Download Miller Electric SCM-5A Specifications

Miller
September
FORM: OM-126853A
1989
Effective With Serial No. JJ401061..
MODEL: ARC PAKIM 350
Manufactured For
OWNERS
Chicago Bridge
& Iron
MANUAL
IMPORTANT: Read and understand the entire contents of this manual, with
special emphasis on the safety material throughout the manual, before
installing, 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
MILLER ELECTRIC MfcI. Co.
-
AMrnGfG(O~OLtd.CO~Y
P0 Box 1079
.Appleton, WI 54912 USA
Tel. 414-734-9821
understand these instructions.
PRINT~D IN U.S.A
I
-J
LIMITED WARRANTY
EFFEC1IVE:
This warranty
supersedes all previous
LIMITED WARRANTY
MARCH 15, 1989
MILLER warranties and is exclusive with no.other guarantees
Subject to the terms and conditions
hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants
to its Distributor/Dealer that all
new and unused Equipment fur
nishedby Miller is free from defect in workmanship and material
as of the time and place of delivery by Miller. No warranty is
made by Miller with respect to engines, trade accessories or
other items manufactured by others. Such engines, trade ac
cessories and other items are sold subject to the warranties of
their respective manufacturers, if any. All engines are war
ranted by their manufacturer for one year from date of original
purchase, except Tecumseh and Onan engines which have a
two
year warranty.
Except as specified below, Millers warranty does not apply to
components having normal useful life of less than one (1) year,
such as spot welder tips, relay and contactor points, MILLER-,
5MA11C parts that come in contact with the welding wire includ
nozzles and nozzle insulators where failure does not result
from defect in workmanship or material.
ing
Miller shall be required to honor warranty claims on warranted
Equipment in the event of failure resulting from a defect within
the following periods from the date of delivery of Equipment to
the original user:
1.
Arc welders, power sources, robots, and
1 year
2.
components
Load banks
3.
Original
4.
5.
6.
7.
All welding guns, feeder/guns and torches
90 days
All other Millermatic Feeders
1 year
Replacement or repair parts, exclusive of labor 60 days
Batteries
6 months
(labor
main power rectifiers
1 year only)
provided that Miller is notified in
the date of such failure.
As a matter of general
submitted by the original
writing within thirty (30) days of
MiHer may honor daims
within the foregoing periods.
policy only,
user
1 year
3 years
or
warranties
expressed or implied.
In the case of Millers breach of warranty or any other duty with
to the quality of any goods, the excluswe remedies
therefore shall be, at Millers option (1) repair or (2) replacement
or, where authorized in writing by Miller in appropriate cases, (3)
the reasonable cost of repair or replacement at an authorized
Miller service station or(4) payment of or credit for the purchase
price (less reasonable depreaation based upon actual use)
upon return of the goods at Customers risk and expense.
MILLERsoption of repairorreplacenientwill be F.O.B.. Factory
at Appleton, Wisconsin, or FOB. ata MILLER authorized serv
ice facility, therefore, no compensation for transportation costs
of any kind will be allowed. Upon receipt of notice of apparent
defect or failure, Miller shall instruct the claimant on the war
ranty claim procedures to be followed.
respect
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTV GUARANTY OR REPRE.
SENTAT1ON AS TO PERFORMANCE, AND ANY REMEDY
FOR BREACH OF CONTRACT WHICH, BUT FOR THIS PRO
VISION, MIGHT ARISE BY IMPLICATION, OPERATION OF
LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN
CLUDING ANY IMPUED WARRANTY OF MERCHAN
TABILITY OR OF FITNESS FOR PARTICULAR PURPOSE,
WiTH RESPECT TO ANY AND ALL EQUIPMENT FUR
NISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN
WRITING, MILLER PRODUCTS ARE INTENDED FOR ULTI
MATE PURCHASE BY COMMERCIAL/INDUSTRIAL USERS
AND FOR OPERATION BY PERSONS TRAINED AND EXPE
RIENCED IN THE USE AND MAINTENANCE OF WELDING
EQUIPMENT AND NOT FOR CONSUMERS OR CON
SUMER USE. MILLERS WARRANTIES DO NOT EXTEND
TO, AND NO RESELLER IS AUTHORIZED TO EXTEND
MILLERS WARRANTIES TO. ANY CONSUMER.
I
OM-126853A9/89
RECEiVING-HANDLING
Before unpacking equipment, check carton for any damage that may have occurred during shipment. File any
claims for loss or damage with the delivering carrier.
Assistance for filing or settling claims may be obtained
from the distributor and/or the eq~iipment manufactur-
Use the following spaces to record the Model Design ation and Serial or Style Number of your unit. The infcr
mation is located on the data card or the nameplate.
Model
_______________________________
ers
Transportation Department.
Senal
requesting information about this equipment, al
ways provide the Model Description and Serial or Style
or
Style No.
____________________
When
Dateof Purchase
_____________________
Number.
TABLE OF CONTENTS
Section No.
SECTION 1
Page
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1.
Introduction
1-2.
General Precautions
1
1-3.
Arc
4
1-4.
Standards Boo k~et Index
1
Welding
SECTION 2SAFETY
5
PRECAUTIONS AND SIGNAL WORDS
2-1.
General Information And
2-2.
Safety
Alert
Symbol
And
Safety
Signal Words
6
6
SECTION 3SPECIFICATIONS
3-1.
3-2.
3-3.
Volt-Ampere Curves
Duty Cycle
Description
8
8
8
SECTION 4-INSTALLATION OR RELOCATION
4-1.
Site Selection
8
4-2.
Transporting Methods
Weld Output Connections
Electrical Input Connections
9
4-3.
4-4.
No.
9
10
SECTION 5-OPERATOR CONTROLS
5-1.
PowerSwitch
5-2.
Pilot
12
5-3.
Light
Output Control
12
5-4.
Arc Control/Inductance Control
12
5-5.
Contactor Switch
13
5-6.
Output Control Switch
13
5-7.
CV/CC Switch
14
12
Page
Section No.
SECTION 6
6-1.
6-2.
6-3.
6-4.
6-5.
6-6.
SECTION 7
SEQUENCE OF OPERATION
(GMAW) And Flux Cored Arc Welding (FCAW)
Welding (GTAW)
Tungsten
Shielded Metal Ait Welding (SMAW)
SubmergedArc Welding (SAW)
Air Carbon Arc Cutting And Gouging (ACA)
Shutting Down
Gas Metal Arc
Arc
14
14
15
15
15
15
MAINTENANCE & TROUBLESHOOTING
16
7-1.
Routine Maintenance
7-2.
Overload Protection
16
7-3.
Thermal Protection
17
7-4.
17
7-5.
Circuit Board Indicator Lights
Circuit Board Handling Procedures
7-6.
Troubleshooting
18
SECTION 8
18
ELECTRICAL DIAGRAMS
Diagram 8-1. Circuit
Diagram 8-2. Circuit
Diagram 8-3. Circuit
Diagram 8-4. Circuit
Diagram 8-5. Circuit
Diagram
Diagram
Diagram
Diagram
Diagram
21
For Control Circuit Board PCI
22
For Base Drive Circuit Boards PC2 And PC3
24
For Snubber Circuit Board PC4
24
For Balance Circuit Board PC5
25
SECTION 9- PARTS LIST
Figure 9-1.
Figure 9-2.
Figure 9-3.
Figure 9-4.
Figure 9-5.
Main
Assembly
Panel, Front W/Components
26
28
Baffle, Center W/Components
30
Transistor
32
Assembly,
Main
Module, Diode
34
LIST OF CHARTS AND TABLES
Table 3-1.
Chart 3-1.
Chart 3-2.
Specifications
Volt-Ampere Curves
Duty Cycle
Table 4-1. Weld Cable Size
Table 4-2.
Input Conductor And Fuse Size
7
7
8
9
11
Table 7-1. Maintenance Schedule
16
Table 7-2.
18
Troubleshooting
No.
SECTION 1
-
SAFETY RULES FOR OPERATION OF
INTRODUCTION
1-1.
by experience. Learning safety through per
experience, like a child touching a hot stove is
harmful, wasteful, and unwise. Let the experience of oth
sonal
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
improperly used or maintained. The rea
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
equipment
son
rules.
Read and understand these safe practices before at
tempting to install, operate, or service the equipment.
Comply with these procedures as applicable to the par
ticular equipment used and their instruction manuals, for
personal safety and for the safety of others.
Failure to observe these safe practices may cause seri
ous injury or death. When safety becomes a habit, the
equipment can be used with confidence.
These safe practices are divided into two Sections:
1-General Precautions, common to arc welding and cut
ting; and 2-Arc Welding (and Cutting) (only).
Reference standards: Published Standards
on
safety
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
are
complete.
The National Electrical Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements also provide a basis for equip
ment installation, use, and service.
12.
or cutting, (and chipping) to protect the eyes
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
Avoid
oily
or
greasy
clothing.
A
spark may ignite them.
Hot metal such as electrode stubs and
should never be handled without gloves.
workpieces
Medical first aid and eye treatment. First aid facilities and
a qualified first aid person should be available for each
shift unless medical facilities are close by for immediate
treatment of flash burns of the eyes and skin burns.
is
for the safe
most
POWER SOURCE
welding
We learn
ers
ARC WELDING
GENERAL PRECAUTIONS
Ear plugs should be worn when working on overhead or
a confined space. A hard hat should be worn when
in
others work overhead.
Flammable hair preparations should not be used
intending to weld or cut.
by per
sons
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
ventilation as described in ANSI Standard
Z49.1 listed in Standards Index. NEVER ventilate with
adequate
oxygen.
Lead -,cadmium-, zinc-, mercury-, and beryllium-bear
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.
ing
Metals coated with orcontaining materials that emit toxic
fumes should not be heated unless coating is removed
from the work surface, the area is well ventilated and, if
necessary, while
wearing
an
air-supplied respirator.
Work in a confined space only while it is being ventilated
and, if necessary, while wearing an air-supplied respira
tor.
Gas leaks in
Leaked gas in
a
confined space should be avoided.
Different arc welding processes, electrode alloys,
and fluxes can produce different fumes, gases, and
large quantities can change oxygen con
centration dangerously. Do not bring gas cylinders into a
radiation levels. in addition to the Information In this
manual, be sure to consult flux and electrode manu
facturers Material Safety Data Sheets (MSDSs) for
confined space.
specific technical data and precautionary measures
concerning their material.
A.
Burn Prevention
Wear protective
clothing-gauntlet gloves designed for
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.
use
in
Wear helmet with safety goggles and glasses with side
shields underneath, appropriate filter lenses or plates
(protected by clear cover glass). This is a MUST for
Leaving confined space, shut OFF gas supply at source
prevent possible accumulation of gases in the space if
downstream valves have been accidentally opened or
to
left open. Check to be sure that the space is safe before
re-entering it.
Vapors from chlorinated solvents can be decomposed
by the heat of the arc (or flame) to form PHOSGENE, a
highly toxic gas, and other lung and eye irritating prod
ucts. The ultraviolet (radiant) energy of the arc can also
decompose trichloroethylene and perchloroethylene
vapors to form phosgene. DO NOT WELD or cut where
solvent vapors can be drawn into the welding or cutting
atmosphere or where the radiant energy can penetrate
OM-126 853
Page
1
atmospheres containing even minute
trichloroethylene or perchloroethylene~
to
C.
Fire and
Explosion Prevention
Causes of fire and
by the
arc,
amounts of
-
explosion are: combustibles reached
heated mate
gases and cylinders; and
flame, flying sparks, hot slag
rial; misuse of compressed
BE AWARE THAT flying sparks or falling slag can pass
through cracks, along pipes, throughwindows ordoors,
and through wall or floor openings, out of sight of the
goggled operator. Sparks and slag can fly 35 feet.
explosion:
short circuits.
If combustibles are in area, do NOT weld or cut. Move
the work if practicable, to an area free of combustibles.
Avoid
below
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.
castings or containers must be vented
welding or cutting. They can explode.
Hollow
Explosive atmospheres.
paint spray rooms, dip tanks, storage areas, venti
lators. If the work cannot be moved, move combustibles
sparks and heat; or
at least 35 feet away out of reach of
Never weld
may contain flammable dust, gas,
as
or
or
before
cut where the air
liquid vapors (such
gasoline).
D.
Compressed
Standard
Keep equipment clean and operable, free of oil, grease,
and (in electrical parts) of metallic particles that can
cause
Waterfilling just
inerting.
or
short circuits.
To prevent fires and
ment as recommended in A6.O.
substitute for
working level may
Gas
EquIpment
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.
protect against ignition with suitable and snug-fitting,
fire-resistant
covers or
Never connect a
shields.
regulator
cylinder containing gas
regulator was designed.
to a
other than that for which the
Walls touching combustibles on opposite sides should
not be welded on (or cut). Walls, ceilings, and floor near
work should be protected by heat-resistant covers or
shields.
Remove faulty regulatorfrom service immediately for re
pair (first close cylinder valve). The following symptoms
indicate a faulty regulator:
Fire watcher must be standing by with suitable fire extin
guishing equipment during and for some time afterweld
ing or cutting if:
Leaks-if gas leaks externally.
Excessive Creep-if delivery pressure continues to rise
with downstream valve closed.
a.
appreciable combustibles (including building
construction) are within 35 feet
Faulty Gauge-if gauge pointerdoes not move off stop pin
when pressurized, nor returns to stop pin after pressure
release.
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
d.
Repair. Do NOT attempt to repair. Send faulty regulators
for repair to manufacturers designated repair center,
where special techniques and tools are used by trained
personnel.
sparks
2.
combustibles adjacent to walls, ceilings, roofs,
or metal partitions can be ignited by radiant or
conducted heat.
Cylinders must be handled carefully to prevent leaks
and damage to their walls, valves, or safety devices:
Hot work
permit should be obtained before operation to
ensure supervisors approval thatadequate precautions
have been taken.
After work is done, check that
glowing embers, and flames.
area
is free of
sparks,
Cylinders
Avoid electrical cittuit contact with cylinders including
third rails, electrical wires, or welding circuits. They can
produce short circuit arcs that may lead to a serious acci
dent. (See 1-3C.)
ICC
or
DOT marking must be
of safety when the
assurance
on
each
cylinder
cylinder. It is an
is properly han
An
dled.
be welded on or cut, unless container has first
been cleaned as described in AWS Standard A6.O, listed
7 in Standards Index.
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.
empty container that held combustibles, or that can
produce flammable or toxic vapors when heated, must
never
This includes: athorough steam or caustic cleaning (or a
solvent or water washing, depending on the combusti
bles solubility) followed by purging and inerting with ni
trogen or carbon dioxide, and using protective equipOM-126 853
Page
2
Empties: Keep valves closed, replace caps securely;
keep them separate from FULLS and return
promptly.
mark MT;
Prohibited use. Never use a cylinder or its contents for
other than its intended use, NEVER as a support or
roller.
Locate
or secure
cylinders
so
they
cannot be knocked
over.
Passageways and work areas. Keep cylinders clear
where they may be struck.
of
outlet away from people and
with a clean lintless cloth.
sources
of
ignition. Wipe
Match regulator to cylinder. Before connecting, check
that the regulator label and cylinder marking area, and
thatthe regulator inlet and cylinderoutlet match. N EVER
CONNECT a regulator designed for a particular gas or
gases to a cylinder containing any other gas.
areas
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
Tighten
connections. When
assembling threaded
con
nections: clean and smooth seats where necessary.
Tighten. If connection leaks, disassemble, clean, and
retighten using properly fitting
wrench.
mag~nets.
Do NOT expose cylinders to excessive heat, sparks,
slag, and flame, etc. that may cause rupture. Do not al
Cool with water spray
low contents to exceed 130F.
where such exposure exists.
cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when moving cylinders.
Protect
hammer orwrench to open a
valve that can not be opened by hand. Notify
Stuck valve. Do NOT use
LEFT HAND threads.
Regulatoroutlet (or hose) connections may be identified
by right hand threads for oxygen and left hand threads
(with grooved hex on nut or shank) for fuel gas.
5.
a
cylinder
your supplier.
Mixing gases.
Adapters. Use a CGA adapter (available from your sup
plier) between cylinder and regulator, if one is required.
usetwowrenchestotighten adaptermarked RIGHTand
Pressurizing Steps:
regulator of residual gas through suitable vent be
opening cylinder (or manifold valve) by turning ad
justing screw in (clockwise). Draining prevents exces
sive compression heat at high pressure seat by allowing
seat to open on pressurization. Leave adjusting screw
engaged slightly on single-stage regulators.
Drain
fore
Never try to mix any gases in
Never refill any
a
cylinder.
cylinder.
Cylinderfittings should never be
modified orexchanged.
Stand to side of regulator while opening cylinder valve.
3.
Hose
Prohibited use. Never use hose otherthan that designed
for the specified.gas. A general hose identification rule
is: red for fuel gas, green for oxygen, and black for inert
gases.
Use ferrules
or
clamps designed for the hose (not ordi
nary wire or other substitute)
hoses to fittings.
No copper
tings
to
tubing splices.
splice hose.
as a
Use
binding
only
to connect
standard brass fit
Avoid long runs to prevent kinks and abuse. Suspend
hose off ground to keep it from being run over, stepped
on, or otherwise damaged.
Open cylinder valve slowly so that regulator pressure in
creases slowly. When gauge is pressurized (gauge
reaches regulator maximum) leave cylinder valve in fol
lowing position: For oxygen, and inert gases, open rully
to seal stem against possible leak. For fuel gas, open to
less than one turn to permit quick emergency shutoff.
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on
regulators.
Check for leaks on first pressurization and regullarly
there-after. Brush with soap solution (capfull of Ivory Liq
uid* or equivalent per gallon of water). Bubbles indicate
leak. Clean off soapy water after test; dried soap is com
bustible.
Coil
excess
hose to prevent kinks and
tangles.
E.
Protect hose from damage by
sparks, slag, and open flame.
sharp edges,
and
area out
and
splic
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
G.
4.
ResponsIbilitIes
Remove
Examine hose regularly for leaks, wear, and loose con
nections. Immerse pressured hose in water; bubbles in
dicate leaks.
Repair leaky orwom hose by cutting
ing (1-203). Do NOT tape.
User
by
source
and drain gas.
Rope Staglng.Support
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
Rope staging-support should not be
cutting operation; rope may burn.
used for welding
or
*Trademark of Proctor & Gamble.
OM-1 26 853
Page
3
ARC WELDING
1-3.
Comply with precautions in 1-1, 1-2, and this section.
Arc Welding, properly done, is a safe process, but a
careless operator invites trouble. The equipment carries
high currents at significant voltages. The arc is very
bright and hot. Sparks fly, fumes rise, ultraviolet and in
frared energy radiates, weldments are hot, and com
pressed gases may be used. The wise operator avoids
unnecessary risks and protects himself and others from
accidents. Precautions are described here andin stan
dards referenced in index.
A.
Others working in
flash
area.
See that all persons
goggles.
Before
starting
are
wearing
-
to weld, make sure that screen
bay
doors are closed.
B.
ToxIc Fume PreventIon
Comply With precautions
flaps
or
in 1-2B.
Generator engine exhaust must be vented to the outside
air. Carbon monoxide can kill.
Protection
Burn
Comply
Viewing the weld. Provide face shields for all persons
who will be looking directly at the weld.
C.
with
precautions
Fire and
Explosion Prevention
in 1-2.
Comply with precautions
in 1 -2C.
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.
Equipments
equipment.
Skin burns resemble acute sunburn, those from gasshielded arcs are more severe and painful. DONT GET
BURNED; COMPLY WITH PRECAUTIONS.
cause a
1.
Protective
Clothing
Wear
long-sleeve clothing (particularly for gas-shielded
gloves, hat, and shoes (1 -2A). As nec
essary, use additional protective clothing such as
leather jacket or sleeves, flame-proof apron, and fire-re
sistant leggings. Avoid outer garments of untreated cot
arc)
in addition to
ton.
Bare skin protection. Wear dark, substantial clothing.
Button collar to protect chest.and neck and button pock
ets to prevent
2.
Eye
rated capacity. Do not overload arcwelding
It may overheat cables and cause a fire.
Loose cable connections may overheat
fire.
or
flash and
-
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
E.
in 1 -2D.
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
entry of sparks.
and Head Protection
protection.
Protect eyes from exposure to
electric arc without protection.
arc.
NEVER look at
an
To protect
against
shock:
Wear
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.
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
Cracked or broken helmet or shield should NOT be
worn; radiation can pass through to cause bums.
body and an electrically HOT part or grounded
metal reduces the electrical resistance, and could en
able dangerous and possibly lethal currents to flow
Cracked, broken,
through
tween
IMMEDIATELY.
pitted1
or
loose filter plates must be replaced
Replace clear cover plate when broken,
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
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,
struck.
workpieces, etc. Never touch the electrode and any
metal object unless the welding power source is off.
eyes
1.
Looking at an arc momentarily with unprotected
(particularly a high intensity gas-shielded arc) can
retinal burn that may leave a permanent dark
in the field of vision.
Grounding
the
Equipment
cause a
area
3.
Protection of
Enclosed welding
Nearby Personnel
For production welding, a sepa
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
area.
rate room or enclosed
ticularly
at floor level.
OM-126 853
Page
4
Arc welding equipment must be grounded according to
the National Electrical Code, and the work must be
grounded according to ANSI Z49.1 usafety In Welding
And Cutting.
When installing, connect the frames of each unit such as
welding power source, control, worktable, and water cir
culatorto the building ground. Conductors must be ade
quate to carry ground currents safely. Equipment made
Welding power sources used with shielded
metal arc welding (SMAW) and similar proc
esses may not be equipped with welding power
output on-off control devices. With such equip
ment the electrode is electrically HOT when the
electrically HOT by stray current may shock, possibly I atally. Do NOT GROUND to electrical conduit, orto a pipe
carrying ANY gas or flammable liquid such as oil or fuel.
Three-phase connection. Check phase requirements of
equipment before installing. If only 3-phase power is
available, connect single-phase equipment to only two
wires of the 3-phase line. Do NOT connect the equip
ment ground lead to the third (live) wire, or the equip
ment will become electrically HOT-a dangerous condi
tion that can shock, possibly fatally.
welding, check ground for continuity. Be sure
conductors are touching bare metal of equipment
Before
frames at connections.
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
If
a
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 threeprong 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.
Connectors
Fully insulated lock-type
join welding cable lengths.
Cables
Frequently inspect cables forwear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn
or damaged insulation to avoid possibly-lethal shock
from bared cable. Cables with damaged areas may be
taped to give resistance equivalent to original cable.
Keep cable dry, free of oil and grease, and
from hot metal and sparks.
5.
Terminals And Other
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 redtag switches) to prevent accidental turning ON of power.
Disconnect all cables from welding power source, and
pull
Leaving equipment
Exposed
b.
shut OFF and
near
ProtectIon For Wearers of ElectronIc Life
port DevIces (Pacemakers)
the
1-4.
STANDARDS BOOKLET INDEX
For more information, referto the
their latest revisions and comply
1.
following standards or
as applicable:
ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING obtainable from the American Welding
Society, 550 N.W. LeJeune Ad, Miami, FL 33126.
NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING obtainable
from the
ernment
3.
(no
Superintendent of Documents, U.S. Gov
Printing Office, Washington, D.C. 20402.
OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the Superintendent of
Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
4.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND.
FACE PROTECTION obtainable from the American
National Standards Institute, 1430 Broadway, New
York, NY 10018.
5.
ANSI Standad Z41.1, STANDARD FOR MENS
SAFETY-TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430 Broad
way, New York, NY 10018.
6.
ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES
in contact with the electrode circuit unless
source is off.
without output on/off control
Sup
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.
welding power
Equipment
contactor)
Always
equipment.
F.
2.
Parts
Welding power sources for use with the gas
metal arc welding (GMAW), gas tungsten arc
welding (GTAW) and similar processes nor
mally are equipped with devices that permit on
off control of the welding power output. When so
equipped the electrode wire becomes electri
cally HOT when the power source switch is ON
and the welding gun switch is closed. Never
touch the electrode wire or any conducting ob
the
plugs.
unattended.
disconnect all power to
Equipment with output on/off control (contactor)
ject
all 115 volts line-cord
Do not open power circuit or change polarity while weld
ing, If, in an emergency, it must be disconnected, guard
against shock burns, or flash from switch arcing.
protected
Electrode
a.
Devices
Safety
Terminals and other exposed parts of electrical units
should have insulating covers secured before operation.
6.
Safety
welding power source.
be used. Do
connectors should be used to
4.
7.
Power disconnect switch must be available
Electrode Holders
Fully insulated electrode holders should
NOT USQ holders with protruding screws.
3.
power switch is turned ON. Never touch the
electrode unless the welding power source is
off.
OM- 126 853
Page
5
from the Compressed Gas Association, 1235 Jeffer
son Davis Highway, Suite 501, Arlington, VA 22202.
AWS Standard A6.0, WELDING AND~ CUTTING
CONTAINERS WHICH HAVE HELD COMBUS
TIBLES obtainable from the American Welding So
ciety, 550 N.W. LeJeune Rd, Miami, FL 33126.
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the Ca
7.
obtainable from the American National Standards
Institute, 1430 Broadway, New York, NY 10018.
NFPA Standard 51, OXYGEN-FUEL GAS SYS
TEMS FOR WELDING, CUTTING, AND ALLIED
PROCESSES obtainable from the National Fire
Protection Association, Batterymarch Park, Quincy,
8.
Standard 70, NATIONAL ELECTRICAL
CODE obtainable from the National Fire Protection
NF?A
Association,
Batterymarch
Park,
Quincy,
MA
02269.
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association,
Batterymarch Park, Quincy,
MA 02269.
ii. CGA
Pamphlet P-i, SAFE HANDLING OF COM
PRESSED GASES
IN
CYLINDERS obtainable
SECTION 2
2.1.
13. NWSA booklet, WELDING SAFETY BIBLIOGRA
PHY.obtainable from the National Welding Supply
Association, 1900 Arch Street, Philadelphia, PA
19103.
MA 02269.
9.
nadian Standards Association, Standards Sales,
178 Rexdale Boulevard, Rexdale, Ontario, Canada
M9W1R3.
Welding Society Standard AWSF4.1,
RECOMMENDED SAFE PRACTICES FOR THE
PREPARATION FOR WELDING AND CUTTING
OF CONTAINERS AND PIPING THAT HAVE HELD
HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd,
Miami, FL 33126.
14. American
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA
TORY PROTECTION, obtainable from the Ameri
can National Standards Institute, 1430 Broadway,
New York, NY 10018.
SAFETY PRECAUTIONS AND SIGNAL WORDS
GENERAL INFORMATION AND SAFETY
A. General
Information presented in this manual and on various la
bels, tags, and plates on the unit pertains to equipment
design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed forthe safe and effective use of this equipment.
2-2. SAFETY
WORDS
B
.
Safety
The installation, operation, maintenance, and trouble
shooting of arc welding equipment requires practices
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be in
stalled, operated, and maintained only by qualified per
Sons in accordance with this manual and all applicable
codes Such as, but not limited to, those listed at the end
of Section 1
Safety Rules For Operation Of Arc Weld
ing Power Source.
OM-126 853
Pages
SYMBOL
AND
SIGNAL
The following safety alert symbol and signal words are
used throughout this manual to call attention to and iden
tify different levels of hazard and special instructions.
a
This safety alert symbolis used with the signal
words WARNING and CAUTION to call atten
tion to the safety statements.
a
WARNING statements identify procedures or
practices which must be followed to avoid seri
ous personal injury or loss of life.
a
CAUTION statements identify procedures or
practices which must be followed to avoid minor
personal injury or damage to this equipment.
The
nameplate of this unit uses international symbols for
labeling the front panel controls. The symbols also ap
pear at the appropriate section in the text.
ALERT
IMPORTANT statements identify special instructions
necessary for the most efficient operation of this equip
ment.
SECTION 3- SPECIFICATIONS
Table 3-1.
SpecifIcations
At Rated
Load Output
50/60
input
Max.
Input
Power
Rated Output
At 100%
Duty Cycle
VoltageRange
Amperage
Range in
in CV Mode
CC Mode
Open-Circuit
Voltage
in CC Mode
Weight
Hz_
Amperes At
230V
460V
kva
kw
42
21
16.7
13.8
Net
Ship
150 lbs.
164 lbs.
(68 kg)
(74 kg)
~
ThreePhase
350 Amperes
At 34 Volts DC
10-35
Volts
SinglePhase
5-350
70
Volts DC
Amperes
275 Amperes
31 Volts DC
14.3
30
60
10
Base
inches
Millimeters
1-9/16
39.7
B
13
330.2
C
23
584.2
0
25.13/32
645.3
E
25/32
19.8
A
K
F
3/4
19.0
G
11-1/2
292.1
H
13
330.2
J
23
584.2
K
26-1/4
666.8
J
B holes
C
Meunting Hole Layout
holes
are
are
3/8 In. (9.5
14/32 in.
mm) Die. (4 hole,)
(13.5 mm) DIe. (4 holes)
TC-131 955
Figure 3-1. Overall Dimensions
Chart 3-1.
And Base
Mounting Hole Layout
Volt-Ampere Curves
N
N
N
0
U
N
I
0
I.
U.
U.
U.
U.
U.
u~.
DC AMPERE5
N
IN
IN
ZN
ZOO
ZOO
DC AMPE~E3
8-099012
Volt-Ampere Curves For CV Mode
(With 3-Phase, 60 Hz Input)
e-ogct 013
Volt-Ampere Curves For CC Mode
(With 3-Phase, 60 Hz Input)
OM-126 853
Page
7
unit can be operated at rated load continuously, If the
welding amperes increase beyond rated output, the duty
cycle decreases.
VOLT-AMPERE CURVES (Chart 3-1)
3-1.
RATED OUTPUT
The
volt-ampere
curves
age output capabilities
Curves of other
settings
show the voltage and amper
of the welding power source.
fall between the curves shown.
With the use of the volt-ampere curves, it is possible to
determine the weld amperage at any particular load volt
Refer to the Duty Cycle chart (Chart 3-2) to determine
Output of the welding power source at various duty
the
cycles.
a
CYCLE
DUTY
EXCEEDING
CAUTION:
RATiNGS will damage the welding power
source.
Do not exceed indicated
age.
DUTY CYCLE
3-2.
duty cycles.
(Chart 3-2)
3-3.
Cycle
Chart 3-2. Duty
DESCRIPTION
a three-phase, or single-phase if derated, dc,
welding power source having constant voltage (CV)
and constant current (CC) output characteristics for
multi-process capability. The unit produces dc weld out
put and is designed for-use with Shielded Metal Arc
(SMAW), Gas Metal Arc (GMAW), Gas Tungsten Arc
(GTAW), Flux Cored Arc (FCAW), Submerged Arc
(SAW), and Air Carbon Arc (ACA) cutting and gouging
welding processes.
This unit is
arc
350~,
300
2~0
200
___________________________________
.5
20
30
2~
:ury
CyCLE
40
60
50
0
Sc
90
00
C
a-ia 983
duty cycle is the percentage of a ten minute period
welding power source can be operated at a given
output without overheating and damaging the unit. This
welding power source is rated at 100% duty cycle. The
The
that a
This unit is capable of both pulsed and no npuised operation. The welding power source compensates for line
voltage fluctuation of –10%.
The solid-state, electronic components of this unit are lo
cated in sealed areas unexposed to airflow and asso
ciated contaminants. The fan motors cool only the heat
sinks and main transformer.
SECTION 4- INSTALLATION OR RELOCATION
4.1.
SITE SELECTION
Base
mounting holes provide the capability to install and
the unit on a running gearor in a permanent loca
tion. Figure 3-1 gives overall dimensions and base
mounting hole layout.
secure
Select
an
installation site which provides the
1.
Correct input power
2.
Shielding gas supply (if applicable)
3.
Water
4.
Adequate ventilation
5.
No flammables
6.
A clean and
supply (see
unit
following:
nameplate)
supply (if applicable)
and fresh air
supply
4A
WARNING: FIRE OR EXPLOSION can result
from placing unit on or over combustible
surfaces; RESTRICTED AIRFLOW can cause
overheating and possible damage to Internal
parts.
7.
dry
Do not locate unit over combustible surfaces.
area
Proper temperature that avoids
extremes of heat or
Maintain at least 6 inches (152 mm) of
unrest ricted space on tight side of unit, and keep
underside free of obstructions,
cold
airflow around unit
8.
Proper
9.
Adequate space for removing top cover and outer
panels for installation, maintenance, and repair
functions.
OM-1 26 853
Pages
Do not place any filtering device over the in
take air passages that pro vide airflow forcoollng
this unit.
Warranty is void if any type of filtering device
used at intake air passages.
is
4-2~
TRANSPORTiNG METHODS
This welding power
lift forks.
a
-
Use weld cable with an insulation voltage rating
equal to or greater than the maximum open-circuit
voltage (ocv) of the welding power source (see
Table 3-1 for unit maximum ocv rating).
3.
Select welding cable size according to maximuim
weld output and total length of connecting cables in
weld circuit. For example, if a 25 foot (7.5 m) wi~re
feeder or electrode holder cable is used with a 25
foot ~7.5 m) work cable, select the cable size recom
mended in Table 4-1 for 50 feet (15 m).
4.
Do not
B.
Weld Cable
1.
Installterminallugs of adequate amperage capacity
has space underneath it for
source
WARNING: ELECTRIC SHOCK
~
2.
can kill.
Do not touch live electrical parts.
Disconnect input power conductors from
deenergized supply line BEFORE moving weld
ing power source.
FALLING EQUIPMENT
can
cause
serious
personal injury and equipment damage.
Use equipmentof adequate capacity to lift the
unit.
If lifting or moving this unit with lift forks under
the base, be sure that lift folks are long enough
to extend beyond opposite side of the base.
WELD OUTPUT CONNECTIONS
1.
3.
Install work clamp onto cable.
(Figure 5-1)
C. Weld Cable Connections To
Source (Figure 5-1)
or cause
Welding
Povier
POSITIVE
NEGATIVE
+
a
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Shutdown welding powersource, and discon
input power employing lockout/tagging
procedures before inspecting or installing.
Lockout/tagging procedures consist of pad
locking line disconnect switch in open position,
removun~ fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
nect
to select weld cables:
possible cables, and place cables
lengths may reduce
close together. Excessive cable
output
Preparation
If installing an electrode holder, follow manufactur
ers installation instructions. Always use an insu
lated electrode holder to ensure operator safety.
Weld Cable SelectIon
Use the shortest
cables.
2.
welding performance.
following guidelines
frayed
weld output terminals.
To obtain full rated output from this unit, it is necessary to
select, prepare, and install properwØld cables. Failure to
comply in any of these areas may result in unsatisfactory
Use the
or
and correct stud size onto cables that connect to the
clamp, wire feeder or electrode holder, and
RATED OUTPUT
A.
damaged
work
Using lift forks too short can damage internal
parts if tips of the lift forks penetrate the unit
base, or may cause personal injury and/or
equipment damage if unit falls off the lift forks.
4-3.
use
unit overload due to added resis
tance.
Table 4-1. Weld Cable Size
Total Cable
(Copper) Length
In Weld Circuit Not
Exceeding
100 ft. Or Less
150 ft.
200 ft.
1
250 ft.
300 ft.
350 ft.
(30 m)
(45 m)
(60 m)
j
(70 m)
(90 m)
(105 m)
400 ft.
(120 m)
10 To 60%
60 Thru 100%
Duty Cycle
Duty Cycle
4
4
4
3
2
1
1/0
1/0
3
3
2
1
1/0
2/0
3/0
3/0
3
2
1
1/0
2/0
3/0
4/0
4/0
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
weld cable size
mils per ampere.
10 Thru 100%
Duty Cycle
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-3/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
(AWG)
is based
on
either
a 4
volts
or
less
drop
or a
current
density of
more than 300 circular
S.0007/8.88
OM-126 853
Page
9
1.
For Shielded Metal Arc Welding
Positive/Reverse Polanty)
(SMAW) (Electrode
locking
a.
Connect end of electrode holder cable to POSI
TIVE (+) weld output terminal.
b.
Connect one end of work cable to NEGATIVE
() weld output terminal and remaining end to
workpiece.
consist of pad
line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnecting device.
Lockout/tagging procedures
-
A.
ElectrIcal
Input Requirements
Operate the welding power source from a three-phase,
single-phase if derated, 50/60 Hertz, ac power supply.
The input voltage must match one of the electrical input
voltages shown on the input data label on the unit name
plate. Contact the local electric utility for information
or
IMPORTANT: For Electrode
Negative/Straight Polarity
connections, reverse cable connections to weld output
terminals; electrode becomes negative.
2.
Fo~
Welding (GMAW), Flux Cored
Arc Welding (FCAW), and Submerged Arc Welding
(SAW) (Electrode Positive/Reverse Polarity)
Gas Metal Arc
Connectneendofweldcableto POSITIVE(+)
weld output terminal and remaining end to ter
a.
minal on drive
feeder Owners
b.
of wire feeder
Manual for location).
housing
(see wire
Connect one end of work cable to NEGATIVE
() weld output terminal and remaining end to
workpiece.
IMPORTANT: For Electrode Negative/Straight Polarity
connections, reverse cable connections to weld output
terminals; electrode becomes negative.
3.
about the type of electrical service available, how proper
connections should be made, and inspection required.
B.
a
Remove top cover and left side
2.
Compare position of jumper links on the input termi
nal board and terminal strip 1 T to the voltage link ar
rangement shown on input voltage label.
a
Position jumper links
Cutting
Gouging (ACA)
(Electrode Positive/Reverse Polarity)
Connect
b.
one
end of work cable to NEGATIVE
and remaining end to
() weld output terminal
workpiece.
IMPORTANT: For Electrode Negative/Straight Polarity
connections, reverse cable connections to weld output
terminals; electrode (torch) becomes negative.
4.4.
ELECTRICAL INPUT CONNECTIONS
INPUT
AA
WARNING: ELECTRIC SHOCK
can
kIll.
Do not touch live electrical parts.
Shutdown welding powersource, and discon
input power employing lockout/tagging
procedures before inspecting or installing.
nect
OM-126 853
Page
10
shown
on
the
input
across
linked
terminals.
And
Connect torch cable to POSITIVE (+) weld out
put terminal.
as
label
(see Figure 4-1).
Store unused jumper links
3.
For Air Carbon Arc
panel.
CAUTION:
INCORRECT INPUT VOLTAGE
JUMPER LINK PLACEMENT can damage
unit.
voltage
IMPORTANT: For Electrode Positive/Reverse Polarity
connections, reverse cable connections to weld output
terminals; electrode (torch) becomes positive.
a.
proceedIng.
1.
piece.
4.
WARNING: Read and follow safety Info rma
tlon at beginning of entire SectIon 4-4 before
to NEGA
Connect one end of work cable to POSITIVE (+)
weld output terminal and remaining end to work-
b.
(FIgure 4-1)
bag attached to the input terminal board and terminal
strip 11 or installed for the highest voltage shown on the
input voltage label.
Tungsten Arc Welding (GTAW) (Electrode
Negative/Straight Polarity)
Connect torch cable or connector
TIVE () weld output terminal.
Link InstallatIon
Jumper links are used to allow the equipment to operate
from different line voltages. The jumper links may be in a
For Gas
a.
Jumper
Install jumper links onto the input terminal board and
terminal strip iT to match the available input line
voltage.
4
Reinstall and
secure
left side panel and top cover
onto unit.
C.
Welding Power Source Input Power Connec
(Figure 4-1)
tions
a
WARNING: ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Install
a
fusible line disconnect switch in the
input circuit to the welding power source.
Connect input conductors to the welding
power source before connecting to singlephase or three-phase input power.
Read and follow safety information at be ginfling of entire Section 4-4 before proceeding.
The line disconnect switch provides a safe and
convenient means to completely remove all
electrical power from the welding power source
whenever it is necessary to inspect or service
the unit.
2.
Use Table 4-2 as a guide to select input conductors
for the installation. The input conductors should be
covered with an insulating material that complies
with national, state, and local electrical codes.
8.
9.
WARNING: ELECTRIC SHOCK
can kill.
11. Use Table 4-2 as a
conductor to
Table 4.2.
result in an
3
Remove
4.
Obtain and install astandard conduit strain relief
connector into access hole in cover plate.
5.
plate from
rear
Power
ThreePhase
panel.
Conductor
Size
Ground
Conductor
Size
Fuse
Size In
(AWG)
(AWG)
Amperes
230
8
10
60
460
1-0
10
30
230
6
10
60
8
10
40
Phase
460
Insert conductors through strain relief installed in
4. Route conductors to input terminals.
tConductor size is based on the 1987 Edition of the National
Electrical Code (NEC) specifications for allowable am
pacities of insulated copper conductors, having a tempera
For three-phase input supply: Connect
ductors to line terminals, L2, and L3.
ture
input
con
rating of 167F (75C), with not more than three single
current-carrying conductors in a raceway (Article 310 of
NEC). (The ground conductor is not counted as a currentcarrying conductor.)
For single-phase input supply: Connect input con
ductors to the top Li and bottom L3 terminals.
tFuse size is based
7.
And Fuse Slze*
Input
Voltage
Single-
Step
6.
Input Conductor
an
electrically energized welding power source
chassis. The ground terminal is connected to
the welding power source chassis and is for
grounding purposes only.
cover
guide to select line fuses for the
Input
can
to a
disconnect switch. Obtain and install proper fuses.
Input
input connections
a
com
remaining ends of input conductors
deenergized line disconnect switch.
input line terminal.
Incorrect
secure in
Connect remaining end of ground conductor to
Do not connect an input conductor to the
ground terminal in the unit.
ground
panel, and
10. Connect
Do not (ouch live electrical parts.
Do not connect the
rear
suitable ground. Use a grounding method that
plies with all applicable electrical codes.
Install terminal Iugs of adequate amperage capacity
and correct stud size onto the input and ground con
ductors.
A~
Reinstallcover plate onto
put cable in strain relief connector.
~
1.
Connect the
nal
ground conductor to the ground termi
(see Fig~ire 4-1).
Ground
on not more
rated input amperage of the
630 of NEC).
Center Panel
Contactor
than 200 percent of the
welding
power
source
(Article
s-oogeił-aa
Fuse Fl
Conductor
Piinel
Input Terminal
Board With
Input Voltage
Jumper
Unks
Terminal
With
Strip 11
Jumper Links
Line Disconnect Switch:
Three-Phase
System
Shown
Route To Unit:
Rear Panel Access Hole
Is 1-3/8 in.
(34.9 mm)
In Diameter
18-096 967-A
FIgure
4-1.
Component
Locations And
Input Conductor ConnectIons
OM-126 853
Page
11
SECTION 5- OPERATOR CONTROLS
CV/CC Switch
Output Control
Output Control
Switch
Circuit Breaker CB1
(+) Weld
Output Terminal
Positive
Power Switch ON
Push Button
Negative () Weld
Output Terminal
Power Switch OFF
Pilot
Ught
Push Button
TC-131 955
Figure 5-1.
5-1.
POWER SWITCH
(Figure 5-1)
5-3
ON
POWER
-e
Front Panel View
Q
OFF
OUTPUT CONTROL
(FIgure 5-1)
The OUTPUT control provides a means of selecting the
desired output within the entire range of the welding
power source. The control adjusts the voltage level(V) in
the CV mode and the amperage level (A) in the CC mode
from minimum to maximum of power source capability.
Rotating the control clockwise increases weld output,
and rotating the control counterclockwise decreases
weld output.
gizes
Depressing the POWER switch ON push button ener
the welding power source. Depressing the POW
ER switch OFF push button shuts down the welding
IMPORTANT: The OUTPUT control may be adjusted
while welding.
power source.
5-4.
ARC
CONTROL/INDUCTANCE
CONTROL
(FIgure 5.1)
IMPORTANT: After any interruption of input power. the
POWER switch ON push button must be depressed to
reenergize the welding power source.
5-2.
PILOT LIGHT
The
(Figure 5.1)
pilot light comes on when the POWER switch ON
button is depressed and indicates that the unit is ener
gized.
OM-126 853
Page
12
The ARC CONTROL/INDUCTANCE control functions
as an arc control in the constant current (CC) mode and
as an inductance control in the constant voltage (CV)
mode.
IMPORTANT:
The ARC CONTROL/INDUCTANCE
control may be adjusted while welding. The control
should be set at 0 (zero) for Gas Tungsten Arc Welding
(GTAVV9.
Arc Control (Used in CC Mode For Shielded
Metal Arc Welding (SMAW) And Air Carbon Arc Cut
ting And Gouging (ACA) Processes)
A.
a
-
The ARC CONTROL
When the control is set at 100, the short-circuit current is
higher (upto 150 amperes) than normal welding current.
(See volt-ampere curve for CC mode and IMPORTANT
beginning of this Subsection.) The increased
current enables arc starting in out-of-position welds, and
it provides the momentary overcurrents necessary for
block at
certain types of electrodes.
When the control is set at 0 (zero), short-circuit current is
the same as the welding current.
When the control is set at 50, short-circuit current is ap
proximately halt that of the 100 position, but still higher
than normal welding current. The 50 position provides a
moderate current increase necessary for arc starting
certain applications and types of electrodes.
Select a setting best suited for the application and type of
electrode.
B.
lnductanc~Control (Used For Constant Voltage
(CV) Operations Only)
Rotating this control clockwise electronically increases
inductance. As the level of inductance increases, the
rate of current change or speed of response slows down.
The slower response time produces a softer arc, more
fluid welding puddle, and flatter, smoother bead.
If CONTACTOR switch is in ON position arid
wire feeder or remote control device is con
nected to terminal strip lOT, weld output
(ocv) will be present whenever the weldi rig
power source is energized.
Although the term CONTACTOR is used
nameplate, the output is not switched on or off by
a physical output contactor; rather, the output is Con
trolled by relay action andsolid-state components on cir
IMPORTANT:
on
the
cuit boards.
When the CONTACTOR switch is in the ON
position,
open-circuit voltage (ocv) is present at the weld output
terminals whenever the welding power source is erier
gized. When the switch is in the OFF/REMOTE position,
no voltage is available at the output terminals ocv goes
to 0 (zero) volts.
If awire feeder or remote control device is controlling the
contactor, place the CONTACTOR switch in the OFF/
REMOTE position. Open-circuit voltage will be present
at the weld output terminals whenever the gun trigger or
remote control device is closed.
The CONTACTOR switch is normally placed in the OFF!
REMOTE position with the Gas Tungsten Arc Welding
Gas
process and all wire feeding processes
Metal Arc Welding (GMAW), Flux Cored Arc Welding
(FCAW), and Submerged Arc Welding (SAW). The
switch is normally placed in the ON position for the
Shielded Metal Arc Welding (SMAW) and the Air Carbon
Arc (ACA) cutting and gouging processes.
(GTAW)
5-6.
--
OUTPUT CONTROL SWITCH (Figure 5-1)
4A
WARNING: ELECTRIC SHOCK
or
if the CONTACTOR switch Si is in the ON
characteristics; for example, a soft, slow-respond
low spatter arc, and high weld puddle fluidity.
tance
5-5.
a
setting best
suited for the
CONTACTOR SWITCH
A~
position and Output Control switch (PANEL!
REMOTE) is in the PANEL position, opencircuit voltage is present at the output termi
nals whenever the welding power source is
energized.
application.
(Figure 5-1)
WARNING: ELECTRIC SHOCK
can
Do not touch gun wire and work clamp at
the same time.
kill.
Do not touch live electrical parts.
Do not touch the weld output terminals
or any metal pails of the welding circuit
when the contactor is energized.
If CONTACTOR switch Si is in the ON posi
tion and Output Control switch (PANEL!
REMOTE) S3 is in the PANEL position,
open-circuit voltage is present at the output
terminals whenever the welding power
source is energized.
kill.
Do not touch the weld output terminals
any metal parts of the welding circuit
when the contactor is energized.
(zero) setting gives minimum inductance; for ex
ample, a stiff, fast-responding arc, and a small, fastfreezing puddle. The 100 setting gives maximum induc
Select
can
Do not touch live electrical parts.
The 0
ing,
Do not touch gun wire and work clamp at
the same time.
Place CONTACTOR switch in OFF!
REMOTE position when using wire
feeder or remote control device to
control contactor.
IMPORTANT: The maximum ARC CONTROL current
available is 150 amperes above the ampere value Se
lectedon the OUTPUTcontro!. However, unit output, in
cluding ARC CONTROL amperes, cannot exceed the
rated output of the welding power- source. (See voltampere curves for CC mode.)
provides variable selection of
short-circuit current to suit individual welding conditions.
Rotating this control clockwise causes the current to in
crease as the short-circuit condition is approached.
.
If remote contactor control is desired, make proper con
nections to terminal strip 1 OT, and place the Output Con
trol switch in the REMOTE position. Open-circuit voltage
(ocv) will be present at the weld output terminals when
ever
the remote control device is closed.
If remote contactor control is not desired, place the Out
put Control switch in the PANEL position. Open-circuit
voltage (ocv) will be present at the output terminals
whenever the
welding
power source is
energized.
OM-126 853
Paie
13
5-7.
CVICC SWITCH (Figure 5-1)
The CV/CC switch provides a means of selecting weld
output characteristics for the desired process. When the
switch is in the CV (constant voltage) position, the unit
provides a constant voltage output specifically designed
Gas Metal Arc Welding
for wire feeding applications
--
SEQUENCE OF OPERATION
SECTION 6
a
(GMAW), Flux Cored Arc Welding (FCAW), and
Shielded Metal Arc Welding (SAW). When the switch is
in the CC (constant current) position, the unit provides a
constant current output specifically designed for
Shielded Metal Arc Welding (SMAW) and Gas Tungsten
Arc Welding (GTAW). The CC position is also used for
the Air Carbon Arc (ACA) cutting and gouging process.
ELECTRIC SHOCK can kill;
WARNING:
MOVING PARTS can cause serious injury;
IMPROPER AIRFLOW AND EXPOSURE TO
ENVIRONMENT can damage Internal parts.
2.
Install and prepare wire feeder according to its Own
ers Manual.
3.
Place the CONTACTOR
REMOTE position.
4.
Place the CV/CC switch in the CV
5.
Place the applicable Output Control switch in the
desired position (see Section 5-6).
Do not touch live electrical parts.
Keep all covers and panels in place while
operating.
Warranty is void if the welding power source is
operated with any portion of the outer enclosure
6.
removed.
ARC RAYS, SPARKS, AND HOT SURFACES
burn eyes and skin; NOISE can damage
can
the
OFF/
position.
Rotate the applicable OUTPUT Control (panel or re
to the desired position (see Section 5-3).
mote)
7.
Rotate the INDUCTANCE control to the desired
position (see Section 5-4B).
hearing.
Wear correct eye, ear, and
FUMES AND GASES can
your health.
Keep
in
switch
body protection.
seriously harm
8.
ANSI Z49.1.
your head out of the fumes.
9.
keep from breathing fumes and
Ventilate to
dry insulating gloves and clothing, and wear
welding helmet with proper filter lens according to
Wear
Prepare
for
welding
as
follows:
Connect work clamp to clean, bare metal at
a.
gases.
workpiece.
If ventilation is
inadequate,
use
approved
WELDING
wounds.
WIRE
can
puncture
cause
Do not point gun toward any part of the body,
any conductive surface, or other personneL
HOT METAL, SPATrER,
and burns.
AND
SLAG
can
Manual.
10. Turn
12.
5-2.
Watch for fire.
Do not use
extinguisher nearby,
near
Allow work and
and know
equipment
to cool before
supply
if
applicable.
TUNGSTEN ARC WELDING (GTAW)
WARNING: Read and follow safety Informa
beginning of entIre Section 6 before
tion at
proceeding.
1.
Install and connect unit
2.
Install and connect the High-Frequency unit accord
ing to its Owners manual if applicable. Scratch start
Gas Tungsten-Arc Welding does not require the use
of external high frequency.
3.
Place the CONTACTOR
REMOTE position.
4.
Place the CV/CC switch in the CC position.
Wearers should consult their doctor before
going neararc welding, gouging, orspot welding
operations.
-
gas
Begin welding.
a
MAGNETIC FIELDS FROM HIGH CURRENTS
can affect pacemaker operation.
Arc
shielding
flammable material.
handling.
See Section 1
on
11. Press the POWER switch ON button.
cause tire
Keep a fire
how to use it.
Select and obtain proper welding wire, and
thread as instructed in wire feeder Owners
b.
breathing device.
Safety Rules
Welding Power Source
safety information.
For Operation Of
for basic welding
5.
Place the
tion
according
to Section 4.
switch
Output Control switch
in
the
in the desired
OFF/
posi
(see Section 5-6).
6.1. GAS METAL ARC (GMAW) AND FLUX CORED
ARC WELDING (FCAW)
6.
WARNING: Read and follow safety Informa
tIon at beginning of entire SectIon 6 before
7.
Rotate the ARC CONTROL to the
8.
Wear dry insulating gloves and clothing, and wear
welding helmet with proper filter lens according to
a
1.
proceeding.
Install and connect unit according to Section 4.
OM-126 853
Page
14
Rotate the applicable OUTPUT Control (panel or
to the desired position (see Section 5-3).
remote)
ANSI Z49.1.
zero.
Prepare
9.
for
welding
as
-
follows:
8.
Rotate the ARC CONTROL/INDUCTANCE CON
TROL to the desired position (see Section 5-4).
9.
Wear
Connect work clamp to clean, bare metal at
a.
workpiece.
b.
Select and obtain proper tungsten electrode.
c.
Prepare tungsten electrode
and insert into
ANSI Z49.1.
10.
torch.
10. Turn on
cable.
shielding gas and
water
supplies
as
dry insulating gloves and clothing, and wear
safety goggles with correct filter shade according to
appli
Prepare for welding as follows:
Connect work clamp to clean, bare metal at
a.
workpiece.
b. Select and obtain proper welding wire, and
thread as instructed in wire feeder Owners
Manual.
11. Press the POWER switch ON button.
12.
Begin welding.
Select and obtain proper flux, and put into flux
c.
SHIELDED METAL ARC WELDING (SMAW)
6-3.
a
WARNING: Read and follow safety Informa
tion at beginning of entire Section 6 before
proceeding.
system.
11. Turn on flux
to Section 4.
Place the CONTACTOR switch in the ON
3.
Place the CV/CC switch in the CC
Place the
4.
tion
Output Control switch
position.
position.
in the desired
posi
AIR CARBON ARC CUTTING AND -GOUGING
(ACA)
4A
Rotate the
remote)
6.
to
applicable OUTPUT Control (panel or
the desired position (see Section 5-3).
proceeding.
Install and connect unit
Rotate the ARC CONTROL to the desired
position
dry insulating gloves and clothing, and wear
welding helmet with proper fllter lens according to
Connect
Place the CV/CC switch in the desired
Section 5-7)..
4.
Place the Output Control switch in the desired
tion (see Section 5-6).
5.
Rotate the
remote)
8.
Prepare for welding
a;
b.
as
follows:
posi
applicable OUTPUT Control (panel or
position (see Section 5-3).
to the desired
Rotate the ARC CONTROL/INDUCTANCE CON
TROL to the desired position (see Section 5-4)~.
workpiece.
7.
Place the CONTACTOR switch in the ON positi~on.
Select and obtain proper electrode, and insert
into electrode holder.
8.
Wear
Press the POWER switch ON button.
10.
Beginwelding.
dry insulating gloves and clothing, and wear
welding helmet with proper filter lens according to
ANSI Z49.1.
9.
SUBMERGED ARC WELDING
a
position (see
6.
Connect work clamp to clean, bare metal at
9.
6-4.
supply
to torch air hose.
3.
Wear
ANSI Z49.1.
compressed
to Section 4.
according
air
2.
(see Section 5-4A).
7.
WARNING: Read and follow safety Informa
tion at beginning of entire SectIon 6 before
(see Section 5-6).
1.
5.
applicable.
Begin welding.
6-5.
2.
as
12. Press the POWER switch ON button.
13.
according
Install and connect unit
1.
supply valve
Prepare
cutting
Connect work
a.
(SAW)
for
gouging as follows:
clamp to clean, bare
or
metal at
workpiece.
WARNING: Read and follow safety informa
tion at beginning of entire SectIon 6 before
Select and obtain proper carbon electrode, and
insert into torch.
b.
proceeding.
10. Press the POWER switch ON button.
to Section 4.
1.
Install and connect unit
2.
Install and prepare wire feeding system according to
its Owners Manual.
3.
Install flux system
4.
Place the CONTACTOR
REMOTE position.
5.
Place the CV/CC switch in the desired
Section 5-7)..
6.
Place the Output Control switch in the desired
tion (see Section 5-6).
according
11.
6-6.
1.
7.
Rotate the
remote)
according to
its Owners
switch
in
Manual.
the
position (see
posi
SHUTTiNG DOWN
Stop welding or cutting.
Press the welding power
source
POWER switch
OFF button.
3.
applicable OUTPUT Control (panel or
position (see Section 5-3).
to the desired
2.
OFF/
Begin operation.
Turnoff the
cable.
a
WARNING:
HIGH CONCENTRATION OF
SHIELDING GAS can harm health or kIll..
S
4.
shielding gas and water supplies if appli
Shut off gas
Turn off flux
supply when
supply
and
not in use.
compressed air supply
if
applicable.
OM-126 853
Page
15
SECTION 7.- MAINTENANCE & TROUBLESHOOTING
C.
ROUTINE MAINTENANCE (Table 7-1)
7-1.
Every six months inspect the labels on
this unit for legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
when necessary. See Parts List for part number of
precautionary labels.
IMPORTANT:
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Shutdown welding po wersource, and discon
nect input power employing locko ut/tagging pro
cedures before
inspecting, maintaining,
Internal
a
of pad
line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
Keep
HOT SURFACES
.
can cause
serious
7-2.
OVERLOAD PROTECTION
4A
inspecting, maintaining,
Injury.
Consist of pad
line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
Lockout/tagging procedures
locking
burns.
servicing.
cooling period
performed only by qualified
INCORRECT FUSE
A.
Units in heavy service environ
month.
Check labels, weld cables, clean
internal parts.
3 months.
Check weld cables (see Section
7-1B).
6 months.
Check all labels (see IMPORT
ANT block, Section 7-1). Clean
internal parts (see Section7-1 C).
Frequency
of service is based on units operated
40 hours per week, Increase frequency of maim
enance if usage exceeds 40 hours per week.
A.
damage unit.
Maintenance
ments:
Every
can
Use only replaceme ntfuse of same size, type,
and rating (see Parts List).
Table 7-1. MaIntenance Schedule
Every
orseri
icing.
persons.
Every
kill.
Do not touch live electrical parts.
cedures before
Maintenance to be
Frequency
can
Shutdown welding powersource, and discon
moving parts.
can cause severe
WARNING: ELECTRIC SHOCK
nect input power employing locko ut/tagging pro
before
Allow
proceeding.
Every six months blow out or vacuum dust and dirt from
the inside of the welding power source. Do not remove
the outer enclosure, but blow a clean, dry airstream
through the cabinet lovers. U dusty or dirty conditions are
present, clean the unit monthly.
locking
away from
WARNING: Read and follow safety Informa
beginnIng of entire Section 7-1 before
tion at
orserv
icing.
Lockout/tagging procedures consist
MOVING PARTS
Cleaning
Main Fuse Fl
a
(Figure 7-1)
WARNING: Read and follow safety Informa
tlon at beginning of entire Section 7-2 before
proceeding.
The unit is protected from overload by fuse Fl located on
the center panel. if fuse Fl opens, the unit will be com
pletely inoperative.
To
replace Fl, proceed
as
follows:
1.
Remove the unit top
2.
Check Fl, and replace if necessary.
3.
Reinstall unit top
B.
Control Circuit Fuse F2 (Figure 7-1)
cover.
cover.
Fan Motors
This unit is equipped with two exhaust fans and relies on
forced draft for adequate cooling. The fan motors are
manufactured with lifetime sealed bearings and require
no maintenance.
B.
Weld Cables
a
WARNING: Read and follow safety Informa
beginning of entire SectIon 7-1 before
tlon at
proceeding.
Every three months inspect cables for breaks in insula~
Repair or replace cables if insulation breaks are
present. Clean and tighten connections at each inspec
a
WARNING: Read and follow safety informa
tion at beginning of entire Section 7-2 before
proceeding.
The power source rectifier SRi is protected from over
load by fuse F2 located behind the lower left portion of
the front panel. Should F2 open, the CV/CC and
CONTACTOR switches would not work.
To
replace F2, proceed
as
follows:
1.
Remove left side
2.
Check F2, and replace if necessary.
3.
Reinstall left side
panel.
tion.
tion.
OM-126 853
Page
16
panel.
Fuse Fl
Unit Front
Panel
input
Terminal
With
Input Voltage Label
Jumper
Links
Strip iT,
Jumper Links
Terminal
With
Fuse F2
Located ~ehlnd
Front p,:aflSi Near
Lower) Left Side
TB-096 9i37.4
/
/I
Figure
7-1.
Component
LocatIons
/
C.
(Circuit
/~
a
Breaker
CBI(Flgure 5-1)
WARNINGS Read and follow safety Informsdon at beginning of entire Section 7-2 before
7-4.
CIRCUIT BOARD INDICATOR LIGHTS
a
WARNING:
ELECTRIC SHOCK
MOVING PARTS can cause Injury.
can
kill;
Do not touch live electrical parts.
proceeding.
Keep away from moving parts.
Circuit Breaker CB1 is an automatic-trip type breaker
and is not manually operable. When the circuit breaker
button is in (ON position), the circuit breaker is function
al. When the button is out (OFF position), the breaker is
open and not functional.
If CB1 opens when equipment use begins, a fault is
probably present in the equipment. If CB1 opens after
prolonged equipment use, an overload condition is prob
ably present. Should CB1 open, locate and correct the
problem, and manually reset CB1.
7-3.
THERMAL PROTECTION
Two normally closed thermostats TP1 are provided on
the unit. One of these thermostats is located on each
transistor module heat sink. A normally closed thermo
stat TP2 is provided on the output diode heat sink. All
three thermostats are wired in series with the main con
tactor W coil. If any heat sink becomes too warm, the re
spective thermostat opens, W contacts open, and the
unit completely shuts down (thermal overload). The
thermostat(s) automatically close when the unit cools
down. After a cooling period, press the POWER switch
ON button to resume operation.
Only qualified persons familiar with
ing standard safety practices are
maintain,
or
and follow
to
inspect,
service.this unit.
uses fiber optics fortransmitting control circuit
ry signals. The light wavelengths used are visible to the
human eye. There is one unnumbered fiber optics cable
from the control circuit board PCi to each of the four indi
vidual base drive boards PC2 and PC3.
This unit
Each of the four base drive boards PC2 and PC3 are
a red indicator light LED 50. The light will
be on when the contactor is energized and the pulse
width modulatorchip on PCi is operating. It is normal for
the LEDs 50 to be on during welding. The brightness of
the LEDs is proportional to machine output, and all
LEDs at any given time should .have the same relative
equipped with
brightness.
balance circuit board PC5, located next to
main control circuit board PCi, is equipped with a red in
dicator light LED1 This light is normally off during opera
tion. LED I only turns on when operating on 460 volts in
put power and a transistor module voltage imbalance
occurs. If LED 1 is on, no machine open-circuit voltage
Additionally,
.
will be available when the contactor is
energized.
OM-126 853
Page
17
CIRCUIT BOARD HANDLING PROCEDURES
7-5.
a
WARNING: ELECTRIC SHOCK
can
7-i. TROUBLESHOOTING (Table 7-2)
a
kIll.
Do not touch live electrical parts.
can kill.
Do not touch live electrical parts.
Shutdown welding powersource, and discon
n~ctinputpoweremploying locko ut/tagging pro
gey#ures before inspecting, maintaining, orseri
~
Shutdown welding powersource, and discon
nect input power employing locko ut/tagging pro
cedures before inspecting, maintaining, orserv
icing.
WARNING: ELECTRIC SHOCK
icing.
LoCkC~utJtagging procedures
k~ckin~ line disconnect switch
consist of pad
in open position,
removt~,g fuses from fuse box, or shutting off and
red-tag~jng circuit breaker or other disconnect
-
consist of pad
in open position,
1removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
Lockout/tagging procedures
locking line disconnect switch
ing devke.
MOVING ARTS
ing device.
can cause
serious
Injury.
Keep awqy from moving parts.
HOT SURFAC~
4A
(ESO)
can
Put
FORE
on
damage circuIt boards.
properly grounded wrist strap BE
Perform work only at
a
static-safe work area.
INCORRECT INSTALLATiON
can
damage
mIsaligned
or
circuit board.
Be sure that plugs are
properly installed and
aligned.
EXCESSIVE
board.
PRESSURE
can break
circuIt
only minimal pressure and gentle move
disconnecting or connecting board
plugs and removing or installing board.
Use
ment when
Table 7-2.
be
servicing.
performed only by
It is assumed that the unit was proper4y installed accord
ing to Section 4 of this manual, the o~,erator is familiar
with the function of controls, the
power source
was Working properly, and that the troub~le is not related
weldi~ig
to the
welding process.
The following table is designed to diagnose and provide
remedies for some of the troubles that may dEwelop in
this welding power source. Use this tablein
con~jnction
with the circuit diagram while performing troubIe~shoot
ing procedures. If the trouble is not remedied after~ per
forming these procedures, contact the nearest Fac~ory
Authorized Service Station. In all cases of equipm~nt
malfunction, strictly follow the manufacturers proce~
dures and instructions.
Troubleshooting
PROBABLE CAUSE
TROUBLE
No weld
Troubleshooting
qualified persons:
to
burns.
handling circuit boards.
Transport circuit boards in proper staticshielding carriers or packages.
plugs
Allow cooling pe:.:~~ before
ELECTROSTATIC DISCHARGE
CAUTION:
can cause severe
REMEDY
output; unit completely Une disconnect switch in the Place line disconnect switch in the ON
inoperative;piIot light
PLI not
on.
~
OFF
position.
position.
Line
fuse(s) open.
Check and
Improper
electrical
nections.
input
con-
See
Section
connections.
Check W
Contactor W.
replace
line
4-4
fuse(s).
for
proper
input
points for wear, and replace points
if necessary.
Fuse Fl open.
.
Unit
Check and replace Fl if necessary (see
Section 7-2).
caused Allow unit
overheating
TP1
and/or
TP2
thermostat(s)
to open (thermal shutdown).
.
to cool down
(see Section 7-3).
No weld output; unit completely Line voltage too high or too low Contact local electric utility to check
inoperative; pilot light PL1 on.
(–10% is maximum fluctuation correct line voltage problems.
and
tolerated).
Transistor
imbalance.
module
voltage Check status of LED
1 on PC5 according to
Section 7-4, and contact factory Service
~
~
OM-126 853
Page
18
Department.
Table 7-2.
Reduced output voltage; only onehalf of unit output voltage available;
one transistor module inoperative,
Input
Troubleshooting (Continued)
voltage
jumper
connected for incorrect
links
See Section 4-4 for proper connections.
input
voltage.
Poorand/orimproperinputand/ See Sections 4-4 and 4-3
and output connections.
output connections.
for proper
input
or
Base drive circuit board(s) PC2
and/or PC3 inoperative.
Check status of LEDs on PC2 and/or PC3
according to Section 7-4, and contact
factory Service Department.
I mproperfiber optic connection.
Contact
-
Erratic
or
improper weld output
incorrect
welding
cable size.
factory Service Department.
Use proper size and type of cable (see
Section 4-3).
Loose or dirty welding cable
connections.
Clean and
tighten
all
welding
Poorand/orimproperinputand/ See Sections 4-4 and 4-3
and output connections.
output connections,
connections.
for proper
inpult
or
.
Improper wire feeding setup,
applicable.
if
See installation Section
Owners Manual.
in
wire
feedeir
CV/CC
CONTACTOR
and
switches inoperative.
Fuse F2 open.
Check and replace F2 if necessary (see
Section 7-2).
Reduced output voltage; only onehalf of unit output voltage available,
Base drive circuit board(s) PC2
and/or PC3 inoperative,
Check status of LEDs on PC2 and/or PC3
according to Section 7-4, and contact
factory Service Department.
OM-126 853
Page
19
NOTES
OM-126 853
Page
20
SECTION 8- ELECTRICAL DIAGRAMS
~R2
/
START
~
COO
/
LIO5
C.,
P30
POWER
c~4
2300)
/
3
1~
C21
~
~LE2
L2C
0
4600
I
z
C24
COO
230)
A
~
If.
L3O
)~.LE
E
~
TEl
C21fl
COO
I~j
C)
(5
II!
TI
9
--
~.
5/
I
_.Aic
0
pTc9
PC5
44
0
~ RCS*
C
cc
-
______
~4SI0
_4z_L<<
2300.
I
~flII
C
12
I
~
LErT~j02j1~103
4600
~~2~STTFeL
29
Bz
2200.
I
PC2
tE2
C
I>>05I
so
(
TRANSISTOR
~06~j
1
R(GHTf~ ~9~
~!k~
:
C
I
TE2
II
:
~.J>>o~i
30I9UT 0I~
)EATSITS.
9*09
~
2!
C
MODI
ILE~
1~
IE~~
JTI~
r1
I
I
fl9cJ
l~
I-–
((SPEW)
~ ~0I2
E
C*03
(5
BOARD
C)
(5
~OI3
A
____________
~0I
TRAIGISTOW
)ATSOM(S
C-)
2
~:
_~
=
=
=
025
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
_________
IC:
~E~j~j
rneHT~9~OA I~I ~I
~C~RI
II
-
026
-
C
I
AR
~i(l,lEl.IE
2
TRANSISTOR MODULE 2
E~__
~0I7
Ii
:c
t;;
I>>~
=
=
-
C
I
=
=
(LOWER)
C.)
~g
1~
POSITIVE
IS
C)
(5
______
I
_____
-~
~OWj~jt 4~
irir P1
JPCS2BI
TI--lI
C!
o-
1/!,
-~-co-~--2--~
I
F
~
II
~~JI
AR
IL
cat
I
(9,4
PiLiRiEiPlI
__________________
El
I
NEGATIVE
______
RIo
I
TO
,~CI
I
pCS
_____
b~1L~J
/5
TO
~I
~45V.~(
~
CR2
~vi
I~<<ARCACRCC~CSCF
_____________
~11
CST
_______
O
to
TCGATOVE
~
I
~r
I
~
50
TARS
I
O27~ a
6
~.A
____
A-P
10
TOACOC
CA-CF
TO
PCI
K>>
RCSI
0404
I
AS
~
________
______________
_____________
-~
~
SO o
AC
LED
221.U.
TO 051
09 PC2
ITRARDISTOW
LED
oo4.-
10091
09 PCO
(191)
TO DPI
09 PC2
(193)
To 051
09 PC3
(lAS)
RC52
(FIRER SRTICS)
LED
-<<RI-OAR.
TO,
S >)~-
(
I
J
I
CI6
__________
S1PL
68
4WP.
r<<~~
I F,j
I
_______________
I-!
BC
FP!CT!OW
(
-<<A(2*0.I
~
I
SR
PA
I
I
0
9
0
AC
RMTI~W
DJTPIJT
~
AH._~::~.:l~__S.
ARC
I~.J..E
I
C09~/
LEADS FR~I
ARCPRR
1ST
49
0
/20
0
/09
..0
3)
/i!
I
32
~
2
6
301076
55
0
76
s,
o
,,
2010
rfi2~
21
DC.
cv
OM-126 853
Page
21
.?~
V.
AA-AH
ON
PC5O
A-P
ON
PC~I
CA-CF ON PC52
I F~
cw
~.npuT
C3~TP~.
~
V~.TAG
cv
.I~
V.
-I~ V.
Diagram
OM-126 853
Page
22
8-2. Circuit
Diagram For Control Circuit Board PCi
.15
V.
~
I~V
.15
V.
Cu
10
*1,
~
~_:~ ~
~CU
V.
V.
I5
V.
~ ~C64
I.~2
039
~e
.1!
037
~63I4I5
-.
052
051
23
15V..ISV.
-,
f~I
22
1~1
L11 1J
U5 I
S
I0
20
~~8D~0
I
C
26
V.
.15
039
03*
-....)~
~
2
2
V60
U52
038
036
C70
~AOE
I~L.
V~TAG
~jPI
C72
9V80 FRICTI00
r~
TABS
-
~
-
-
-
rr
--
-4;
C99
~A5965
CII
Dl
8
5
13
21.1871
19
2312
2622
II
9
57
I~~T0L~J
¶~
010
CIA
L
859
58
*0.i.
02
CV
~HXNY
L~J~
cc
552
C73
1~15
1F605
ICAIl.
L1~
!
05
IV
2
.15
300
A51
+
CIOl
~
6
144
-
~JTY
CV ~E
-
C93~~
.15
~
1.1 1
V.
6F
-I.
,
L2
ARC
:1
c~4TRU_/
ITOCTANcE
~ ~I3 1C12
80
>5
I
F#E~00CV
~~i
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do
CW
SCM~E
~SV~
.15
V.
C92
.18
3
2
r+A9
#8
73
.15*
V.
IS
V
*57
3
+
3
ID
~
~3
~L6
7
053
657
15
C16
.15
V.
+
cc
s5I
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.15
V.
5
6O~~~7
*
C91
8*
o~
5
-IS
+
7
15
V.
*62
______________________________________
6
8
081
cie
Circuit Diagram No. D-119 151
OM-126 853
Pa~e
23
.12
V.
I
-by.
a
-12
V.
c6o
-12
-2
V.
12
V.
V.
065
-12
V.
C
Circuit Diagram No. B-122 636
Diagram
8-3. Circuit
Diagram
48
(C
25
(A
53
(B
For Base Drive Circuit Boards PC2 And PC3
IRlo
)I
1R211
1R22
45
Circuit Diagram No. A-123 501
Diagram
OM-126 853
Page
24
8-4. Circuit
Diagram
For Snubber Circuit Board PC4
687
B-107
A
No.
Diagram
Circuit
Isv.
-
PC5
Board
Circuit
Balnce
For
Diagram
CircuIt
8-5.
Diagram
FROM BOARD
EXIT PC
I
~
15V.
.
lciiIs~ TCI2
~
3
~
~
ICI
~
~CI4I
£
D4,d
I
~D2
j.
D3
DI
Rc04
<
ON
AD
AC<
AA(
C
DO
A -AF
A
0
rs
0) 0) 01 C.) -u (0 0
01
SECTION 9
PARTS LIST
9
>1
E
Ce
/
OM-126 853
Page
26
IL
Item
No.
Part
No.
Dia.
Mkgs.
Descnption
FIgure
1
2
Zi
3
4
5
6
7
8
Cii ,2
TM1 ,2
RC5O
9
10
11
PCi
12
RC51
13
14
109005
098 451
010 116
09~ 462
Fig 9-3
096 659
122950
072 566
097 474
119219
080 509
081 380
096 430
1186730008626
+1065370008626
124 245
0345870008398
15
083 426
601 835
601 836
038
038
010
010
010
16
C1,2
.
17
18
19
-
FM1,2
888
887
913
915
957
111 019
022 160
096 601
109004
124 175
120 131
20
21
22
23
24
25
26
27
28
117037
096 454
T2,3
124 419
124416
124 415
Ti
124 152
096427
Fig 9-2
098 173
096423
9-1. MaIn
Quantity
Assembly
COVER,top
1
STABILIZER
1
GROMMET, rbr .375 ID
x
.500
I
BAFFLE, air
BAFFLE, center w/components
1
TRANSFORMER,
2
.
1
current
TRANSISTOR ASSEMBLY, main
HOUSING, term header 8 pin
CABLE, fiber optics w/plugs
(Fig 9-4)
2
1
4
CIRCUITCARD,control
GROMMET, scr No. 8/10
HOUSING, term header 14 pin
PANEL, mtg circuit card
1
.5
1
1
PANEL,rear
PLATE, cover terminal assembly
LABEL, warning electric shock can kill etc
TERMINAL ASSEMBLY, primary (consisting of)
TERMINAL BOARD, primary
NUT, brs hex 10-32 reg
NUT, brs hex .250-20 jam hvy
STUD, primary board brs .250-20 x 1.500
STUD, primary board brs 10-32 x 1.375
WASHER, fIat brs .187 ID x .500 OD
WASHER, flat brs .250 ID x .625 OD
TUBING, stl .500 OD x l7ga wall (mtg terminal assembly)
CAPACITOR, elctlt 2500uf 45OVDC pair
CLAMP, capacitor 3.000 dia
1
1
1
1
1
6
2
I
3
3
2
2:
1
2
BRACKET, mtg fan motor
PANEL,sideRH
FAN, motor 230V50/60 Hz (consisting of)
HOUSING, plug nyl 2 contacts
HOUSING,termheater2skt
BRACKE1~ mtg transformer
2
1
TRANSFORMER, power main 320 (consisting of)
COIL, pri/sec 320 bottom
COIL, pn/sec 320 top
TRANSFORMER, KVA 1/2 115-230-2301230-4
2
BASE
1
2
ii
2
2
PANEL, front w/components
DIODE MODULE (Fig 9-2)
PANEL,sideLH
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-126 853
Page
27
913
TC-13
~15
14
ii:::
21
22
\
29
W/Compnets
Front
Pane,
9-2.
Figure
0
M
cli (.3 -o
3
Item
No.
Dia.
Part
Mkgs.
No.
FIgure 9-2. Panel, Front W/Components (Fig
097 922
126 600
0937270008398
1
2
3
4
5
R28,29
6
S1-3
7
8
9
10
11
lOT
CB1
R31
TD1
12
13
CR3
14
R30
PB1
15
16
17
18
19
20
21
Cl 0,11
22
23
24
25
26
27
28
29
30
31
32
33
34
HD1
SR1,2
35
36
R25
37
38
C16,17
F2
39
40
41
42
R26
43
C6
44
45
PL1
035 897
011 609
1224460008398
038 782
011 991
030 047
047 133
1224420008398
108 358
030087
105 572
081 008
090 354
018 606
027 878
059 885
087 209
039 047
039 046
601 976
039 049
039 045
601 880
039 044
601 879
+118671 0008625
106353
121316
108 830
035 704
~72 253
090 476
601 394
000 859
*012 643
093 376
010 311
099 596
601 934
031 613
010610
048 573
Quanflty
Descnption
9.1 Item
26)
KNOB, pointer
PLATE, control panel
PANEL, mtg components
NAMEPLATE, (order by model & serial number)
POTENTIOMETER, C sltd 5ff lIT 2W 1K ohm
SWITCH, tgl SPDT 15A 125VAC
BRACKET, mtg block terminal
BLOCK, term 20A lop
CIRCUIT BREAKER, man reset 1 p 1 .5A 250V
RESISTOR, C .5W 39K ohm
RELAY, delay adj 120 VAC DPDT
BRACKET, mtg relay
2
CONTACTOR, def pip 25A
2P 24VAC coil
1
RESISTOR,WWfxd25W200ohm
SWITCH, pb (consisting of)
BRACKET, mtg switch
PUSH BUTTON SET, w/cable & housing
SPRING, compression
SWITCH, limit leaf actuating SPDT
BUTTON, push reset red
ii
CAPACITOR,
disc .OO3uf 2000VAC
TERMINAL, pwr output red (consisting of)
TERMINAL, pwr output black (consisting of)
SCREW, cap hex hd 1/2-13 x 1-1/2
TERMINAL BOARD, red
TERMINAL BOARD, black
NUT, hex jam 1/2-13
BUS BAR
NUT, hex full 1/2-13
PANEL, front
2
SENSOR,current
LABEL, warning general precautionary
BRACKET, mtg rectifier
1
RECTIFIER, integrated 30A 600V
STUD, gid 10-32 x 1/2
CAPACITOR ASSEMBLY, (consisting of)
RESISTOR, C 2W 10K ohm
CAPACITOR, elctlt 220uf 35V0C
FUSE, minat gi sb bbo 1A
HOLDER, fuse minat
CLAMP, nyl .875 clamp dia x .500
CAPACITOR ASSEMBLY, (consisting of)
RESISTOR, C 2W 10K ohm
CAPACITOR, elctit lOOuf 15OVDC
2
1
1
1
2
3,
1
1
1
1
I
1
1
-
1
cer
1
1
1
1
1
1
.
CONNECTOR,clamp
1
1
1
1
1
I
1
:2
1
1
1
1
1
1
cable .500
1
LIGHT, md red lens 28V
1
+When
ordering a component originally displaying a precautionary label, the label should also be ordered.
*Re~mmended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-126 853
Page
29
N
U,
C
C,
C
0
a.
E
0
C)
OM-126 853
Page
30
Item
No
Dia.
Mkgs.
Part
No.
Description
Figure
1
081 016
2
082456
070250
098975
034896
057358
*012639
070 404
108831
107597
096517
096759
080509
3
4
025,26
R23,24
Wl1,2
5
6
7
Fl
9
10
PC5
11
12
13
9-3. Battle, Center
Quantity
W/Components (Fig
9-1 Item
5)
BRACKET, mtg
DIODE ASSEMBLY, (consisting of)
DIODE, 3A 600V
RESISTOR,WW fxd 1 OW 500 ohm
INTERLOCK, cntor NC
BUSHING, snap-in nyl 1.000 ID x 1.375 mtg hole
FUSE, crtg 6A 600V
HOLDER, fuse crtg
ANGLE, mtg components
CIRCUIT CARD, balance
1
1
2.
1
2
1
1
1
1
1
HEAT SINK
WEATHERSTRIPPING, adhesive rbr 1/2
GROMMET, scr No. 8/10 panel hole
1
x
1/2
(order by ft)
2rt
4
14
PMI-3
095279
DIODE, power module 55A 1400V
3
15
16
17
C20-25
087 337
096606
118 153
015712
015 722
038 639
038620
120 561
027811
026 202
027810
108842
096 463
038 887
601 835
010913
CAPACITOR, cer disc .OO3uf 3000 VAC
BUS BAR, jumperpri
BAFFLE, center
GROMMET, rbr .625 ID x .875 mtg hole
GROMMET, 1-1/4 ID x 1-1/2 mtg hole
6
2
18
19
TE2
20
21
D27
22
23
CR2
TEl
038 618
026 754
24
R1,2
25
26
27
28
W
098864
079 844
048 029
603 097
111 461
028 982
*003 567
4
BLOCK, term 30A 6P
LINK, jumper
2
CONNECTOR, term block 20A
SOCKET, relay
10
DIODE, 1A400VSP
RELAY, end 24VDC 4PDT
TERMINAL ASSEMBLY, pn iph 2V (consisting of)
TERMINAL BOARD
STUD, brs No. 10-32 x 1-3/8
NUT, brs hex 10-32
WASHER, flat brs 3/16 ID x 1/200
4
8
4
LINK, jumper
2
INSULATION, pri stud barrier
4
RESISTOR, WW fxd low 20K ohm
SPRING, hoiddown relay
CLIP, retaining socket relay
2
GROMMET, rbr .84310 x 1.250 mtg hole
CONTACTOR, 50A 3P 1 20V (consisting of)
1
COIL
1
KIT, point
:3
Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-126 853
Page
31
4,
1
16
11
19
Ret. TD-091 114-9
Figure
OM-126 853 Page 32
9-4. Transistor
Assembly, Main
Item
No.
Dia.
Part
Mkgs.
No.
1
.
2
Qi-lO
3
4
5
6
7
PC2,3
8
TP1
9
10
Dl ,3
11
12
R3,7&8,9
13
14
R13-20
15
C3,5,12,13,18,19
16
17
.
-
18
29
.
-.
Quantity
Description
9-4. Transistor
098 335
Figure
122949
096 769
122 931
122776
122 930
126 102
122920
098 691
032 810
096 766
095 254
096 770
125 844
113 781
126 109
074 111
098 325
126 108
122 923
098 219
094 300
098 252
098 253
098 254
098 255
010 885
MODULE, (consisting of)
Assembly,
Main
(Fig
9-1 Item
7)
2
2
BUS BAR, driver board to collector bus bar
BUS BAR, emitter
2
~TRANSISTOR,NPN3OA850V
HEAT SINK, transistor
CIRCUIT CARD, base drive
BAFFLE, air
STAND-OFF, No. 6-32 x 1/2
THERMOSTAT, NC
10
1
.
2
.
1
.
.
.
.
.
.
4
1
BUS BAR, diode to emitter bus bar
DIODE, 30A 300V
BUS BAR, drive board to emitter bus bar
2
RESISTOR ASSEMBLY, (consisting of)
RESISTOR, C 2W lOOK ohm
BUS BAR, diode to collector bus bar
RESISTOR, C 2W 47 ohm
CAPACITOR, poly film .027uf 630V
2
2
4
2
.
1
4
6
BUS BAR, collector
ANGLE, mtg heat sink
BAFFLE, air & cable support
BUSHING, snap-in 5/8 OD x 1/2 ID
BUS BAR, cap to emitter 3/16 x 3/8 x 4-3/8
BUS BAR, cap to emitter 3/16 x 3/8 x 5-1/8
BUS BAR, cap to collector 3/16 x 3/8 x 4
BUS BAR, cap to collector 3/16 x 3/8 x 3-3/4
STRIP, conductor .031 x .375 x 5.375
2
2
1
4
1
1
1
1
1
BE SURE TO PROVIDE MODEL AND SERiAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-126 853
Page
33
Item
No.
Dia.
Mkgs.
1
2
3
4
5
6
7
D9-24
TP2
8
PC4
9
10
Part
No.
Quantity
Desciiption
098173
FIgure 9-5. Module, Diode (Fig
026947
096 604
096603
096421
095 251
032810
052413
098 154
098 691
038328
STAND-OFF, 1/4-20 x 1
ANGLE, mtg heat sink diode
STRIP, mtg components
HEAT SINK, diodes
DIODE, 70A 400V
THERMOSTAT, NC
STUD, brs 1/4-20 x 7/8
CIRCUIT CARD, snubber
STAND-OFF, No. 6-32 x 1/2
STUD, brs 1/4-20 x 1-1/4
9-1 item
27)
4
2
2
1
16
1
4
1
2
2
6
TC-097115-8
FIgure
9-5. Module, Diode
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-126 853
Page
34