
welded
on
or
cut,
unless
container
has
first
been
cleaned
as
described
in
AWS Standard
A6.O,
listed
7
in
Standards
Index.
This
includes:
a
thorough
steam
or
caustic
cleaning
(or
a
solvent
or
water
washing,
depending
on
the
combusti
bles
solubility)
followed
by
purging
and
inerting
with
ni
trogen
or
carbon
dioxide,
and
using
protective~
equip-
ment
as
recommended
in
A6.O.
Waterfilling just
below
working
level
may
substitute
for
inerting.
A
container with unknown
contents
should be cleaned
(see
preceding
paragraph).
Do
NOT
depend
on sense
of
smell
or
sight
to determine
if
it is safe
to
weld
or
cut.
Hollow
castings
or
containers
must
be
vented before
welding
or
cutting.
They
can
explode.
Explosive atmospheres.
Never weld
or
cut
where
the
air
may
contain flammable
dust,
gas,
or
liquid
vapors
(such
as
gasoline).
D.
Compressed
Gas
Equipment
Standard
precautions.
Comply
with
precautions
in
this
manual,
and those detailed
in
CGA
Standard
P-i,
SAFE
HANDLING OF COMPRESSED GASES
IN
CYLIN
DERS,
listed
11
in
Standards
Index.
1. Pressure
Regulators
Regulator
relief valve
is
designed
to
protect
only
the
regulator
from
overpressure;
it
is
not
intended
to
protect
any
downstream
equipment.
Provide
such
protection
with
one
or
more
relief
devices.
Never
connect
a
regulator
to
a
cylinder containing
gas
other than that for which
the
regulator
was
designed.
Remove
faulty
regulator
from
service
immediately
for
repair (first
close
cylinder
valve).
The
following
symp
toms
indicate
a
faulty regulator:
Leaks-if
gas
leaks
externally.
Excessive
Creep-if
delivery
pressure
continues
to
rise
with
downstream
valve
closed.
Faulty
Gauge-if
gauge
pointer
does
not
move
off
stop
pin
when
pressurized,
nor
returns
to
stop
pin
after
pres
sure
release.
Repair.
Do NOT
attempt
to
repair.
Send
faulty regula
tors
for
repair
to
manufacturers
designated
repair
cen
ter,
where
special
techniques
and tools
are
used
by
trained
personnel.
2.
Cylinders
Cylinders
must
be handled
carefully
to
prevent
leaks
and
damage
toiheir
walls,
valves,
or
safety
devices:
Avoid electrical
circuit
contact
with
cylinders
including
third
rails,
electrical
wires,
or
welding
circuits.
They
can
produce
short
circuit
arcs
that
may
lead
to
a
serious
ac
cident.
(See 1-3C.)
ICC
or
DOT
marking
must
be
on
each
cylinder.
It
is
an
assurance
of
safety
when
the
cylinder
is
properly
han
dled.
Identifying
gas
content.
Use
only
cylinders
with
name
of
gas
marked
on
them;
do
not
rely
on
color
to
identify
gas
content.
Notify
supplier
if
unmarked. NEVER
DEFACE
or
alter
name,
number,
or
other
markings
on
a
cylinder.
It
is
illegal
and
hazardous.
Empties: Keep
valves
closed,
replace
caps
securely;
mark
MT;
keep
them
separate
from
FULLS
and
return
promptly.
Prohibited
use.
Never
use a
cylinder
or
its
contents
for
other than
its intended use, NEVER
as a
support
or
roller.
123516
Page
2

Locate
or
secure
cylinders
so
they
cannot
be
knocked
over.
Passageways
and
work
areas.
Keep cylinders
clear
of
areas
where
they
may
be
struck.
Transporting
cylinders.
With.a
crane,
use a secure
sup
port
such
as a
platform
or
cradle. Do
NOT
Lift
cylinders
off
the
ground
by
their
valves
or
caps,
or
by
chains,
slings,
or
magnets.
Do
NOT
expose
cylinders
to
excessive
heat,
sparks,
slag,
and
flame,
etc.
that
may
cause
rupture.
Do
not
al
low
contents
to
exceed
130F.
Cool
with
water
spray
where
such
exposure
exists.
Protect
cylinders
particularly
valves
from
bumps,
falls,
falling objects,
and
weather.
Replace
caps
securely
when
moving
cylinders.
Stuck
valve.
Do
NOT
use
a
hammer
or
wrench
to
open
a
cylinder
valve
that
can
not
be
opened by
hand.
Notify
your supplier.
Mixing
gases.
Never
try
to
mix any
gases
in
a
cylinder.
Never
refill
any
cylinder.
Cylinder
fittings
should
never
be
modified
or
ex
changed.
3.
Hose
Prohibited
use.
Never
use
hose
other than
that de
signed
for the
specified
gas.
A
general
hose
identifica
tion rule
is:
red for fuel
gas,
green
for
oxygen,
and black
for
inert
gases.
Use
ferrules
or
clamps
designed
for the
hose
(not
ordi
nary
wire
or
other
substitute)
as
a
binding
to
connect
hoses
to
fittings.
No
copper
tubing
splices.
Use
only
standard brass
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
orworn
hose
by
cutting
area
out
and
splic
ing
(1-2D3).
Do
NOT
tape.
4.
Proper
Connections
Clean
cylinder
valve outlet
of
impurities
that
may
clog
orifices
and
damage
seats
before
connecting
regulator.
Except
for
hydrogen,
crack
valve
momentarily,
pointing
outlet
away
from
people
and
sources
of
ignition.
Wipe
with
a
clean
lintless
cloth.
Match
regulator
to
cylinder.
Before
connecting,
check
that the
regulator
label and
cylinder
marking
area,
and
that
the
regulator
inlet and
cylinder
outlet
match.
NEVER
CONNECT
a
regulator
designed
for
a
particular
gas
or
gases
to
a
cylinder
containing
any
other
gas.
Tighten
connections.
When
assembling
threaded
con
nections,
clean
and
smooth
seats
where
necessary.
Tighten.
If
connection
Ieaks,
disassemble,
clean,
and
retighten using
properly fitting
wrench.
Adapters.
Use
a
CGA
adapter
(available
from
your sup
plier)
between
cylinder
and
regulator,
if
one
is
required.
use
two
wrenches
to
tighten
adapter
marked RIGHT
and
LEFT
HAND
threads.
Regulatoroutlet
(or
hose)
connections
maybe
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
pressunzation.
Leave
adjusting
screw
engaged
slightly
on
single-stage
regulators.
Stand
to
side
of
regulator
while
opening
cylinder
valve.
Open
cylinder
valve
slowly
so
that
regulator
pressure
in
creases
slowly.
When
gauge
is
pressurized
(gauge
reaches
regulator
maximum)
leave
cylinder
valve
in
fol
lowing position:
For
oxygen,
and inert
gases,
open
fully
to seal
stem
against possible
leak.
For fuel
gas, open
to
less
than
one
turn to
permit
quick
emergency
shutoff.
Use
pressure
charts
(available
from
your
supplier)
for
safe
and
efficient,
recommended
pressure
settings
on
regulators.
Check
for
leaks
on first
pressurization
and
regularly
there-after~
Brush
with
soap
solution
(capfull
of
Ivory
Uquid*
or
equivalent
per
gallon
of
water).
Bubbles
indi
cate
leak. Clean
off
soapy
water
after
test;
dried
soap
is
combustible.
E.
User
ResponsibilItIes
Remove
leaky
or
defective
equipment
from
service
im
mediately
for
repair.
See
User
Responsibility
statement
in
equipment
manual.
F.
Leaving
EquIpment
Unattended
Close
gas
supply
at
source
and
drain
gas.
G.
Rope
Staging-Support
Rope
staging-support
should
not
be
used
forwelding
or
cutting
operation;
rope
may
bum.
Trademark
of Proctor &
Gamble.
123516
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
nse,
ultraviolet
and
in
frared
energy
radiates,
weidments
are
hot,
and
com
pressed
gases
may
be used.
The
wise
operator
avoids
unnecessary
risks
and
protects
himself and
others
from
accidents.
Precautions
are
described here and
in
stan
dards
referenced in
index.
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
leatherjacketorsleeves,
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 bro
ken,
pitted,
or
spattered.
Flash
goggles
with
side
shields
MUST
be worn
under
the helmet
to
give
some
protection
to
the
eyes
should
the
helmet
not
be lowered
over
the face before
an
arc
is
struck.
Looking
at
an arc
momentarily
with
unprotected
eyes
(particularly
a
high
intensity
gas-shielded
arc)
can
cause
a
retinal bum
that
may
leave
a
permanent
dark
area
in the field of
vision.
3.
Protection
of
Nearby
Personnel
Enclosed
welding
area.
For
production
welding,
a
sepa
rate
room
or
enclosed
bay
is best.
In
open
areas,
sur
round
the
operation
with
low-reflective,
non-combusti
ble
screens
or
panels.
Allow for
free
air
circulation,
par
ticularly
at
floor
level.
Viewing
the weld. Provide
face shields for
all
persons
who
will
be
looking directly
at
the weld.
Others
working
in
area.
See
that
all
persons
are
wearing
flash
goggles.
Before
starting
to
weld,
make
sure
that
screen
flaps
or
bay
doors
are
closed.
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
1-20.
Equipments
rated
capacity.
Do
not
overload
arc
weld
ing equipment.
It
may
overheat cables and
cause
a
fire.
Loose cable connections
may
overheat
or
flash and
cause
a
fire.
Never
strike
an arc
on
a
cylinder
or
other
pressure
ves
sel.
It
creates
a
brittle
area
that
can
cause
a
violent
rup
ture
or
lead
to
such
a
rupture
under
rough handling.
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
Safety
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
123516
Page
4

electrically
HOT
by
stray
current
may
shock,
possibly
fa
tally.
Do
NOT GROUND
to
electrical
conduit,
orto
a
pipe
carrying
ANSi
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
use
holders
with
protruding
screws.
3.
Connectors
Fully
insulated
lock-type
connectors
should
be
used
to
join
welding
cable
lengths.
4.
Cables
Frequently
inspect
cables
for
wear,
cracks and
damage.
IMMEDIATELY REPLACE
those with
excessively
worn
or
damaged
insulation to
avoid
possibly-lethal
shock
from
bared cable. Cables
with
damaged
areas
may
be
taped
to
give
resistance
equivalent
to
original
cable.
Keep
cable
dry,
free
of oil
and
grease,
and
protected
from hot
metal
and
sparks.
5.
Terminals
And
Other
Exposed
Parts
Terminals and
other
exposed parts
of
electrical
units
should have
insulating
covers
secured
before
opera-
tion.
6.
Electrode
a.
Equipment
with
output
on/ott control
(contactor)
Welding
power
sources
for
use
with the
gas
metal
arc
welding
(GMAW),
gas
tungsten
arc
welding (GTAW)
and
similar
processes
nor
mally
are
equipped
with
devices
that
permit
on
off
control
of
the
welding
power
output.
When
so
equipped
the electrode wire
becomes
elec
trically
HOT
when
the
power
source
switch is
ON
and the
welding
gun
switch
is closed. Never
touch
the electrode
wire
or
any
conducting
ob
ject
in
contact
with
the
electrode
circuit
unless
the
welding
power
source
is
off.
-
b.
Equipment
without
output
on/off
control
(no
contactor)
Welding
power
sources
used with
shielded
metal
arc
welding
(SMAW)
and
similar
proc
esses
may
not
be
equipped
with
welding
power
output
on-oft control devices. With
such
equip
ment
the
electrode is
electrically
HOT
when
the
power
switch is turned
ON.
Never
touch the
electrode
unless
the
welding
power
source
is
of f.
7.
Safety
Devices
Safety
devices such
as
interlocks
and
circuit
breakers
should
not
be disconnected
or
shunted
out.
Before
installation,
inspection,
or
service,
of
equipment,
shut
OFF
all
power
and
remove
line
fuses
(or
lock
or
red-tag
switches)
to
prevent
accidental
turning
ON
of
power.
Disconnect
all cables from
welding
power
source,
and
pull
all
115
volts
line-cord
plugs.
Do
not
open power
circuit
or
change
polarity
while
weld
ing.
If,
in
an
emergency,
it
must
be
disconnected,
guard
against
shock
bums,
or
flash
from switch
arcing.
Leaving
equipment
unattended.
Always
shut OFF
and
disconnect all
power
to
equipment.
Power
disconnect
switch
must
be
available
near
the
welding
power
source.
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,
ref
erto
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 Ameri
can
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
5.
ANSI Standard
Z41.1,
STANDARD
FOR
MENS
SAFETY-TOE FOOTWEAR
obtainable
from the
American National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
123516
Page
5

6.
ANSI
Standard
Z49.2,
FIRE
PREVENTION
IN
THE
USE
OF CUTTING
AND
WELDING
PROCESSES
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY 10018.
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
Ad,
Miami,
FL
33126.
8.
NFPA
Standard
51,
OXYGEN-FUEL
GAS SYS
TEMS
FOR
WELDING,
CUTTING,
AND
ALLIED
PROCESSES obtainable
from the
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
9.
NFPA
Standard
70,
NATIONAL
ELECTRICAL
CODE obtainable
from the
National Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
10. NFPA
Standard
51B,
CUTTING
AND
WELDING
PROCESSES
obtainable
from
the
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
11.
CGA
Pamphlet
P-i,
SAFE HANDLING
OF
COM
PRESSED
GASES
IN
CYLINDERS
obtainable
from the
Compressed
Gas
Association,
1235
Jef
ferson Davis
Highway,
Suite
501,
Arlington,
VA
22202.
12.
CSA
Standard
W1i7.2,
CODE
FOR SAFETY
IN
WELDING AND
CUTTING
obtainable
from
the
Ca
nadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1R3.
13.
NWSA
booklet,
WELDING SAFETY
BIBLIOGRA
PHY
obtainable
from the
National
Welding
Supply
Association,
1900
Arch
Street,
Philadelphia,
PA
19103.
14.
American
Welding
Society
Standard
AWSF4.1,
RECOMMENDED
SAFE PRACTICES FOR
THE
PREPARATION FOR WELDING
AND
CUTTING
OF
CONTAINERS
AND
PIPING
THAT HAVE
HELD
HAZARDOUS
SUBSTANCES,
obtainable
from the
American
Welding
Society,
550
N.W.
LeJeune
Ad, Miami,
FL
33126.
15.
ANSI
Standard
Z88.2,
PRACTICE
FOR RESPIRA
TORY
PROTECTION,
obtainable
from the
Ameri
can
National Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
123516
Page
6

SECTION
2
-
INTRODUCTION
.
Input
At
Rated
Load
Output
Rated
Output
Current
Amperes
100%
Duty Cycle
Output
Current
Range
Amperes
Max.
Open-
Circuit
Voltage
50/60
Hz.
Three-Phase
Overall
Dimensions
Weight
 -
Net
Ship
Amperes
At
~~
220V 380V
440V
460V
575V

kva kw
Length
-
48-1/2
in.
1000@80
120-1050
160
284
165 142 136, 109 108
91
(1232
mm)
Width
-
27-1/4
in.
1992
2192
(692
mm)
1500
@40
120-1550 80 218 126
109
104
83 83
72
Height
-
50-3/4
(1319 mm)
includes
3
in.
(76
mm)
for
lifting
eye.
Fig
ure
2
-
1.
Specifications
For
PS-2000
Models
.
Input
At Rated
Load
Output
Rated
Output
Current
Amperes
100%
Duty
Cycle
Output
Current
Range
Amperes
Max.
Open-
Circuit
Voltage
50/60
Hz. Three-Phase
.



~!.____

~30V
380V 440V 460V
575V
kva
kw
Overall
Dimensions
.
Net
Ship
Length
-
48-1/2
in.
500
@
80
70-550
160
156 94
82
78
62
62 36
(1232
mm)
1477 1577
Width
-
27-1/4
in.
(692
mm)
750
@40
60-850
60
112
68
59
56
45
44
46
Height
-
50-3/4
(1319
mm)
Figure
2
-
2.
Specifications
For PS-1005
Models
2
-
1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual and
on
various
labels,
tags,
and
plates
provided
on
this
unit
pertains
to
equipment
design,
installation,
operation,
maintenance
and
troubleshooting
which
should
be
used,
understood
and
followed
for
the
safe
and
effective
use
of
this
equip
ment.
B.
Safety
carefully
followed
could
result in serious
personal
inury
or
loss
of
life.
CAUTION
statements
include
installation,
operating,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed could
result
in
minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
A
third
signal
word,
______________
highlights
instruc
tions which
need
special
emphasis
to
obtain
the
most
efficient
operation
of
this
equipment.
WARNING
and
The
installation,
operation, maintenance,
and
troubleshooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal safety
and
the
safety
of others.
Therefore,
this
equipment
is
to
be
installed,
operated
and
maintained
only by
qualified
persons
in
accordance with this
manual and all
ap
plicable
codes such
as,
but
not
limited
to,
those listed
at
the
end
of
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source.
Safety
instructions
specifically
pertaining
to
this
unit
ap
pear
throughout
this manual
hi~hIiqhted
by
the
signal
words
____________
___________
which
identify
different levels
of
hazard.
statements
include
installation,
operating,
and maintenance
procedures
or
practices
which
if
not
CAUTION
WARNING
2
-
2.
RECEIVING-HANDLING
-
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the unit
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for loss
or
damage
that
may
have
occurred
in
transit
must
be filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
will
be furnished
by
the
manufacturer
on re
quest
if
occasion
to
file claim
arises.
When
requesting
information
concerning
this
equip
ment,
it
is
essential
that
Model
Description
and
Serial
Number of
the
equipment
be
supplied.
2
-
3.
DESCRIPTION
-
This
unit
is
a
direct
current
power
source
with
three-phase
electrical
input.
This
unit
is
designed
for
Plasma
Spraying.
123516
Page
7

SECTION
3
-
INSTALLATION
3
-
1.
LOCATION
t4~A1iIs]~
IMPROPER
LIFTING
OF
EQUIPMENT
can
result
in
personal
injury
and
equipment
damage.

Use
equipment
of
adequate
capacity
to
lift
the
unit.

If
using
llft
forks
to
handle this
unit,
be
sure
the
fift
forks
are
long
enough
to
extend
out
of
the
op
posite
side of
the base.
Using
lift
forks
too
short
will
expose
internal
com
ponents
to
damage
should
the
tips
of
the lift
forks
penetrate
the
bottom
of
the
unit.
RESTRICTED AIR
FLOW
causes
overheating
and
possible
damage
to
internal
parts.

Maintain
at
least
18
inches
(457
mm)
of
unrestricted
space
on
all
sides
of unit and
keep
underside
free of
obstructions.

Do
not
place
any
filtering
device
over
the
intake
air
passages
of
this
power
source.
Warranty
is
void
if
any
type
of
filtering
device is
used.
This
power
source
has
a
lifting
device
for
moving
the
unit
and
holes
in
the base
for
mounting
purposes.
The
location
should
allow
room
to
remove
cover
and
panels
for
maintenance
and
repair
functions.
The
service life
and
efficiency
of
this
unit
are
reduced
when
the
unit
is
subjected
to
high
levels
of
dust,
dirt,
moisture,
corrosive
vapors,
and
extreme
heat.
3
-2.
SECONDARY
CONNECTIONS
-
To
obtain
the full
rated
output
from
this
unit,
it
is
necessary
to
select,
install,
and
maintain
proper secondary
cables.
Failure
to
comply
in
any
of
these
areas
may
result
in
less
than
satisfactory
welding performance.
A.
Secondary
Cables
If
secondary
cables
were
not
ordered
with
this
unit,
the
steps
listed
should
be followed
to
ensure
the
best
per
formance:
1.
Keep
cables
as
short
as
possible
and
place
cables
close
together.
Excessive
cable
length
adds
resistance which
may
reduce
output
or
cause
overloading
of
the unit.
2.
Select
adequate
size
cable for the
anticipated
maximum
secondary
current
with
a
voltage
rating
of
300
volts.
Use
total
length
of
secondary
cable
in
the
circuit
to
determine cable
size.
For
example:
If
the
electrode
holder cable
is 75
feet
(23
m)
long
and the work
cable is 25
feet
(8 m)
long,
select
the
size
cable
recommended
in
Table
3-1 for 100
ft
(31 m).
3.
Do
not
use
damaged
or
frayed
cables.
4.
Install
electrode
holder
to
cable
following
manufacturers
instructions.
An
insulated elec
trode
holder
must
be used
to
ensure
operator
safety.
5.
Install
correct
size
lugs
to
remaining
end
of
elec
trode
holder cable
and
to
both ends
of
work
cable.
6. Install
work
clamp
to
cable.
Table 3-1.
Secondary
Cable
Size
Welding
Amperes,
DC

Total
Length
Of
Cable
Copper)
In
W
eld
Circuit
50 100 150
200 250 300 350
400
100
4
4
2
2 2
1
1/0
1/0
150
2
2
2
1
1/0
2/0 3/0 3/0
200
1
1
1
1/0
2/0
3/0 4/0
4/0
250
1/0
1/0
1/0 2/0 3/0
4/0.
2-2/0
2-2/0
300
2/0 2/0
2/0
3/0
4/0
2.2/0 2-3/0 2-3/0
350
3/0
3/0
3/0
4/0 2-2/0 2-3/0 2-3/0 2-4/0
400
3/0
3/0
3/0
4/0
2-2/0
2.3/0 2-4/0 2.4/0
500
4/0
4/0 4/0
.
2-2/0 2-3/0
2-4/0 500MCM 1000MCM
600
4/0
4/0
2-2/0
2-3/0 2-4/0 500MCM 1000MCM 1000MCM
700 4/0
4/0
2-3/0
2-4/0
500MCM 1000MCM 1000MCM 1000MCM
800
2-2/0
2-2/0 2-3/0 2-4/0 I000MCM
1000MCM
1000MCM 1000MCM
900
2-3/0
2-3/0 2-410 500MCM 1000MCM
1000MCM
1000MCM 1000MCM
1000
2-3/0 2-3/0 2-4/0
1000MCM 1000MCM 1000MCM 1000MCM
1250
2-4/0
2-4/0
500MCM
1000MCM 1000MCM
1000MCM
1500
500MCM
500MCM
1000MCM
I000MCM I000MCM
1750
1000MCM
1000MCM
1000MCM 1000MCM
2000 1000MCM 1000MCM 1000MCM
TA-052
764
123516
Page
8
NOTE:
A.
50
FEET OR
LESS.
B.
CABLE
SIZE
IS
BASED ON
DIRECT
CURRENT
(DC),
100% DUTY
CYCLE
AND
EITHER
A
4
VOLTS
OR
LESS
DROP
OR
A
CURRENT DENSITY OF
NOT OVER
300
CIRCULAR MILS
PER
AMP.
C.
WELD
CABLE
INSULATION
WITH
A
VOLTAGE
RATINGTO WITHSTAND
THE
OPEN
CIRCUIT
VOLTAGE
(OCV)
OF THE
WELDING
POWER
SOURCE
MUST BE
USED.
WHILE
MOST
WELDING
POWER
SOURCES
HAVE AN
OPEN-CIRCUIT
VOLTAGE
OF
LESS
THAN
100
VOLTS.
SOME
WELDING POWER
SOURCES
OF
SPECIAL
DESIGN
MAY
HAVE
HIGH
ER
OPEN-CIRCUIT
VOLTAGE.

1.
Locate
secondary
terminals
on
the
lower
front
panel.
2.
Connect
electrode and work cables
to
the
POSITIVE and
NEGATIVE
output
terminals
to
obtain
the
desired
polarity.
Ensure
that
connec
tions
are
clean
and
tight.
Circuit
Breaker
Remote
Control
Receptacle
j~Negative
Output
~
Terminals
Positive
Output
Terminals
Figure
3-1.
Weld
Output
Connections
3
-
3. OPEN-CIRCUIT
VOLTAGE
CONNEC
TIONS
-
This
unit is
shipped
connected
for 80
open-
circuit
volts.
To
reconnect
the
unit
for
160 volts
open
circuit;
proceed
as
follows:
~
ELECTRIC
SHOCK
can
kill.

Do
not
touch live
electrical
parts.

Shut down
the unit
and disconnect from
line
power
employing
lockout/tagging
procedures
before
attempting
open-circuit
voltage
connec
tion.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect switch
in
open
position,
removing
fuses
from
fuse
box,
or
tagging
circuit
breaker
or
other
disconnecting
device.
1.
Remove
both
side
panels.
2.
Locate
open-circuit
voltage changeover
board
below
center
baffle
and
terminal
strip
1
T
on
front
side
of
baffle
(see
Figure
3-4).
3.
Reposition
the bus
bars
on
the
changeover
board
for 160
open-circuit
volts
as
illustrated
in
Figure
3-2.
4.
Reposition
the
jumper
links
on
terminal
strip
1 T
for 160
open-circuit
volts
ac
illustrated
in
Figure
3-2.
5.
Replace
side
panels.
3
-4.
REMOTE
CONTROL CONNECTIONS
-
This
unit
is
controlled via
a
remote
console.
A
20-socket
receptacle,
located
on
the
front
panel,
is
provided
for
making
connections
between the
remote
control and
the
power
source.
Insert
the
plug
from
the
remote
con
trol
fully
into
the
receptacle
and
rotate
the
locking ring
clockwise.
damage
torch.

Current
transformer
jumper
links
on
terminal
str~p
iT
located
on
center
baffle
must
be
positioned
to
correspond
with
secondary
open-circuit
voltage.
B.
Installation
(Figure
3-1)
WARNING


ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
unit down
and
be
sure
it
cannot
be
acciden
tally
energized
before
making
secondary
connec
tiOns.
115
Volts
AC
Duplex
Receptacle
80
O.C.V.
l'
'l t~ ~I ( ~I
I'
~ ( '1
l@~
@1
CURRENT
TRANSFORMER
JUMPER
800.C.V.
160
O.C.V.
078
p073
~074
079
~~07l
~075
080
(072
…076
~O78
073
074
p079
~0ii
076
080
0
72
076
CAUTION
IMPROPER
SECONDARY
CONNECTIONS
can
Figure
3
-
2.
Open-Circuit
Voltage
Connections
TA-083
843
123516
Page
9

3
-5.
ELECTRICAL
INPUT
CONNECTIONS
Table
3-2.
Input
Conductor
And
Fuse
Size
A.
Electrical
Input Requirements
This
power
source
is
designed
to
be
operated
from
three-phase,
50/60
Hertz,
ac
input
power
which
has
a
voltage rating
that
corresponds
with
one
of
the
electrical
input votages
shown
on
the
nameplate.
Consult
the
local
electric
utility
if
there
is
any
question
about
the
type
of
electrical
system
available
at the installation
site
or
how
proper
connections
to
the
power
source
are
to
be
made.
B.
Matching
the
Welding
Power
Source
To
The
Available
Input
Voltage--Multiple
Voltage
Models
Only
This
unit is
equipped
with
input
voltage jumper
links
on
the
primary
terminal
board
which
allow
operation
from
different line
voltages.
This
unit
is
shipped
with
jumper
links
positioned
for
the
highest
voltage
stated
on
the
nameplate.
If the
unit is
to
be
operated
from
a
lower
in
put
votage,
remove
the
top
cover
and
reposition
the
jumper
links
to
correspond
to
the
available
line
voltage
(see
input
voltage
label
on
primary
terminal
board).
I~L!!LJ~J(
INCORRECT
INPUT
VOLTAGE
JUMPER
LINK PLACEMENT
can
damage
unit.
S
Position
jumper
links
as
shown
on
the
input
voltage
label
located
on
primary
terminal board.
IMPORTANT
ed
terminals.
Store
unused
jumper
links
across
link-
C.
Input
Conductor
Connections
IYLVL~:h~ll~Ier
ELECTRIC
SHOCK
can
kill.

It
is
recommended
that
a
fusible
line
disconnect
switch
be
installed
in the
input
circuit
to
the
power
source.
This would
provide
a
safe and
convenient
means
to
completely
remove
all
electrical
power
from the
power
source
whenever
it
is
necessary
to
internally
inspect
or
service
the
unit.

Employ
lockout/tagging
procedures
on
input
line
before
making
input
connections
to
the
power
source.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
tagging
circuit
breaker
or
other
disconnecting
device.

Connect
input
conductors to
the
power
source
before
connecting
to
three-phase
input
power.
Table
3-2
provides
guidelines
for
selecting
the
proper
size
input
conductors
and
line fuses.
The
input
conduc
tors
should
be
covered
with
an
insulating
material
that
meets
local
electrical
standards.
Attach
terminal
lugs
to
correct
amperage
capacity
to
the
input
and
ground
conductors.
The
hole
diameter
in
the
terminal
lug
must
be
the
correct
size to
fit
the
line
and
ground
terminal
studs.
10501
C
200V
I.
230
Onduoto,
S~
AWG
I
3sov
I
440V 460V
L
sisv
Fiji.
Sios
In
An~ii,s
200v
I
22ovj
360v
I
.~ov 400v
I
350
MCMI
300
MCMI
2/0
1
1/0
I
No.
I
I
No.2
No.
2(
(No.2)
IN0.
~
6)1500.
8LNO.e
500
(
400
250
200 200
175
PS-2000
Models
Inpot
200V 230V
Cofld~jctor So,
-
AWG
F~ie
So.
380V
440V
460V 575V
200V
I
230V
I
380V
In
Anipinen
I
440V
I
460V
I
575V
3)0
2/0 No. 3
No. 4 No.
4
No.
6
(No.4) (No.4) (No.6) (No.8) (No.6)
(No. 8(
250 225
t25
110
ItO 90
PS-1005
Models
*lnput
conductor
sizes
are
based
on
National
Electrical
Code
specifications
for
allowable
ampacities
of
in
sulated
copper
conductors,
having
a
temperature
rating
of
75C,
with
not more
than
three
conductors
in
a
raceway
or
cable.
Numbers in
( ) are
equipment
ground
conductor
sizes.
Insert
the three
input
conductors
plus
one
ground
con
ductor
through
the
access
hole
on
the left side
panel.
This
hole
will
accept
standard
conduit
fittings.
See
Figure
3-4
for
hole location.
WARNING
_________
ELECTRIC SHOCK
can
kill.

Do
not connect
an
input
conductor
to
the
ground
terminal
in
the unit.

Do
not
connect
the
ground
conductor
to
an
input
line
terminal.
Incorrect
input
connections
can
result
in
an
electrically
energized
power
source
chassis.
The
ground
terminal is
connected
to
the
power
source
chassis
and
is
for
groun
ding
purposes
only.
Connect
the three
input
conductors
to
the line terminals
on
the
primary
terminal board and
connect
the
ground
conductor
to
the
ground
terminal. The
remaining
end
of
the
ground
conductor
should
be connected to
a
proper
ground.
Use
a
grounding
method
that is
acceptable
to
the
local electrical
inspection
authority.
Primary
~
Terminal
~
Board
Voltage
Selection
Board
Location
(If
Applicable)
WIth
Jumper
Links
Current
Transformer
~Chan~eover_Strip
iT
/1.
Input
Conductor
Access
Hole
Open
Circuit
Voltage
Changeover
Board
Figure
3-4.
Input
Conductor
Connections
123516
Page
10

SECTION
4
-
OPERATOR
CONTROLS
4-1.
PILOT
LIGHT
(Figure
3-1)
-
The
pilot
light
PL1
is
wired
in
parallel
with
contactor
W coil and
indicates
when
the
contactor
is
energized.
4
-
2.
VOLT-AMPERE
CURVES
(Figures
4-1 and
4-2)
-
The
volt-ampere
curves
show
the
voltage
and
amperage
output capabilities
of
the
power
source
at
mm.
and
max.
of
each
coarse
range.
Voltage
and
amperage
adjustment
within
each
range
is
provided
by
the
Amperage
Adjustment
control.
With
the
use
of
the
volt-ampere
curves
it
is
possible
to
determine
the
load
voltage
at
any
particular
weld
cur
rent.
MODEL
0,
0.
C,
50
PS2O~9)
8-084
009
Figure
4-3.
Duty Cycle
Chart
For
PS-2000
Models
9700
5
607
(30S15 500550)
100
150
U
31 50
00 50
70
5050)50
%DUTYCYCLE
000
900
000
700
600
000
 --
 
6,6,~
~,
645*
(4
0
605
00W
RN~
~-
--
B-084
007
Volt-Ampere
Curves
For
PS-2000
Models
7900

009
9~W
0M~)
60
40
20
00
005
4.315
0N~)
400

70
40
00 60 70 50
90
100
-
ZC,JTYCYD.E
B-118
83
1
Figure
4-4.
Duty
Cycle
Chart
For
PS-i
005
Models
00
C
40
CAUTION:
____
EXCEEDING DUTY CYCLE
RATING
will
damage
the
power
source.

Do
not exceed
duty cycles
indicated
on
duty
cycle
0
00
200
300
400
600 700
000
900
l~ 1100
00
Figure
4-2.
Figure
4-1.
8
chart.
4
-4.
115 VOLTS
AC DUPLEX
RECEPTACLE
(Figure
3-1)
-
The
duplex
receptacle
is
provided
for
running
accessory
equipment. Up
to
10
amperes
of
115
volts
ac,
60
Hertz
power
is
available
at
the
receptacle.
8116832
4
-
5.
OVERLOAD PROTECTION
(Figure
3-1)
-
The
unit
is
protected
from
damage
caused
by
an
overload
by
circuit breaker
CB.
When
an
overload
oc
curs
CB
opens,
dropping
out contactor W
thereby
suspending
output.
CB
must
be
manually
reset.
4
-
3.
DUTY
CYCLE
(Figures
4-3
And
4-4)
-
The
du
ty
cycle
of
a
power
source
is
the
percentage
of
a
ten
The
control
transformers
T2
and
T3
are
protected
by
minute
period
that
the unit
can
be
safely
operated
at a
fuses
Fl, F2,
and
F3,
located
on
the
center
baffle.
If
an
given
output.
These
units
are
rated at
100
percent
duty
overload
occurs,
the
appropriate
fuse
opens,
suspen
cycle.
This
means
that
they
can
be
safely
operated
at
ding
output.
rated
load
continuously.
Figures
4-3
and
4-4 enable
the
operator
to
determine
the safe
output of
each
unit
at
various
duty
cycles.
Volt-Ampere
Curves
For
PS-i
005
Models
IMPORTANT:
Be
sure
the
replacement
fuse is
of the
same
size,
type,
and
rating
as
the
fuse
being
replaced.
123516
Page
11

SECTION
5
-
SEflhI~~
WARNING
_________
ELECTRIC
SHOCK
can
PARTS
can
cause
serious
injury;
IMPROPER
AIR
FLOW AND
EXPOSURE
TO
ENVIRONMENT can
damage
internal
parts.

Keep
all
covers
and
pane/s
in
p/ace
while
operating.
Warranty
is
void if
the
power
source
is
operated
with
any
portion
of the
outer
enclosure
removed.
WARNING
_________
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.

Use
enough
ventilation
to
keep
fumes
and
gases
from
the
breathing
zone.
See Section
1
-
Safety
Rules For
Operation
Of Arc
Welding
Power Source
for
basic
welding
safety
infor
mation.
1. Ensure
that the
unit has
been
installed
as
in
structed
in
Section
3.
2.
Connect
desired
accessory
equipment
to
the 115
VOLTS AC
duplex
receptacle.
3. Set
the
controls
on
the
remote
control.
4.
Energize
the
power
source
and
associated
equip
ment.
Before
shutting
down,
remove
the
load
and allow the
unit
to
idle for
a
few
minutes.
IMPORTANT
SECTION
6
-
MAINTENANCE
WARNING
_________
ELECTRIC
SHOCK
can
kill.

Disconnect
input
power
and
employ
lockout/tagging
procedures
before
internally
inspecting
or
servicing.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
tagging
circuit breaker
or
other
disconnecting
device.
IMPORTANT
______________
Periodically
inspect
the
labels
on
this
unit
for
legibility.
All
labels
must
be
maintained
in
a
clearly
readable
state
and
replaced
when
necessary.
See the
Parts List
for
part
number
of
labels.
6
-
1.
FAN
MOTOR
-
This
unit
is
equipped
with
an
exhaust
fan
and
relies
on
forced
draft
for
adequate
cool
ing.
The fan
motor
is
manufactured
with
lifetime
sealed
bearings
and
requires
no
maintenance.
6
-
2. INTERNAL
CLEANING
-
Occasional
blowing
out
or
vacuuming
of the
dust
and
dirt from
around the
internal
components
is
recommended.
This
should be
done
periodically
depending
on
the location of
the
unit~
and the
amount
of
dust
and dirt in
the
atmosphere.
The~
weld
ing
power
source
outer
enclosure
should
be
remov-~
ed and
a
clean,
dry
airstream
or
vacuum
suction
should
be used for
this
cleaning
operation.
6
-
3.
SPARK
GAPS
(Figure
6-1)
-
It is
necessary
to
readjust
the
spark
gaps every
three to
four
months
or
when
intermittent
operation
occurs.
High-frequency
output
varies
with
the
spark
gap
set
ting.
When
a
great
amount
of
high
frequency
is
necessary,
the
spark
gaps
can
be
adjusted
to
0.010 in.
to
0.013 in.
(0.254
to
0.330
mm).
This,
however,
in
creases
high-frequency
radiat~on
which
increases
in
terference
with communications
equipment.
IMPORTANT
_____________
Do
not
clean
or
dress the
points
of
the
Spark
gaps
because
the
material
at
the
points
is
tungsten
and
is
impossible
to
file.
Rep/ace
the
entire
point
when
the
tungsten
section
has
completely
disap
peared.
The
high
frequency
panel
is
located
behind
the
left
side
panel.
To
adjust
the
spark
gaps,
proceed
as
follows:
1.
Loosen
screws
A
on
both
sides.
2.
Place
feeler
gauge
of
proper
thickness
between
points
C.
3.
Apply
slight
pressure
against
points
B
so
feeler
gauge
is
held
firmly
in
gap.
4.
Tighten
screws
A.
Figure
6-1.
Spark
Gap
Adjustment
TA-020
623-A2
123516
Page
12

SECTION
7
-
TROUBLESHOOTING
WARNING
_________
ELECTRIC
SHOCK
can
kill.

Do
not
touch
live
electrical
parts.

Disconnect
unit
from
input
power
before
internal
ly
inspecting
or
servicing.
MOVING
PARTS
can
cause
serious
injury.

Keep
clear
of
moving
parts.
HOT SURFACES
can
cause
severe
burns.

Allow
cooling
period
before
servicing.
Troubleshooting
of
internal parts to
be
performed
only
by
qualified
persons.
The
following
chart
is
designed
to
diagnose
and
provide
remedies for
some
of the
troubles
that
may
develop
in
this
power
source.
It
is
assumed
that
proper
installation
has
been
made,
ac
cording
to
Section
3 of this
manual,
and
that
the
power
source
has
been
functioning
properly
until
this
trouble
develped.
Use this
chart
in
conjunction
with
the
circuit
diagram
while
performing
troubleshooting
procedures.
If
the
trouble is
not
remedied after
performing
these
pro
cedures,
the
nearest
Factory
Authorized Service
Sta
tion
should
be
contacted.
In
all
cases
of
equipment
malfunction,
the
manufacturers
recommendations
should
be
strictly
followed.
TROUBLE PROBABLE
CAUSE
REMEDY
inoperative.
No
power
output.
Check
position
of line
disconnect switch.
Open
line
fuse(s)
and/or
circuit
breaker(s).
Replace
the
fuse(s)
and/or
reset
circuit
breaker(s).
~
Poor
and/or
improper
input
connections.
Refer
to
Section 3-5 for
proper
input
connections.
Poor
or
improper
Remote
Control
connections.
Check
remote
control
connections
(see
Section
3-4).
Printed
circuit card PCi
il-i-
operative
or
loose
in
edge
connector.
Check
printed
circuit
card PCi
connection.
If
PCi
loose
in
connector, tighten.
If PCi
inoperative,
replace.
and
low
Operation
on
single-phase.
voltage. Open
line fuse
on one
phase.
Poor
and/or
improper
input
and/or
secondary
connec-
tions.
Check
incoming
three-phase
power
for
correct
voltage.
Replace
fuse
if
open.
.
Refer
to
Section
3-5
and
3-2
for
proper
input
and
secondary
connections.
~
Incorrect
secondary
cable
size.
Use
proper
size
and
type
of cable. See
Section
3-2.
Loose
secondary
cable
con-
nection.
Tighten
all
welding
connections.
SCR
in
main
rectifier SRi.
Replace
SCR.
Printed
circuit
card
PCi.
Replace
printed
circuit
card
PCi.
123516
Page
13

I
4~
V0T9
04Y
.POSFTIVE
T5
N
P
U
1-29/PIG2
Circuit
Diagrm
No.
SC-i
56
507-A
FIgure
7-1.
Circuit
Diagram
For
P5-2000
Models

a
a

0)
Circuit
Diagram
No.
SC-i
56
506-A
FIgure
7-2.
CIrcuit
Diagram
For
PS-i
005
Models

Circuit
Diagram
No.
A-098 879
Figure
7-3.
Primary
Circuit
Diagram
For PS-2000
And
PS-i
005
Models
THIS
PRIMARY
REPLACES
THAT ABOVE
123516
Page
16