Miller Two Fifty Twin User manual

August
1973
FORM:
OM-313
Effective
with
serial
No.
72-61
2483
MODEL
Two
Fifty
Twin
Two
Fifty
Twin-P
STOCK
NO.
901 973
901 976
ADDITIONAL
COPY
PRICE 60
CENTS
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
OWNERS
MANUAL
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
NWSA CODE
NO. 4579
U.S
...

TABLE
OF CONTENTS
Paragraph
No.
Page
No.
SECTION
1

SAFETY RULES
FOR
OPERATION OF ARC WELDING MACHINE
1-1.
General
1
-2.
1
-3.
1
-
4.
1
-5.
1
-
6.
1-7.
1
-
8.
1
-
9.
1-10.
1-11.
1-12.
1-13.
Welding
Cables
Electrode Holder
Code
Conformance
Parallel
Connections
Power
Disconnect
Switch
Polarity
Switch
Range
Switch
Exhaust Gases
Power
Circuit Ground
Containers
Which
Held Combustibles
Hollow
Castings
(Welding
of)
Explosion
Hazards
1-14.
Ventilation
1-15. Solvents
1-16.
Fire
Hazards
1-17.
Electrical
Shock-Voltage
1-18.
Electrical
Shock-Dampness
1-19.
Starting
Under
Load
1-20.
Face Protection
1-21.
Eye
Protection
1-22.
Clothing
1-23.
Hot
Metal
Burns
1-24.
Grinding
and
Chipping
1-25.
Compressed
Gas
Cylinder
SECTION
2
INTRODUCTION
2-1.
2
-
2.
2
-
3.
2
-4.
SECTION
3
3-1.
3
-
2.
3
-
3.
1
1
1
1
1
1
1
1
1
2
2
2
2
2
3
3
3
3
3
3
3
4
4
4
4
5
.5
5
5
5
5
6
6
7
7
8
8
8
8
8
9
9
9
General
Receiving-Handling
Description
Safety

INSTALLATION
Line Disconnect
Switch
Location
Primary
Connections
3
-
4.
Secondary
Welding
Connections
SECTION
4
OPERATION
4
-
1.
Range
Selector
Switch
4-2.
Fine Current Control
& Current
Indicator
4
-
3.
On-Off
Power
Switch
4
-
4.
Duty
Cycle
4
-
5.
Volt-Ampere
Curve
SECTION
5

SEQUENCE
OF
OPERATION
5
-
1.
Shielded Metal-Arc
Welding
(SMAW)
SECTION
6
MAINTENANCE
6
-
1.
Power Factor
Correction
Capacitors
6
-
2.
Transformer
6
-
3. Fan
Motor
6
-
4.
Input
Power
&
Welding
Cables
SECTION
7
TROUBLESHOOTING
PARTS
LIST

SECTION 1-
SAFETY
RULES
FOR
OPERATION
OF ARC
WELDING
MACHINE
1
-
1.
GENERAL
These
rules
apply
to
ac
and
dc
welding
generators.
ac
trans
former
and
ac/dc
welding
machines,
and
dc
transformer
recti
fier
welding
machines.
In
arc-welding
operations,
where
electrically
energized
parts
are
exposed,
observe
the
following
safety
rules
to
insure
max
imum
personal
safety
and
protect
nearby
persons.
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
maxi
mum
assurance.
1
-2.
WELDING
CABLES
Figure
1-1.
Dont
overload
cables
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.
)Figure
1-2)
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
improved
by
elimination of
these
dangerous
grounds,
and
by
keeping
connections
tight.
1
-
3.
ELECTRODE HOLDER
DONT
use
electrode holders with
defective
jaws.
(Figure
1-3)
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
wob
ble,
making
control
of
the
welding
operations
difficult.
Figure
1-3.
Dont
use
Electrode Holder with
defective
jaws
DONT
use
electrode
holder
with
loose cable
connections.
Keep
the
connections of
the electrode lead
to
the holder
tight
at
all
times.
Use
only
fully
insulated
electrode
holders
(and
without
pro
truding
screwheads.)
Never touch
two
electrode holders
from
two
separate
welding
machines
at
the
same
time.
1
-4.
CODE CONFORMANCE
The
machine
and
its
equipment
must
be installed and main
tained in
accordance
with
the
National Electrical
Code and
local
requirements.
1
-5. PARALLEL
CONNECTIONS
See
diagrams
in the
instruction
manual
applying
to
the
weld
ing
machine used.
1
-
6. POWER
DISCONNECT
SWITCH
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.
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
5
open.
The
potential
dan
gers
of
opening
the
Circuit while
carrying high
current
are:
1.
An
arc
will
form between
the
contact
surfaces of the
switch
and
severely
burn
them.
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.
The
range
switch
lwhen
supplied)
is
provided
for
obteining
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.
The
potential
danger
of
switching
the
Circuit
while
carrying high
current
is the
formation
of
an arc
be
tween 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
vent
ing
the
exhaust
gases.
)Figure
1-4)
If
gasoline
or
other fuel
driven
welding
machines
are
operated
indoors,
provide
means
to
pipe
the
exhaust
gases
to
the
Out
side air
to
avoid
carbon
monoxide
poisoning.
DONT
overload
cables,
(Figure
1-1)
Figure
1-2.
Dont
use
worn or
poorly
connected
cables
OM-313
Page
1

Figure
1-4.
Vent
exhaust
gases
1-10.
POWER
CIRCUIT
GROUND
DONT
use
welding
machine
without
grounding
frame
or
case.
(Figure
1-5)
Figure
1-5.
Ground frame
or
case
Ground
the
ground
cable
of
every
power
Circuit
to
prevent
accidental shock
by stray
current.
The
potential
danger
is
that
development
of
a
stray
current
may
give
a
fatal
shock
should
a
person,
for
example, place
one
hand
on
the
welding
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 conduc
tors. Be
sure
conductors
can
safely
carry
the
ground
current.
When
connecting
the
welding
machine,
properly
ground
the
machine frame
or
case.
1-11. CONTAINERS
WHiCH
HELD
COMBUSTIBLES
DONT
weld
on
containers
which have
held combustible
or
flammable materials
or
materials
which,
when
heated,
give
off
ftammabte
or
toxic
vapors
without
proper
cleaning,
purg
ing,
or
inerting.
Welding
containers which have held flammable
or
combust
ible
materials
may
be
extremely
dangerous.
To
prevent
a
fire
or
explosion
of
the
container,
follow
the
recommendations
of the American
Welding
Society
Pamphlet
A6.O
Welding
or
Cutting
Containers Which Have
Held
Combustibles.
DONT
depend
on
your
eyes
or
nose
to
decide
if
it
is
safe
to
weld
on
a
closed container.
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.
When
you
know
the
container
held
a
gas
or
liquid
which
will
readily
dissolve
in
water:
1.
Flush
out
with
water
several
times and then
fill
with
water
as
far
as
work
permits,
positioning
container
to
permit
introduction of
as
much water
as
possible.
2.
Before
welding
be
sure
there
is
a
vent
or
opening
to
pro
vide for release
of air
pressure.
When
you
know
the
container
held
a
gas
or
liquid
which will
not
readily
dissolve
in
water:
1.
Clean
out
thouroughly
with
steam
or
a
cleansing
agent
and
purge
all air
or
inert
with
a
gas
such
as
carbon
dioxide
or
nitrogen
before
repairing.
Carbon
dioxide
is heavier
than air
and
will
tend
to remain
in
the container
if the
opening
is
at
the
top.
2.
Use
steam
to clean
out
light
material,
3. Use
a
strong
caustic
soda
solution to clean
out
heavy
oils
or
grease.
4.
Be
sure
to
purge
all
air
or
inert
with
a
gas,
such
as
nitro
gen
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.
Be
careful
when
cleaning
with
steam
or
caustic
soda
wear
goggles
and
gloves.
DONT
clean
where
there is
poor
ventilation.
Ventilation
is
necessary
to
carry away
harmful
or
explosive
vapors.
DONT
clean where there
are
open
flames.
When
scraping
or
hammering
to
remove
heavy sludge
or
scale,
use
a
spark
resistive
tool
and
keep
it wet
to
avoid
sparks.
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.
(Figure
1-6)
Figure
1-6.
Dont
weld
on
hollow
(cored)
castings
1-13.
EXPLOSION
HAZARDS
NEVER
weld
in
or
near
explosive
atmospheres.
Such
atmos
pheres
can
be
created
by
flammable
gas
leaks
or
by
vapors
from
flammable
liquids
(gasoline,
alcohol,
etc.)
or
by
com
bustible dusts.
1.14.
VENTILATION
DONT
weld
in
confined
spaces
without
adequate
ventilation.
When
welding
in
confined
spaces,
provide
ventilation
in
accordance
with
United States of
American
Standard
Z49.1,
1967.
Always provide
adequate
ventilation
by
blowers,
air
lines,
or
other
acceptable
means:
Never
use
compressed
ox
ygen.
The
depletion
of
the
oxygen
supply,
the
heat
of
weld
ing,
and
the fumes
given
off
may
cause severe
discomfort
or a
serious
illness.
When toxic
fumes from
lead
or
cadmium
bearing
materials
or
any
other
substances
are
present
in
harmful
concentrations,
always
use
an
air
supplied
respirator.
-~
______---
S
I
/
Page
2

1-15.
SOLVENTS
Do
not
weld
where
chlorinated
hydrocarbon
vapors
from
de
greasing,
cleaning,
or
spraying
may
reach
or
be drawn into air
surrounding
the
welding
operation.
The heat of
the
arc
can
decompose
solvent
vapors
to
form
phosgane,
a
highly
toxic
gas
and
other
irritating
decomposition
products.
Do not
weld
where ultraviolet
light
from the electric
arc can
penetrate
air
containing
even
minute
amounts
of
vapors
from
~olvents
such
as
trichloroethylene
or
perchloroethylene.
Ul
traviolet
light
can
decompose
the
vapors
to
form
phosgene,
a
highly
toxic
gas
and other
irritating products.
1-16. FIRE
HAZARDS
electrode
on
the
table
top
or
in
contact
with
a
grounded
metallic
surface.
(Figure
1-7)
When it
is
not
in
use,
never
place
an
electrode holder
in
contact
with
the
tabletop
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
excessive
load
on
the
ma
chine and
may
damage
the
insulation.
1-20.
FACE
PROTECTION
DONT
use
cracked
or
defective helmets
or
shields.
DONT
weld
near
flammable
or
combustible materials.
Fires
can
be
caused
by
the
arc,
by
contact
with
the
heated
metal,
by
slag,
or
sparks. Keep
combustibles
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
par
tition
walls
in
contact
with
combustibles.
Heats metal
on
the other side of
partition
wall
being
weded
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
extinguishing
equipment
for
at
least
one-half
hour
after
the
welding
is
completed.
1-17.
ELECTRICAL
SHOCK-VOLTAGE
OPEN
power
circuits before
checking
machines.
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.
However,
all
of
these
voltages
are
capable
of
developing
a
harmful
or
fatal
current
to
the
body.
DONT touch
electrically
hot
parts.
NEVER
touch
any
exposed
or
non-insulated
part
of
the
cables,
cable
connectors, clamps,
electrode
holders,
elec
trodes,
or
the
power
supply equipment
to
prevent
harmful
or
fatal
electric shock
or
burns.
1-18.
ELECTRICAL
SHOCK-DAMPNESS
NEVER work
in
a
damp
area
without
suitable
insulation a
gainst
shock.
Keep
hands,
feet,
and
clothing dry
at
all times.
To.prevent
harmful
body
shocks, keep hands,
feet
and
cloth
ing
dry.
Never
stand
or
lie in
puddles
of
water,
damp
ground,
or
against
grounded
metal
when
welding
without
suitable
in
sulation
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
energized
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
lowers
contact
resistances.
Figure
1-7,
Dont
leave electrode
in
contact
with
grounded
metallic surface.
Keep
the
helmet,
hand
shields,
or
face shield
in
good
condi
tion.
If
cracks
occur
in the fibre
material, replace
the
shield,
since
the
leakage
of
arc
rays may
cause
serious
burns.
1-21. EVE
PROTECTION
NEVER under
any
circumstances,
look
at
an
electric
arc
without
eye
protection.
Make
sure
that
flash
goggles
are
used under
the weld
ing
helmet at
all
times,
particularly
while
gas
shielded-
arc
welding.
In
some
type
of
arc
welding,
such
as
gas
shielded-arc
welding,
ultra-violet and infra-red 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.
NEVER
strike
an arc
without
ascertaining
that
nearby
per
sons
either have
the
necessary
protective
equipment
or are
looking
in the
opposite
direction.
For
welding
operations
in
open
areas,
provide portable,
non-
ref
Iecting
screens
to
shield
persons
nearby
from
the
rays
of
the
arc.
Eye
burns
from
the
arc,
through
not
generally
per
manent
injuries,
are
exceedingly
painful.
Such burns fre
quently
referred
to
as
flashes,
feel
like hot sand
in
the
eye.
If
the
eye
is
focused
on
the
arc
without
filter-glass
protec
tion,
infra-red radiation
can cause
retinal
scarring
and
im
paired
vision. For
eye burns
consult
your
first
aid
station
or
doctor.
NEVER
use
cracked,
ill-fitting,
or
defective
plates.
The
filter
glass
plate provided
in the helmets and
shields
must
be of
reputable
manufacture
conforming
to
the
latest
Ameri
can
National
Standards
Institute,
Standard
Z2.1.
Replace
cracked
or
ill-fitting
filter
plates
promptly.
NEVER
use
filter
plates.without
a
protecting
cover
glass.
Figure
1-8,
Use
eye
protection
at
all times
I
I
U
I
1-19.
STARTING
UNDER LOAD
DONT
leave
an
uninsulated
electrode
holder,
or a
live
OM-313
Page
3

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
clothing.
Wear
heavy shoes,
tightly
laced.
Keep
clothing
dry.
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
obstruct
the
rays
of
the
arc
and,
when
necessary,
insulate the
body
from
harmful electri
cal
currents.
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
in
tense ultra-violet
rays
given
of f
by
the
process.
Avoid
cotton
fabrics
when
gas
shielded-arc
welding.
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
gallon
of
water,
then
wrun9
out
and
dipped
in
a
solution
of
1/4
pound
ammonium
sulphate
per
gallon
of
water.
Dont
wash
clothing
so
prepared
in
water,
but
dry
clean.
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
pieces
of
metal
which
have
just
been welded
or
heated,
or
the
stub
ends
of electrodes
which have been
discarded.
1-24.
GRINDING
AND
CHIPPING
NEVER
do
any
chipping
or
grinding
without
protective
goggles.
(Figure
1-10)
Whenever
it is
necessary
to
grind
or
chip
metal,
wear
protec.
tive
goggles
specifically
designed
for this
purpose.
Serious
eye
injuries may
result
from
failure
to
wear
protective goggles.
1-25.
COMPRESSED
GAS
CYLINDERS
NEVER strike
an arc on a
compressed
gas
cylinder.
Always
observe the
following
precautions
in
regards
to
compressed
g~
cylinders:
1.
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.
2.
Use
I.C.C.
or
DOT.
cylinders. They
are
manufactured
and
maintained
in
accordance with
DOT.
require
ments
and
are
safe
so
long
as
they
are
properly
hayidled.
Dont
drop
cylinders.
3. Identify
gas
content
by
the
name
marked
on
the
cylin
der.
If
the
cylinder
is
unmarked,
do
not
use
it.
Return
it
to
the
supplier.
Do
not
rely
on
a
color code.
4.
Never
use a
cylinder
or
its
contents
for
other
than
intended
purposes.
5.
Keep
oil and
grease
away
from
oxygen
cylinders
and
cylinder
valves.
6.
Keep
cylinders
away
from
exposure
to
sparks,
hot
slag,
open
flame
and all
possible
sources
of
ignition
or
excessive
heat.
7.
Be
careful
that
cylinders
are
not
placed
so as
to
be
come
a
part
of
an
electrical
circuit.
Avoid third
rails,
wires
and
electric
welding
circuits.
8.
When
transporting
cylinders
by
crane,
use
cradle
plat
form
or
other
suitable
support.
9.
Never
lift the
cylinders by
slings,
by
the
caps
or
by
electric
magnets.
Never
use
cylinders
as
supports
or
rollers.
Never
try
to
mix
any
gases
in
a
cylinder.
Never
try
to
refill
a
cylinder.
Mark
or
tag
empty cylinders
Empty
or
MT.
Send
Emptys
back
to
the
supplier
promptly.
15,
15.
Keep
Emptys
and
Fulls
separate.
16.
Never
tamper
with
or
alter
cylinder
numbers
or
other
markings.
This is
not
only
foolish
but
may
be
illegal.
Do
not
tamper
with
or
change
fittings
on
cylinders.
If
valves
cannot
be
opened by
hand,
do
not
use
ham
mer
or
wrench.
Notify
supplier,
19.
Protect
cylinder
valves from
bumps, falls,
falling
ob
jects,
and
from
weather.
Keep
them covered with
cylinder
caps
when
moving cylinders.
Keep
valves closed
on
empty
cylinders.
See
that
your
cylinders
are
clear
of
passageways
and
active
work
areas
and
that
they
are
secured
against
falling,
22.
If
adapter
is
required
between
cylinder
and
regulator,
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.
23.
Do not
store
cylinders
in
unventilated
areas.
NEVER
pick
up
hot
objects. (Figure
1-9)
10.
11.
12.
13.
14.
Figure
1-9.
Never
pick
up
hot
objects
17,
18.
20,
21.
Figure
1-10.
Never do
any
chipping
or
grinding
without
protective
goggles.
Page
4

SECTION
2-INTRODUCTION
Model
Welding
Current
Ranges
Amperes
Mao.
Open
Ciruuit
Vollugo
Rated
Wsldieg
Current
Amperes
Amperes
Input
At
Ruled
LoS
Output
60Hz.

208)260
Vults
230
Volts
460
Volts hoe
kw
Ooerull
Oimensions
Inches)
.
Weight
Net
Ship
Without
Power
Poctor
Correction
With
Power
Pector
Correction
ec
Low
25-125
High
105-325
dc
Low
20-88
High
70-250
oc
78
dc
75
250W
30
Volts,
30%
Outy
Cycle
103
90
45
20.7
11.8
.
~
H ht
-
26-1/4
Wdth
-
15
0
th
25
~-
.
332

340
342

350
200
@
28
Volts,
50%
Ooty
Cycle
go
io
65
35
34
16.1
8.2
25051
30
Volts.
30%
Ouly Cycle
78
15.6
11.8
20051
28
Volts,
50%
Outy Cycle
~y
5~
25
11.5 8.2
~NEMA RATIN~jthe
above electrical
specifications
Conform
with
Nema
Rating
EW
1-1971,
Nema
Class
11(30)
and
comply
with ANSI
Standard
C87.1-1971.
Figure
2-1.
Specifications
This
manual
has been
prepared
especially
for
use
in
familiar
izing
personnel
with the
design,
installation,
operation,
main
tenance, and
troubleshooting
of this
equipment
All
information
presented
herein
should
be
given
careful
con
sideration
to
assure
optimum
performance
of this
equipment
Prior
to
installing
this
equipment,
clean all
packing
material
from around
the unit and
carefully
inspect
for
any
damage
that
may
have occurred
during
shipment. Any
claims for
loss
or
damage
that
may
have occurred
in
transit
must
be
filed
by
the
purch~er
with the
carrier.
A
copy
of the bill of
lading
and
freight
bill
will
be furnished
by
the carrier
on
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equipment,
it is
essential that
M0%Jel
Designation
and/or
Stock Number and
Serial
(or
Style)
Number
of the
equipment
be
supplied.
This
unit is
a
single
phase
powered welding
power
source,
which
produces
both
ac
and
dc
welding
current.
This
welding
power
source
is
capable
of
operation
on
either
200,
230
or
460
volt
60
Hertz
primary
electricel
power.
Jumper
links
are
provided
with the
welding
power
source
for
the
purpose
of
matching
the
machine
to
one
of
the above
available
input voltages.
AA-gol g73-4
Before
the
equipment
is
put
into
operation,
the
safety
sec
tion
at
the front of this manual should be read
completely.
This
will
help
avoid
possible
injury
due
so
misuse
or
improper
welding
applications.
The
following
definitions
apply
to
CAUTION,,
IMPORTANT,
and
NOTE
blocks found
throughout
this
manual:
Installation,
operating,
and
maintenance
procedures,
practices,
etc.,
which
will
result
in
personnel
injury
or
~.
loss of
life if
not
carefully
followed.

I
Installation,
operating,
and
maintenance
procedures,
practices,
etc.,
which
will
result
in
damage
to
equip-
men
t.
Proper
installation
can
contribute
materially
to
the
satisfac
tory
and
trouble-free
operation
of
the
welding
power
source.
It
is
suggested
that each
step
in
this section
be
studied
care
fully
and
followed
in
detail.

Installation,
operating,
and
maintenance
procedures,


practices.
etc.,
which
it is
essential
to
emphasize
3-1.
LINE
DISCONNECT
SWITCH
SECTION
3
-
INSTALLATION
CAUTION
I
A
precautionary
measure
should
be
toprovide
maximum
protection against
electrical shock. Before
electrical connections
are
made from
the
switch,
be
sure
that the
line
disconnect
switch has
been
opened
or
the
primary
input
circuit fuses
have
been removed
and
remain that
way
until
the
installation has been

completed.
.
Proper
installation
can
contribute
materially
to
the satisfac
tory
and trouble.free
operation
of
the
welding
machine.
It
is
suggested
that
each
step
in this
section
be
studied
carefully
and followed
in
detail.
3-2. LOCATION
A
good
installation
is
essential
if
the
welding
power
source
is
to
provide
satisfactory
and
dependable
service.
2-1.
GENERAL
Figure
2-2.
Block
Diagram
24. SAFETY
2-2. RECEIVING-HANDLING
2-3. DESCRIPTION
I
NOTE
OM-313
Page
5

~ldi
ng
p
owe
r
~e
should be
loca ted
so
that
the front
and
rear
panels
with the
air
vents
are
clear
of
any
obstruction.
Cooling
air is
drawn
in
through
the
front
upper
air
vent and
expelled
Out
of the
rear
panel
air
vent.
The
location should be such
that
a
minimum
amount
of dust
and dirt
will
be drawn
into
the air
stream.
Preventive
main
tenance
consists
of
removing
the
wrapper
from
the
welding
power
source
and
blowing
Out
the dust
accumulation
inside
the unit. For
this
reason
it is
desirable
to
locate the unit
so
that
the
wrapper
can
be
removed without
any
difficulty.
This
ac/dc
arc
welding
power
source
is
a
single
phase
unit
and
must
be
connected
to
a
single phase
power
line.
Consult
the
local
public
electric
utility
if
there
is
any
question
about the
system
used
locally
or
the
proper
connections
necessary
to
connect
single phase
power
service
to
the
welding
power
source.
NOTE

It
is
recommended
that the
primary
leads be
of
the
heavy
rubber
covered
type
or
run
in
solid
or
flexible
conduit. Select
the
proper
size
primary
fuse
and
cable
from
Table 3-1.
Table
3-1.
Primary
Wire
and
Fuse
Size
PRIMARY
WI
RE SIZE
IAWGI
FUSE SIZE
IN
AMPERES
MODEL 200V
230V
460V 57Ev 200V 230V
460V
57EV
WIhoot
P,F.C.
No.
2
No.2
No.6
No.8 150 150
70
60
With P.F.C.
No. 3
No.4
No.8
No. 10 125
100 50
40
18) (8) (8) (8)
Numbers
in
(I
indicate
ground
wire
size.
Insert
the
two
primary
leads
plus
one
ground
lead
through
the
access
hole
provided
on
the
lower
left
portion
of
the
rear
panel.
See
Figure
3-2
for
hole
location.
This
1-3/4
inch
dia
meter
hole will
accept
standard
conduit
fittings.
The
two
primary
leads
are
to
be
connected
to
terminals Li
and
L2
on
the
primary
terminal board
(TEl),
which
is
located behind
the
primary
access
door
on
the
rear
panel.
The
ground
lead
must
be connected
to
the
stud
on
the
pri
mary
terminal
board labeled GAD. The
remaining
end
of
the
ground
lead
should
be connected
to
a
suitable
ground
such
as:
a
water
pipe, ground
rod,
etc.
Use
whatever
grounding
means
is
acceptable
to
the
local electrical
inspection
authority.
.
The stud
labeled
CR0
is
connected~
welding
power
source
chassis
and
is
for
grounding
purposes
only.
Do
not
connect
a
wire
from
the
terminal labeled
GAD
to
either
one
of
the
single phase
line terminals
as
this will
result
in
an
electrically
hot
welding
power

source
chassis.
The
standard
welding
power
source
is
designed
to
operate
on
either
200,
230
or
460
volts,
60
Hertz
primary
electrical
power.
This
machine
was
shipped
from
the
factory
with
the
jumper
links
arranged
for
the
highest voltage
the
machine has
been
designed
to
operate
on.
To
setup
the
welding
power
source
for
the
voltage
to be
used,
position
the
jumper
links,
located
on
the
primary
terminal
board,
as
shown
in
Figure
3-3.
200
(208)
VOLTS
230
VOLTS
460
VOLTS
~oo~
o~o oo~~
0
00
00
0. 00 0
GA.
LI 17
Gfl
LI 12
60
II
17
A-OlO
586
Figure
3-3.
Primary
Voltage
Jumper
Link
Arrangement
~ver
on
ly
a
ne
umper
link
con
nection
is
nec
essary
to
obtain
the
proper
input
voltage
connections,
such
as
460
volts,
connect
both
jumper
links
across
the
same
two
terminals.
This
will
prevent
losing
the
second
jumper
link.
It
is
recommended
that the
welding
cables
be
kept
as
short
as
possible,
placed
close
together
and
be
of
adequate
current
carrying
capacity.
The
resistance
of the
welding
cables and
connections
cause a
voltage drop
which
is
added
to
the
volt
age
of
the
arc.
Excessive cable
resistance
may
result
in
over
loading
as
well
as
reducing
the
maximum
current
output
of
which the
welding
power
source
is
capable.
The
proper
operation
of
any
arc
welding
power
source
is
to
a
great
extent
dependent
on
the
use
of
welding
cables and
connections
that
are
in
good
condition
and
of
adequate
size.
An
insulated
holder
must
be used
to
ensure
the
operators
safety.
Id
in
gw~h
ac,
if
the
cables
a
re
coiled
up
they
will
generate
a
magnetic
field that will seri
ously
affect the
operation
of
the
welding
power
source.
Always
lay
the
welding
cables
out.
PRIMARY CABLE
INPUT HOLE
PRIMARY VOLTAGE
JUMPER
LINKS
3-3/8
LINE
DISCONNECT
SWITCH
GROUND
CONNECTION
Figure
3-2.
Primary
Connections
AC-901 973.3
Figure
3-1, Dimensional
Drawing
3-3.
PRIMARY
CONNECTIONS
3-4. SECONDARY
WELDING
CONNECTIONS
Page
6