Miller February - Norco Medical€¦ · ERRATASHEET Afterthismanualwasprinted, refinementsin...

Miller February 1990 FORM: OM-317B

Effecfive With Serial No. JK646436

MODEL: DIALARCfi 400 AC/DC

OWNER�S MANUAL

IMPORTANT: Read and understand the entire contents of this manual, with

special emphasis on the safety material throughout the manual, beforeMILLER ELECTRIC Mfg. Co.AMHe~~~Ltd.. Co~any

installing, operating, or maintaining this equipment. This unit and these

Instructions are for use only by persons trained and experienced in the safe1079

Ap~leton, WI 54912 USA

operation of welding equipment. Do not allow untrained persons to install, Tel. 414-734-9821

operate, or maintain this unit. Contact your distributor if you do not fullyunderstand these instructions.

PRINTED IN U.S.A

_J <,,�I�

LIMITED WARRANTY

EFFECTIVE: MARCH 15, 1989

This warranty supersedes all previous MILLER warranties and is exclusivewith no other guarantees or warranties expressed or implied.

LIMITED WARRANTY � Subject to the terms and conditions

hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants

to its Distributor/Dealer that all new and unused Equipment fur

nished by Miller is free from defect in workmanship andmaterial

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 originalpurchase, except Tecumseh and Onan engiqes 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, MILLERMATIC parts that come in contact with the welding wire includ

ing nozzles and nozzle insulators where failure does not result

from defect in workmanship or material.

Miller shall be required to honor warranty claims on warranted

Equipment in the event of failure resulting from a defect within

the following periods from the date of delivery of Equipment to

the original user:

1. Arc welders, power sources, robots, and 1 year

components2. Load banks 1 year3. Original main power rectifiers 3 years

(labor � 1 year only)4. All welding guns, feeder/guns and torches 90 days5. All other Millermatic Feeders 1 year6. Replacement or repair parts, exclusive of labor 60 days7. Batteries 6 months

provided that Miller is notified in writing within thirty (30) days of

the date of such failure.

As a matter of general policy only, Miller may honor claims

submitted by the original user within the foregoing periods.

In the case of Miller�s breach of warranty or any other duty with

respect to the quality of any goods, the exclusive remedies

therefore shall be, at Miller�s option(1)repairor (2) replacementor, where authorized in writing by Miller in appropriate cases,

(3) the reasonable cost of repair or replacement at an author

ized Miller service station or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual

use) upon return of the goods at Customers risk and expense.MILLER�s option of repair or replacement will be FOB., Fac

tory at Appleton, Wisconsin, or FOB. at a MILLER authorized

service facility, therefore, no compensation for transportationcosts of any kind will be allowed. Upon receipt of notice of ap

parent defect or failure, Miller shall instruct the claimant on the

warranty claim procedures to be followed.

ANY EXPRESS WARRANTY NOT PROVIDED HEREINAND ANY IMPLIED WARRANTY, GUARANTY OR REPRE

SENTATION AS TO PERFORMANCE, AND ANY REMEDYFOR BREACH OF CONTRACT WHICH, BUT FOR THIS

PROVISION, MIGHT ARISE BY IMPLICATION, OPERATIONOF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,INCLUDING ANY IMPLIED 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 ULTIMATE PURCHASE BY COMMERCIALi1NDUSTRIAL USERSAND FOR OPERATION BYPERSONSTRAINEDAND EXPE

RIENCED IN THE USE AND MAINTENANCE OF WELDINGEQUIPMENT AND NOT FOR CONSUMERS OR CON

SUMER USE. MILLER�S WARRANTIES DO NOT EXTEND

TO, AND NO RESELLER IS AUTHORIZED TO EXTENDMILLER�S WARRANTIES TO, ANY CONSUMER.

UI

ERRATA SHEET

After this manual was printed, refinements in equipment design occurred. This sheet lists exceptionsto data appearing later in this manual.

Replace warranty with the following:

.j� -~.. i.

MILLER�S TRUE BLUETM LIMITED WARRANTY

Effective January 1, 1992

(Equipment with a serial number preface of �KC� or newer)

This limited warranty supersedes alt previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.

LIMITED WARRANTY � Subject to the terms and conditiona below. MILLER Electric � Accessory Kits

Mfg. Co., Appleton. Wisconsin, warrants tO its original retail purchaser that new * Replacement PartsMILLER equipment sold after the effective date of this limited warranty is free of de

fects in material and workmanship at the time it is shipped by MILLER. THIS WAR-.

PANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES. EXPRESS ORMILLER S True Blue Limited Warranty shall not apply to:

IMPLIED. INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT-

NESS. 1.. Items furnished by MILLER. but manufactured by oth�irs. such as engines or

trade accessories. These items are covered by the manufacturer�s warranty, It

Within the warranty periods listed below. MILLER will repair or replace any war- any.

ranted parts or components that tail due to such defects in material or workmanship.MILLER must be notified in writing within thirty (30) days of such defector failure, at 2.. Con~umabIe components; such as contact lips, cutting nozzles. contactora

which lime MILLER will provide instructions on the warranty ciaim procedures lobe and relays.

followed.

3.. Equipment that has been modified by any party other than MILLER. or equip.MILLER shall honor warranty claims on warranted equipment listed below in tP,e ment that has been improperfy Installed, improperly operated or misused

event of such a failure within the warranty time periods. All warranty time periods based upon industry standards, or equipment which has not had reasonable

start on the date that the equipment was delivered to the original retail purchaser, and necessary maintenance, or equipment which has been used for operation

and are as follows: outside oI the specifications for the equipment.

1.. 5 Years Parts �3 Years Labor MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER

CIALJINDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN� Original main power rectifiers THE USE AND MAINTENANCE OP WELDING EQUIPMENT.

2.. 3 Years�Parts and LaborIn the event of a warranty claim covered by this warranty, the exclusive remedies

� Transformer/Rectifier Power Sources shall be. at MILLER�S optIon: (1) repaIr; or (2) replacement; or. where authorized In

� Plasma Arc Cuffing Power Sources writing by MILLER inappropriate cases. (3) the reasonable cost of repair or replace-* Semi-Automatic and Automatic Wire Feeders ment at an authorized MILLER service station: or (4) payment of or Credit forthe pur�

P b tschase price (less reasonable depreciation based upon actual use) upon return of the

0 0goods at customer�s risk and expense. MILLER�S option of repair or replacement

3.. 2 Years � Parts and Labor wilt be FOB.. Factory atAppleton. Wisconsin. or FOB. ate MILLER authorized ser

vice facility as determined by MILLER. Therefore no compensation or reimburse-

Engine Driven Welding Generators ment for transportation costs of any kind will be allowed.

(NOTE: Engines are warranted separately by the engine manufacturer.)

4 ,,, ~TO THE EXTENT PERMITTED BY LAW. THE REMEDIES PROVIDED HEREIN

ear � arts and rARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE

� Motor Driven Guns LIABLE FOR DIRECT, INDIRECT. SPECIAL, INCIDENTAL OR CONSEQUENTIAL� Process Controllers DAMAGES (INCLUDING LOSS OF PROFIT). WHETHER BASED ON CON

� Water coolant SystemsTRACT, TORT OR ANY OTHER LEGAL THEORY.

� HF UnitsANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR-

� Grids PANTY. GUARANTY OR REPRESENTATION AS TO PERFORMANCE. AND ANY* Spot Welders REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL� Load Banks THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION.

� SDX TransformersOPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING. IN

CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS* Running Gear/Trailers

FOR PARTICULAR PURPOSE, WITh RESPECT TO ANY AND ALL EQUIPMENT� Field Options FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.

(NOTE: Field options are covered under True Blue for the remainingwarranty period of the product they are Installed in. or for a minimum ot Some states In the U.S.A. do not allow limitations of how long an Implied warranty

one year � whichever is greater.) lasts, or the exclusion of Incidental, Indirect, special or consequential damages, so

the above limitation or exclusion may not apply to you. This warranty provides ape-

5.. 6 Months � Batteries cific legal rights, and other rights may be available, but may vary from state to slate.

6.. 90 Days � Parts and Labor.

in Canada, legislation In some provinces provides for certain additional warranties

� Ior remedies other than as stated herein, and to the extent that they may not be

u 0 C CSwaived, the limitations and exclusions set Out above may not apply. This Limited

� Plasma cutting Torches Warranty provides specifIc legal rights, and other rights may be available, but may� Remote Controls vary from province to province.

_1

�I �WI,

AMENDMENT TO SECTION 9� PARTS LIST

Amend Parts List as follows:

Dia. Part ReplacedMkgs. No. With Description Quantity

21-4....

W...

009 859..

137 900.. KIT, contactor (Eff w/KB022071) 1

21-25 081 016~.. Deleted..

Effw/KB022071 1

~First digit represents page no � digits following dash represent item no.

+Quantity changes for 090 716 Assembly only.BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-317B Page 2

OM.3178-2/gO

RECEIVING-HANDLING

Before unpacking equipment, check carton for any dam- Use the following spaces to record the Model Designaage that may have occurred duiing shipment. File any tion and Senal or Style Number of your unit. The infor

claims for loss or damage with the delivering carTler. mation is located on the data card or the nameplate.Assistance for filing or settling claims may be obtained

from the distnbutor and/or the equipment manufactur- Model___________________________�

er�s Transportation Department.Serial or Style No.

________________�

When requesting information about this equipment, al

ways provide the Model Description and Serial or Style Date of Purchase_________________�

Number.

TABLE OF CONTENTS

Section No. Page No.

SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE

1-1. Introduction 1

1-2. General Precautions 1

1-3. Arc Welding 4

1-4. Standards Booklet Index 5

SECTION 2� SAFETY PRECAUTIONS AND SIGNAL WORDS

2-1.

General Information And Safety 6

2-2. Safety Alert Symbol And Signal Woitis 6

SECTION 3� SPECIFICATIONS

3-1. Volt-Ampere Curves 8

3-2. Duty Cycle 8

3-3. Description 8

SECTION 4- INSTALLATION OR RELOCATION

4-1. Site Selection 8

4-2. Transporting Methods 9

4-3. Weld Output Connections 9

4-4. Remote Amperage Control Receptacle Information And Connections 10

4-5. Electrical Input Connections 10

SECTION 5- OPERATOR CONTROLS

5-1. Power Switch 13

5-2. Range Switch 13

5-3. AC/DC Selector Switch 13

5-4. Amperage Adjustment Control 13

5-5. Remote Amperage Control Switch 13

5-6. Control Circuit Overload Breaker 13

Section No. Page No.

SECTiON 6� SEQUENCE OF OPERATION

6-1. ShIelded Metal Arc Welding (SMAW)6-2. Shutting Down

SECTION 7- MAINTENANCE & TROUBLESHOOTING

Routine Maintenance

Oveiload Protection

Thermal Protection

Voltage Reducer Circuit OperationCircuit Board Handling Precautions

Troubleshooting Chart

SECTION 8- ELECTRICAL DIAGRAMS

Diagram 8-1. Circuit Diagram

Diagram 8-2. Circuit Diagram For Firing Board PCi

Diagram 8-3. Circuit Diagram For Voltage Reducer Board PC2

SECTION 9� PARTS LIST

Figure 9-1. 20

Figure 9-2. 22

Figure 9-3. 24

Figure 9-4. 25

Figure 9-5. 26

Figure 9-6. 28

Figure 9-7. 30

Figure 9-8. 30

Figure 9-9. 31

Figure 9-10. 32

Table 3-1. 7

Chart 3-1. 7

Chart 3-2. 8

Table 4-1. 9

Table 4-2. 11

Table 7-1. 15

Table 7-2. 16

7-1.

7-2.

7-3.

7-4.

7-5.

7-6.

14

14

14

15

15

15

15

16

17

17

18

Main AssemblyPanel, Front - w/ComponentsSwitch, PIrt

Switch, RangeCircuit Card, MA Control PCi

Circuit Card, Voltage Reducer PC2

Switch, PB

Rectifier, Si Diode

Panel, Rear - w/ComponentsSCR Contactor & Primary Terminal

LIST OF CHART AND TABLES

Specifications

Volt-Ampere Curves

Duty CycleWeld Cable Size

Input Conductor And Fuse Size

Maintenance Schedule

Troubleshooting Chart

SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE

1-1. INTRODUCTION

We learn by experience. Learning safety through per

sonal experience, like a child touching a hot stove is

harmful, wasteful, and unwise. Let the experience of

others teach you.

Safe practices developed from experience in the use of

welding and cutting are described in this manual. Re

search, development, and field experience have

evolved reliable equipment and safe installation, operation, and servicing practices. Accidents occur when

equipment is improperly used or maintained. The rea

son for the safe practices may not always be given.Some are based on common sense, others may requiretechnical volumes to explain. It is wiser to follow the

rules.

Read and understand these safe practices before at

tempting to install, operate, or service the equipment.

Comply with these procedures as applicable to the par

ticular equipment used and their instruction manuals, for

personal safety and for the safety of others.

Failure to observe these safe practices may cause sen

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 safetyare also available for additional and more complete procedures than those given in this manual. They are listed

in the Standards Index in this manual. ANSI Z49.1 is the

most complete.

The National Electrical Code, Occupational Safety and

Health Administration, local industrial codes, and local

inspection requirements also provide a basis for equipment installation, use, and service.

1-2. GENERAL PRECAUTIONS

Different arc welding processes, electrode alloys,and fluxes can produce different fumes, gases, andradiatIon levels. In addition to the Information In

this manual, be sure to consult flux and electrode

manufacturers MaterIal Safety Data Sheets

(MSDSs) for specifIc technical data and precautionary measures concerning their material.

A. Burn Prevention

Wear protective clothing-gauntlet gloves designed for

use in welding, hat, and high safety-toe shoes. Button

shirt collar and pocket flaps, and wear cuffless trousers

to avoid entry of sparks and slag.

Wear helmet with safety goggles and glasses with sideshields underneath, appropriate filter lenses or plates(protected by clear cover glass). This is a MUST for

welding or cutting, (and chipping) to protect the eyes

from radiant energy and flying metal. Replace cover

glass when broken, pitted, or spattered. See I -3A.2.

Avoid oily or greasy clothing. A spark may ignite them.

Hot metal such as electrode stubs and workpiecesshould never be handled without gloves.

Medical first aid and eye treatment. First aid facilities

and a qualified first aid person should be avadab~e for

each shift unless medical facilities are close by for im

mediate treatment of flash burns of the eyes and skin

burns.

Ear plugs should be worn when working on overhead or

in a confined space. A hard hat should be worn when

others work overhead.

Flammable hair preparations should not be used by perSons intending to weld or cut.

B. Toxic Fume Prevention

Severe discomfort, illness or death can result from

fumes, vapors, heat, or oxygen enrichment or depletionthat welding (or cutting) may produce. Prevent them

with adequate ventilation as described in ANSI Stan

dard Z49.1 listed in Standards Index. NEVER ventilate

with oxygen.

Lead -, cadmium-, zinc -, mercury-, and beryllium-bearing and similar materials, when welded (or cut) may produce harmful concentrations of toxic fumes. Adequatelocal exhaust ventilation must be used, or each personin the area as well as the operator must wear an air-supplied respirator. For beryllium, both must be used.

Metals coated with or containing materials that emit

toxic fumes should not be heated unless coating is re

moved from the work surface, the area is well ventilated

and, if necessary, while wearing an air-supplied respirator.

Work in a confined space only while it is being ventilated

and, if necessary, while wearing an air-supplied respirator.

Gas leaks in a confined space should be avoided.

Leaked gas in large quantities can change oxygen con

centration dangerously. Do not bring gas cylinders into a

confined space.

Leaving confined space, shut OFF gas supply at source

to prevent possible accumulation of gases in the space if

downstream valves have been accidentally opened or

left open. Check to be sure that the space is safe before

re-entering it.

Vapors from chlorinated solvents can be decomposedby the heat of the arc (or flame) to form PHOSGENE, a

highly toxic gas, and other lung and eye irritating products. The ultraviolet (radiant) energy of the arc can also

decompose trichloroethylene and perchioroethylenevapors to form phosgene. DO NOT WELD or cut where

solvent vapors can be drawn into the welding or cutting

OM-317 Page 1

atmosphere or where the radiant energy can penetrateto atmospheres containing even minute amounts of

trichioroethylene or perchioroethylene.

C. Fire and Explosion Prevention

Causes of fire and explosion are: combustibles reached

by the arc, flame, flying sparks, hot slag or heated mate

rial; misuse of compressed gases and cylinders; and

short circuits.

BE AWARE THAT flying sparks or falling slag can pass

through cracks, along pipes, through windows or doors,and through wall or floor openings, out of sight of the

goggled operator. Sparks and slag can fly 35 feet.

To prevent fires and explosion:

Keep equipment clean and operable, free of oil, grease,and (in electrical parts) of metallic particles that can

cause short circuits.

If combustibles are in area, do NOT weld or cut. Move

the work if practicable, to an area free of cdmbustibles.

Avoid paint spray rooms, dip tanks, storage areas, venti

lators. If the work cannot be moved, move combustibles

at least 35 feet away out of reach of sparks and heat; or

protect against ignition with suitable and snug-fitting,fire-resistant covers or shields.

Walls touching combustibles on opposite sides should

not be welded on (or cut). Walls, ceilings, and floor near

work should be protected by heat-resistant covers or

shields.

Fire watcher must be standing by with suitable fire extin

guishing equipment during and for some time afterweld

ing or cutting if:

a. appreciable combustibles (including buildingconstruction) are within 35 feet

b. appreciable combustibles are further than 35

feet but can be ignited by sparks

c. openings (concealed orvisible) in floors orwalls

within 35 feet may expose combustibles to

sparks

d. combustibles adjacent to walls, ceilings, roofs,or metal partitions can be ignited by radiant or

conducted heat.

Hot work permit should be obtained before operation to

ensure supervisor�s approval that adequate precautionshave been taken.

After work is done, check that area is free of sparks,glowing embers, and flames.

An empty container that held combustibles, or that can

produce flammable or toxic vapors when heated, must

never be welded on or cut, unless container has first

been cleaned as described in AWS Standard A6.O,listed 7 in Standards Index.

This includes: a thorough steam or caustic cleaning (ora solvent or water washing, depending on the combusti

ble�s solubility) followed by purging and inerting with ni

trogen or carbon dioxide, and using protective equip-

ment as recommended in A6.O. Waterfilling just below

working level may substitute for inerting.

A container with unknown contents should be cleaned

(see preceding paragraph). Do NOT depend on sense

of smell or sight to determine if it is safe to weld or cut.

Hollow castings or containers must be vented before

welding or cutting. They can explode.

Explosive atmospheres. Never weld or cut where the air

may contain flammable dust, gas, or liquid vapors (suchas gasoline).

D. Compressed Gas EquIpment

Standard precautions. Comply with precautions in this

manual, and those detailed in CGA Standard P-I, SAFEHANDLING 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 protectionwith one or more relief devices.

Never connect a regulator to a cylinder containing gasother than that for which the regulator was designed.

Remove faulty regulator from service immediately for

repair (first close cylinder valve). The following symptoms indicate a faulty regulator:

Leaks-if gas leaks externally.Excessive Creep-if delivery pressure continues to rise

with downstream valve closed.

Faulty Gauge-if gauge pointer does not move oft stoppin when pressurized, nor returns to stop pin after pressure release.

Repair. Do NOT attempt to repair. Send faulty regulators for repair to manufacturer�s designated repair center, where special techniques and tools are used bytrained personnel.

2. Cylinders

Cylinders must be handled carefully to prevent leaks

and damage to their walls, valves, or safety devices:

Avoid electrical Circuit contact with cylinders includingthird rails, electrical wires, or welding circuits. They can

produce short circuit arcs that may lead to a serious ac

cident. (See l-3C.)

ICC or DOT marking must be on each cylinder. it is an

assurance of safety when the cylinder is properly handled.

Identifying gas content. Use only cylinders with name of

gas marked on them; do not rely on color to identify gascontent. Notify supplier if unmarked. NEVER DEFACE

or alter name, number, or other markings on a cylinder.It is illegal and hazardous.

Empties: Keep valves closed, replace caps securely;mark MT; keep them separate from FULLS and return

promptly.

Prohibited use. Never use a cy�inder or its contents for

other than its intended use, NEVER as a support or

roUer.

OM-317 Page 2

Locate or secure cylinders so they cannot be knocked

over.

Passageways and work areas. Keep cylinders clear of

areas where they may be struck.

Transporting cylinders. With a crane, use a secure sup

port such as a platform or cradle. Do NOT lift cylindersoff the ground by their valves or caps, or by chains,

slings, or magnets.

Do NOT expose cylinders to excessive heat, sparks,slag, and flame, etc. that may cause rupture. Do not al

low contents to exceed 130°F. Cool with water spraywhere such exposure exists.

Protect cylinders particularly valves from bumps, falls,

falling objects, and weather. Replace caps securelywhen moving cylinders.

Stuck valve. Do NOT use a hammer or wrench to open a

cylinder valve that can not be opened by hand. Notify

your supplier.

Mixing gases. Never try to mix any gases in a cylinder.

Never refill any cylinder.

Cylinder fittings should never be modified or ex

changed.

3. Hose

Prohibited use. Never use hose other than that de

signed for the specified gas. A general hose identifica

tion rule is: red for fuel gas, green for oxygen, and black

for inert gases.

Use ferrules or clamps designed for the hose (not ordi

nary wire or other substitute) as a binding to connect

hoses to fittings.

No copper tubing splices. Use only standard brass fit

tings to splice hose.

Avoid long runs to prevent kinks and abuse. Suspendhose off ground to keep it from being run over, steppedon, or otherwise damaged.

Coil excess hose to prevent kinks and tangles.

Protect hose from damage by sharp edges, and bysparks, slag, and open flame.

Examine hose regularly for leaks, wear, and loose connections. immerse pressured hose in water; bubbles in

dicate leaks.

Repair leaky or worn hose by cutting area out and splicing (1 -2D3). Do NOT tape.

4. Proper Connections

Clean cylinder valve outlet of impurities that may clogorifices and damage seats before connecting regulator.Except for hydrogen, crack valve momentarily, pointing

outlet away from people and sources of ignition. Wipewith a clean lintless cloth.

Match regulator to cylinder. Before connecting, check

that the regulator label and cylinder marking area, and

that the regulator inlet and cylinder outlet match.

NEVER CONNECT a regulator designed for a particulargas or gases to a cylinder containing any other gas.

Tighten connections. When assembling threaded con

nections, clean and smooth seats where necessary.Tighten. If connection leaks, disassemble, clean, and

retighten using properly fitting wrench.

Adapters. Use a CGA adapter (available from your sup

plier) between cylinder arid regulator, if one is required.use two wrenches to tighten adapter marked RIGHT

and LEFT HAND threads.

Reguiatoroutiet(orhose) connections may be identified

by right hand threads for oxygen and left hand threads

(with grooved hex on nut or shank) for fuel gas.

5. Pressurizing Steps:

Drain regulator of residual gas through suitable vent be

fore opening cylinder (or manifold valve) by turning ad

justing screw in (clockwise). Draining prevents exces

sive compression heat at high pressure seat by allowingseat to open on pressurization. Leave adjusting screw

engaged slightly on single-stage regulators.

Stand to side of regulator while opening cylinder valve.

Open cylinder valve slowly so that regulator pressure in

creases slowly. When gauge is pressurized (gaugereaches regulator maximum) leave cylinder valve in fol

lowing position: For oxygen, and inert gases, open fullyto seal stem against possible leak. For fuel gas, open to

less than one turn to permit quick emergency shutoff.

Use pressure charts (availab�e from your supplier) for

safe and efficient, recommended pressure settings on

regulators.

Check for leaks on first pressurization and regularlythere-after. Brush with soap solution (capfull of IvoryLiquid* or equivalent per gallon of water). Bubbles indi

cate leak. Clean off soapy water afterlest; dried soap is

combustible.

E. User Responsibilities

Remove leaky or defective equipment from service im

mediately for repair. See User Responsibility statement

in equipment manual.

F. Leaving Equipment Unattended

Close gas supply at source and drain gas.

G. Rope Staging-Support

Rope staging-support should not be used for welding or

cutting operation; rope may bum.

*Trademark of Proctor & Gamble.

OM-317 Page 3

1-3. ARC WELDING

Comply with precautions in 1-1, 1-2, and this section.

Arc Welding, property done, is a safe process, but a

careless operator invites trouble. The equipment carneshigh currents at significant voltages. The arc is very

bright and hot. Sparks fly, fumes rise, ultraviolet and in

frared energy radiates, weidments are hot, and com

pressed gases may be used. The wise operator avoids

unnecessary risks and protects himself and others from

accidents. Precautions are described here and in stan

dards referenced in index.

A. Burn Protection

Comply with precautions in 1-2.

The welding arc is intense and visibly bright. its radiation

can damage eyes, penetrate lightweight clothing, reflect

from light-colored surfaces, and burn the skin and eyes.

Skin burns resemble acute sunburn, those from gas-shielded arcs are more severe and painful. ~ONT GETBURNED; COMPLY WITH PRECAUTlOI~IS.

1. Protective Clothing

Wear long-sleeve clothing (particularly for gas-shieldedarc) in addition to gloves, hat, and shoes (1 -2A). As nec

essary, use additional protective clothing such as

leather jacket or sleeves, flame-proof apron, and fire-re

sistant leggings. Avoid outer garments of untreated cot

ton.

Bare skin protection. Wear dark, substantial clothing.Button collar to protect chest and neck and button pockets to prevent entry of sparks.

2. Eye and Head Protection

Protect eyes from exposure to arc. NEVER look at an

electric arc without protection.

Welding helmet or shield containing a filter plate shadeno. 12 or denser must be used when welding. Place over

face before striking arc.

Protect filter plate with a clear cover plate.

Cracked or broken helmet or shield should NOT be

worn; radiation can pass through to cause burns.

Cracked, broken, or loose filter plates must be replacedIMMEDIATELY. Replace clear cover plate when bro

ken, pitted, or spattered.

Flash goggles with side shields MUST be worn under

the helmet to give some protection to the eyes shouldthe helmet not be lowered over the face before an arc is

struck. Looking at an arc momentarily with unprotectedeyes (particularly a high intensity gas-shielded arc) cancause a retinal bum that may leave a permanent dark

area in the field of vision.

3. Protection of Nearby Personnel

Enclosed welding area. For production welding, a separate room or enclosed bay is best. in open areas, sur

round the operation with low-reflective, non-combusti

ble screens or panels. Allow for free air circulation, particularly at floor level.

Viewing the weld. Provide face shields for all personswho will be looking directly at the weld.

Others working in area. See that all persons are wearingflash goggles.

Before starting to weld, make sure that screen flaps or

bay doors are closed.

B. Toxic Fume Prevention

Comply with precautions in 1 -2B.

Generator engine exhaust must be vented to the outside

air. Carbon monoxide can kill.

C. Fire and ExplosIon Prevention

Comply with precautions in 1 -2C.

Equipment�s rated capacity. Do not overload arc weld

ing equipment. It may overheat cables and cause a fire.

Loose cable connections may overheat or flash and

cause a fire.

Never strike an arc on a cylinder or other pressure vessel. It creates a brittle area that can cause a violent rupture or lead to such a rupture under rough handling.

D. Compressed Gas Equipment

Comply with precautions in 1 -2D.

E. Shock Prevention

Exposed hot conductors or other bare metal in the weld

ing circuit, or in ungrounded, electrically-HOT equipment can fatally shock a person whose body becomes a

conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR

TOUCH a wet surface when welding, without suitable

protection.

To protect against shock:

Wear dry insulating gloves and body protection. Keepbody and clothing dry. Never work in damp area without

adequate insulation against electrical shock. Stay on a

dry duckboard, or rubber mat when dampness or sweat

can not be avoided. Sweat, sea water, or moisture be

tween body and an electrically HOT part or groundedmetal reduces the electrical resistance, and could en

able dangerous and possibly lethal currents to flow

through the body.

A voltage will exist between the electrode and any con

ducting object in the work circuit. Examples of conduct

ing objects include, but are not limited to, buildings, electrical tools, work benches, welding power source cases,

workpieces, etc. Never touch the electrode and anymetal object unless the welding power source Is off.

1. Grounding the Equipment

Arc welding equipment must be grounded according to

the National Electrical Code, and the work must be

grounded according to ANSI Z49.1 �Safety In WeldingAnd Cutting.�

When installing, connect the frames of each unit such as

welding power source, control, worktable, and water ci r

culatorto the building ground. Conductors must be ade

quate to carry ground currents safely. Equipment made

OM-317 Page 4

electrically HOT by stray current may shock, possibly fa

tally. Do NOT GROUND to electrical conduit, orto a pipecarrying 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 equipment ground lead to the third (live) wire, or the equipment will become electrically HOT-a dangerous condi

tion that can shock, possibly fatally.

Before welding, check ground for continuity. Be sure

conductors are touching bare metal of equipmentframes at connections.

If a line cord with a ground lead is provided with the

equipment for connection to a switchbox, connect the

ground lead to the grounded switchbox. If a three-prongplug is added for connection to a grounded mating re

ceptacle, the ground lead must be conne~cted to the

ground prong only. If the line cord comes with a three-

prong plug, connect to a grounded mating receptacle.Never remove the ground prong from a plug, or use a

plug with a broken off ground prong.

2. Electrode Holders

Fully insulated electrode holders should be used. Do

NOT use holders with protruding screws.

3. Connectors

Fully insulated lock-type connectors should be used to

join welding cable lengths.

4. Cables

Frequently inspect cables forwear, cracks and damage.IMMEDIATELY REPLACE those with excessively wornor 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 protectedfrom hot metal and sparks.

5. Terminals And Other Exposed Parts

Terminals and other exposed parts of electrical units

should have insulating covers secured before operation.

6. Electrode

a. Equipment with output on/oft control (contactor)

Welding power sources for use with the gasmetal arc welding (GMAW), gas tungsten arc

welding (GTAW) and similar processes nor

mally are equipped with devices that permit onoff control of the welding power output. Whenso equipped the electrode wire becomes elec

trically HOT when the power source switch is

ON and the welding gun switch is closed. Nevertouch the electrode wire or any conducting object in contact with the electrode circuit unlessthe welding power source is off.

b. Equipment without output on/off control (nocontactor)

Welding power sources used with shielded

metal arc welding (SMAW) and similar processes may not be equipped with welding poweroutput on-oft control devices. With such equipment the electrode is electrically HOT when the

power switch is turned ON. Never touch the

electrode unless the welding power source is

off.

7. Safety Devices

Safety devices such as interlocks and circuit breakers

should not be disconnected or shunted out.

Before installation, inspection, or service, of equipment,shut OFF all power and remove line fuses (or lock or

red-tag switches) to prevent accidental turning ON of

power. Disconnect all cables from welding power

source, and pull all 115 volts line-cord plugs.

Do not open power circuit or change polarity while welding. It, in an emergency, it must be disconnected, guardagainst shock bums, or flash from switch arcing.

Leaving equipment unattended. Always shut OFF and

disconnect all power to equipment.

Power disconnect switch must be available near the

welding power source.

F. Protection For Wearers of Electronic Life Support Devices (Pacemakers)

Magnetic fields from high currents can affect pacemakeroperation. Persons wearing electronic life supportequipment (pacemaker) should consult with their doctor

before going near arc welding, gouging, or spot weldingoperations.

1-4. STANDARDS BOOKLET INDEX

For more information, refertothefollowing standards or

their latest revisions and comply as applicable:

1. ANSI Standard Z49.1, SAFETY IN WELDING AND

CUTTING obtainable from the American WeldingSociety, 550 N.W. LeJeune Rd, Miami, FL 33126.

2. NIOSH, SAFETY AND HEALTH IN ARC WELDING

AND GAS WELDING AND CUTTING obtainable

from the Superintendent of Documents, U.S. Gov

ernment Printing Office, Washington, D.C. 20402.

3. OSHA, SAFETY AND HEALTH STANDARDS,29CFR 1910, obtainable from the Superintendentof Documents, U.S. Government Printing Office,Washington, D.C. 20402.

4. ANSI Standard Z87.1, SAFE PRACTICES FOR

OCCUPATION AND EDUCATIONAL EYE AND

FACE PROTECTION obtainable from the Ameri

can National Standards Institute, 1430 Broadway,New York, NY 10018.

5. ANSI Standard Z41.1, STANDARD FOR MEN�S

SAFETY-TOE FOOTWEAR obtainable from the

American National Standards Institute, 1430

Broadway, New York, NY 10018.

OM-317 Page 5

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE

USE OF CUTTING AND WELDING PROCESSES

obtainable from the American National Standards

Institute, 1430 Broadway, New York, NY 10018.

7. AWS Standard A6.O, WELDING AND CUTTING

CONTAINERS WHICH HAVE HELD COMBUS

TIBLES obtainable from the American Welding So

ciety, 550 N.W. LeJeune Ad, Miami, FL 33126.

8. NFPA Standard 51, OXYGEN-FUEL GAS SYS

TEMS FOR WELDING, CUTTING, AND ALLIED

PROCESSES obtainable from the National Fire

Protection Association, Batterymarch Park, Qui ncy,MA 02269.

9. NFPA Standard 70, NATIONAL ELECTRICAL

CODE obtainable from the National Fire Protection

Association, Batterymarch Park, Quincy, MA

02269.

10. NFPA Standard 51B, CUTTING AND~WELDINGPROCESSES obtainable from the l~s#ationaI Fire

Protection Association, Batterymarch Park, Quincy,MA 02269.

ii. CGA Pamphlet P-i, SAFE HANDLING OF COM

PRESSED GASES IN CYLINDERS obtainable

from the Compressed Gas Association, 1235 Jef

ferson Davis Highway, Suite 501, Arlington, VA

22202.

12. CSA Standard W117.2, CODE FOR SAFETY IN

WELDING AND CUTTING obtainable from the Ca

nadian Standards Association, Standards Sales,178 Rexdale Boulevard, Rexdale, Ontario, Canada

M9W 1R3.

13. NWSA booklet, WELDiNG SAFETY BIBLIOGRA

PHY obtainable from the National Welding SupplyAssociation, 1900 Arch Street, Philadelphia, PA

19103.

14. American Welding Society Standard AWSF4.1,RECOMMENDED SAFE PRACTICES FOR THE

PREPARATION FOR WELDING AND CUTTING

OF CONTAINERS AND PIPING THAT HAVE

HELD HAZARDOUS SUBSTANCES, obtainable

from the American Welding Society, 550 N.W.

LeJeune Ad, Miami, FL 33126.

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA

TORY PROTECTION, obtainable from the Ameri

can National Standards Institute, 1430 Broadway,New York, NY 10018.

SECTION 2- SAFETY PRECAUTIONS AND SIGNAL WORDS

2-1. GENERAL INFORMATION AND SAFETY

32. General

Information presented in this manual and on various la

bels, tags, and plates on the unit pertains to equipmentdesign, installation, operation, maintenance, and

troubleshooting which should be read, understood, and

followed for the safe and effective use of this equipment.

The nameplate of this unit uses international symbolsfor labeling the front panel controls. The symbols also

appear at the appropriate section in the text.

33. Safety

The installation, operation, maintenance, and trouble

shooting of arc welding equipment requires practicesand procedures which ensure personal safety and the

safety of others. Therefore, this equipment is to be in

stalled, operated, and maintained only by qualified persons in accordance with this manual and all applicablecodes such as, but not limited to, those listed at the end

of Section 1 � Safety Rules For Operation Of Arc Weld

ing Power Source.

2-2. SAFETY ALERT SYMBOL AND SIGNAL

WORDS

The following safety alert symbol and signal words are

used throughout this manual to call attention to and

identify different levels of hazard and special instruc

tions.

a This safety alert symbol is used with the signalwords WARNING and CAUTION to call atten

tion to the safety statements.

a

a

WARNING statements identify procedures or

practices which must be followed to avoid seri

ous personal injury or loss of life.

CAUTION statements identify procedures or

practices which must be followed to avoid minor

personal injury or damage to this equipment.

IMPORTANT statements identify special instructions

necessaiy for the most efficient operation of this equipment.

OM-31 7 Page 6

SECTION 3� SPECIFICATIONS

Table 3-1. SpecIfications

NEMA

Class 1(60)Rated Output

At 60%

Duty_Cycle

WeldinFRange n

Amperes

Reduced

Open-Circuit

voltage

Max.

open-Circuit

voltage

Amperes in~ut AtRated Load utput*

�

60 Hz Single-Phase

200V 230V 460V 575V kva kw

Weight

Net Ship

400 AmperesAt 32 VoltsAC/DC

50-500AC 36 AC 80 AC

150 130 65 52 29.9 22.8650 I bs.

(295 kg)670 lbs.

(304 kg)45-400DC 32 DC 72 DC

IMPORTANT: The power factor correcting capacitors supplied in this product contain no PCB �s. The dielectric ma

terial is an OSHA class Ill B fluid having a f4~sh point of 44~? F (227~ C). Each individual capacitor is protected by aninternal UL recognized pressure sensitive disconnect and an internal fuse.

inches Millimeters

A 2.1/2 64

B 26 660

C 7/16 11

D 19 483

E 16-3/4 425

F 1-1/8 29

G 35-3/4 908

H 32-3/4 862

I 1-1/2 38

TC-087 183

Figure 3-1. Overall Dimension And Base Mounting Hole Layout

90

60

70

60

cnI-.

50

>

~ 40

30

20

l0

Chart 3-1. Volt-Ampere Curves

100 200 300 400 500 600 700 000

DC AMPERES8.085 715

300 400

AC AMPERES

600 700

8-085 692

OM-31 7 Page 7

Chart 3-2. Duty Cycle 3-2. DUTY CYCLE (Chart 3-2)

600

~ 500

4

400

z

0

300

3-1. VOLT-AMPERE CURVES (Chart 3-1)

(34. RATED OUTPUT

The volt-ampere curves show the voltage and amper

age output capabilities of the welding power source.

Voltage and amperage adjustment is provided by the

AMPERAGE ADJUSTMENT Control. Curves of other

settings fall between the curves shown.

With the use of the volt-ampere curves, it is possible to

determine the weld amperage at any particular load volt

age.

The duty cycle is the percentage of a ten minute periodthat a welding power source can be operated at a givenoutput without overheating and damaging the unit. This

welding power source is rated at 60% duty cycle when

operated at 400 amperes. The unit can be operated at

400 amperes for six consecutive minutes, but it must operate at no load for the remaining four minutes to allow

proper cooling. If the welding amperes decrease, the

duty cycle increases.

Refer to the Duty Cycle chart (Chart 3-2) to determine

the output of the welding power source at various dutycycles.

3-3. DESCRIPTION

This unit produces constant current ac/dc weld outputfor the Shielded Metal Arc Welding (SMAW) process.This unit requires single-phase input power of the volt

age specified on the nameplate.

Rated output is 400 amperes, 36 volts ac/dc at 60% dutycycle. This unit is equipped with a voltage reducer which

maintains terminal open-circuit voltage at 32 volts DC or

36 volts Ac when the unit is energize but not actuallywelding.

SECTION 4- INSTALLATION OR RELOCATION

4-1. SITE SELECTION

Select an installation site which provides the following:

1. Correct input power supply (see unit nameplate)

2. Shielding gas supply (if applicable)

3. Water supply (if applicable)

4. Adequate ventilation and fresh air supply

5. No flammables

6. A clean and dry area

7. Proper temperature that avoids extremes of heat or

cold

8. Proper airflow around unit

9. Adequate space for removing top cover and outer

panels for installation, maintenance, and repairfunctions.

OM-317 Page 8

Base mounting holes provide the capability to install and

secure the unit on a running gearorin a permanent loca

tion. Figure 3-1 gives overall dimensions and base

mounting hole layout.

a WARNING: FIRE OR EXPLOSION can result

from placing unit on or over combustible

surfaces; RESTRICTED AIRFLOW can

cause overheating and possible damage to

Internal parts.� Do not locate unit overcombustible surfaces.

� Maintain at least 18 inches (457 mm) of

unrestricted space on all sides of unit, and keepunderside free of obstructions.

� Do not place any filtering device over the in

take airpassages thatprovide airflow for coolingthis unit.

Warranty is void if any type of filtering device isused at intake air passages.

800

700

MODEL

GOLD STAR

600Ss

200

20 25

40055

30055

30 35 40 50 60 70 80 90 100

% DUTY CYCLE B-000865.C a CAUTION: EXCEEDING DUTY CYCLERATINGS will damage the welding powersource.

� Do not exceed indicated duty cycles.

4-2. TRANSPORTING METHODS

This welding power source is equipped with a lifting eyefor moving the unit during installation. Weight capacityof the lifting eye only allows for supporting the welding

power source.

a WARNING: ELECTRIC SHOCK can kill.

� Do not touch live electrical parts.

� Disconnect input power conductors from

deenergized supply line BEFORE moving weld

ing power source.

FALLING EQUIPMENT can cause serious

personal Injury and equipment damage.� Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any other heavyaccessories or devices.

� Use equipment of adequate capacity to lift

the unit. �I�

� If lifting or moving this unit with lift forks under

the base, be sure that lift forks are long enoughto extend beyond opposite side of the base.

Using lift forks too short can damage internal

parts if tips of the lift forks penetrate the unit

base, or may cause personal injury and/or

equipment damage if unit falls off the lift forks.

4-3. WELD OUTPUT CONNECTIONS (FIgure 4-1)

RATED OUTPUT

To obtain full rated output from this unit, it is necessaryto select, prepare, and install proper weld cables. Fail-

ure to comply in any of these areas may result in unsatis

factory welding performance.

A. Weld Cable Selection

Use the following guidelines to select weld cables:

1. Use the shortest possible cables, and place cables

close together. Excessive cable lengths may re

duce output or cause unit overload due to added re

sistance.

2. Use weld cable with an insulation voltage ratingequal to or greater than the maximum open-circuitvoltage (ocv) of the welding power source (seeTable 3-1 for unit maximum ocv rating).

3. Select welding cable size according to maximum

weld output and total length of connecting cables in

weld circuit. For example, if a 25 foot (7.5 m) elec

trode holder cable is used with a 25 foot (7.5 m)work cable, select the cable size recommended in

Table 4-1 for 50 feet (15 m).

4. Do not use damage or frayed cables.

Weld Cable Preparation

Install terminal lugs of adequate amperage capacityand correct stud size onto cables that connect to the

work clamp, electrode holder, and weld output ter

minals.

2. When installing an electrode holder, follow manu

facturer�s installation instructions. Always use an in

sulated electrode holder to ensure operator safety.

3. Install work clamp onto cable.

Table 4-1. Weld Cable Size

Total Cable (Copper) Length In Weld Circuit Not Exceeding*�

100 ft. Or Less 150 It. 200 ft. 250 ft. 300 ft. 350 ft. 400 ft.

(30 m) (45 m) (60 m) (70 m) (90 m) (105 m) (120 m)

10 To 60% 60 Thru 100%10 Thru 100% Duty Cycle

Duty Cycle Duty Cycle

4

3

3

2

1

1/0

1/0

2/0

3/0

4

3

2

1

1/0

2/0

2/0

3/0

4/0

4

2

1

1/0

2/0

3/0

3/0

4/0

2-2/0

3

1

1/0

2/0

3/0

4/0

4/0

2-210

2-3/0

2

1/0

210

3/0

4/0

2-2/0

2-2/0

2-3/0

2-4/0

1

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

2-4/0

3-3/0

1/0

3/0

4/0

2-2/0

2-3/0

2-3/0

2-4/0

3-3/0

3-4/0

1/0

3/0

4/0

2-2/0

2-3/0

2-4/0

2-4/0

3-3/0

3-4/0

*weld cable size (AWG) is based on either a 4 volts or less drop or a current density of more than 300 circularmils per ampere. S0007/8-88

B.

1.

OM-317 Page 9

WARNING: ELECTRIC SHOCK can kill.

� Do not touch IWe electrical parts.

� Shut down welding power source, and dis

connect inputpower employing lockout/taggingprocedures before inspecting or installing.

Lockout/tagging procedures consist of padlocking line disconnect switch in open position,removing fuses from fuse box, or shutting off

and red-tag9ing circuit breaker or other discon

necting device.

Socket E: Amperage control connection (wiper con

tact).

IMPORTANT: The remaining sockets in the receptacleare not used.

3-0005

Figure 4-2. Front View Of 5-Socket Amphenol Re

ceptacle With Socket Locations

1. Open lower front access doorto gain access to weld

output terminals.

2. Connect electrode holder cable to ELECTRODE

output terminal.

3. Connect one end of work cable to WORK output ter

minal.

I IWork Electrode

Output OutputTerminal Terminal

R~. TA-087 338

Figure 4-1. Lower Front Panel View With Access

Door Open

4-4. REMOTE AMPERAGE CONTROL RECEPTA

CLE INFORMATION AND CONNECTIONS

(Figure 4-2 And Figure 5-1)

REMOTE AAMPERAGE

The five-socket Amphenol REMOTE AMPERAGE con

trol receptacle RC1 is usedto connect a Remote Amperage Control to the control circuitry of the welding powersource. To connect the Remote Amperage Control to

the REMOTE AMPERAGE control receptacle, alignkeyway, insert plug, and rotate threaded collar fullyclockwise.

Receptacle Rd socket connections to the weldingpower source control circuitry are as follows:

Socket C: Amperage control connection (maximum

Socket D: Amperage control connection (minimumside).

4-5. ELECTRICAL INPUT CONNECTIONS

INPUT

AA WARNING: ELECTRIC SHOCK can kill.



connect inputpower employing lockout/taggingprocedures before inspecting or installing.

Lockout/tagging procedures consist of

padlocking line disconnect switch in open position, removing fuses from fuse box, or shuttingott and red-tagging circuit breaker or other.dis

connecting device.

A. Electrical Input Requirements

Operate the welding power source from a single-phase,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 nameplate. Contact the local

electric utility for information about the type of electrical

service available, how proper connections should be

made and inspection required.

B. Jumper Link Installation (Figure 4-3)

a WARNING: Read precautionary InformatIonat beginning of entire Section 4-5 before proceeding.

Jumper links are used to allow the equipment to operatefrom different line voltages. The jumper links may be in a

bag attached to the input terminal board or installed on

the input terminal board for the highest voltage shown

on the input voltage label.

1. Remove right side panel.

2. Compare position of jumper links on the inputterminal board to the voltage link arrangement shown on

input voltage label.

C. Weld Cable Connections (Figure 4-1)

W RK ELECTRODE0

I

O~O O~O

side).

OM-317 Page 10

4A CAUTION: INCORRECT INPUT VOLTAGE

JUMPER LINK PLACEMENT can damageunit.

� Position jumper links as shown on the inputvoltage label (see Figure 4-3).

� Store unusedjumper links across linked ter

minals.

3. Install jumper links onto the input terminal board to

match the available input line voltage.

C. Welding Power Source Input Power Connec

tions (FIgure 4-3)



� Install a fusible line disconnect switch in the

input circuit to the welding power source.

� Connect input conductors to the weldingpowersource before connecting to single-phaseinput power.

� Read and follow safety information at beginfling of entire Section 4-4 before proceeding.

The line disconnect switch provides a sate and

convenient means to completely remove all

electrical power from the welding power source

whenever it is necessary to inspect or service

the unit.

Input Voltage 220 230 460 575

Input ConductorSize (AWG)

1/0 1 6 6

Ground Conductor

Size_(AWG)6 6 8 8

Fuse SizeIn Amperes

225 200 150 80

*Conductor size is based on the 1987 Edition of the National

Electrical Code (NEC) specifications for allowable am

pacities of insulated copper conductors, having a temperature rating of 167°F (75°C), with not more than three singlecurrent-carrying conductors in a raceway (Article 310 of

NEC). (The ground conductor is not counted as a current-

carrying conductor.)

¶use size is based on not more than 200 percent of the

rated input amperage of the welding power source (Article630 of NEC).

S.~2/4.8a

1. Use Table 4-2 as a guide to select input conductorsfor the installation. The input conductors should be

covered with an insulating material that complieswith national, state, and local codes.

2. Install terminal lugs of adequate amperage capacityand correct stud size onto the input and ground conductors.

Table 4-2. input Conductor And Fuse Slze*

Ground

IGreen)Conductor

Input Terminal

Board With

Jumper

Rear Panel

Access Hole - 1-3/4 in.

(44 mm) Dia.

Input VoltageTerminal Board

Terminal

Figure 4-3. LocatIon Of Electrical Input Conductor Connections And Components

Ret: TB-ill 134

OM-317 Page 11

aWARNING: ELECTRIC SHOCK can kill.

� Do not connect an input conductor to the

ground terminal in the unit.

� Do not connect the ground conductor to an in

put line terminal.

Incorrect input connections can result in an elec

trically energized welding power source chassis. The ground terminal is connected to the

welding power source chassis and is for grounding purposes only.

Install and connect input and ground conductors as fol

lows:

3. Obtain and install a standard conduit strain relief

connector into the rear panel access hole.

4. Insert conductors through strain relief installed in

Step 3, and route conductors to input terminal

board.

5. Connect input conductors to the line terminals on

the input terminal board (see Figure 4-3).

6. Connect ground conductor to ground terminal (seeFigure 4-3).

7. Connect remaining end of ground conductor to a

suitable ground. Use a grounding method that com

plies with all applicable electrical codes.

8. Connect remaining ends of input conductors to a

deenergized line disconnect switch.

9. Secure input cable in strain relief.

10. Reinstall right side panel.

11. Use Table 4-2 as a guide to select line fuses for the

disconnect switch. Obtain and install proper fuses.

SECTION 5- OPERATOR CONTROLS

Figure 5-1. Front Panel Controls

TA-087 338

AC/DC

Selector

Switch

Range~Switch

OutputTerminal

Switch

OFF Push Button

Remote AmperageReceptacle

AmperageAdjustment

Control

OM-317 Page 12

REMOTEAMPERAGE ON OFF

10

5-1. POWER SWITCH (Figure 5-1) 5-4. AMPERAGE ADJUSTMENT CONTROL

POWER ON

~j0 OFF

(FIgure 5-1)

AAMPERAGEADJUSTMENT

Pressing the Power switch ON push button energizesthe welding Power source. The fan motor starts indicat-

ing that the unit is receiving input power.

The AMPERAGE ADJUSTMENT control provides fine

amperage adjustment within the range selected on the

RANGE switch. Rotatethe control clockwise to increase

Pressing the Power switch OFF push button shuts down amperage output. The scaie surrounding the control is

the welding power source and fan. calibrated in ac/dc amperes for the Shielded Metal Arc

IMPORTANT: After any interruption of input power, the Welding (SMAW) process.

Power switch ON push button must be pressed to IMPORTANT: The AMPERAGE ADJUSTMENT con

reenergize the welding power source. trol may be adjusted while welding.

5-2. RANGE SWITCH (Figure 5-1)�

4~ CAUTION: ARCING can damageswitch con-

tacts.

� Do not change position of Range switch while

5-5. REMOTE AMPERAGE CONTROL SWITCH

(Figure 5-1)

welding or under load.

The Range switch provides a means of selecting one of

three coarse amperage ranges. The amperage ranges

are displayed on the nameplate. If the desired amper

age is in the overlapping area of two ranges, use the

lower range for better fine amperage control.

5-3. AC/DC SELECTOR SWITCH (Figure 5-1)

STRAIGHT REVERSE

POLARITY AC POLARITY


� In wet or confined areas, use only DC outputor remote output controL

� Read Safety Rules at beginning of this man

ual.

The AC/DC Selector switch allows the operatorto select

AC, ELECTRODE POSITIVE, or ELECTRODE NEGA

TIVE output without changing weld output cable con

nections. To ensure that weld output matches the dc p0-

larity positions, make weld output connections as in

structed in Section 4-3.

a CAUTION: ARCING can damage switch contacts.

� Do not change the position of the AC/DC Selector switch while welding or under load.

Arcing causes the contacts to become pittedand eventually inoperative.

If remote amperage control is desired, make connec

tions to the REMOTE AMPERAGE control receptacleas instructed in Section 4-4. Place the REMOTE AM

PERAGE switch in the ON position.

When remote amperage control is used, the Remote

Amperage control has complete control of the output re

gardless of the position of the AMPERAGE ADJUST

MENT control on the welding power source.

If remote amperage control is not desired, place the RE

MOTE AMPERAGE control switch in the OFF position.Only the AMPERAGE ADJUSTMENT control on the

front panel then regulates the output.

5-6. CONTROL CIRCUIT OVERLOAD BREAKER

(Figure 5-1)

CONTROL CIRCUIT ~L CLOSEDOVERLOAD BREAKER

£1 OPEN

The control circuit is protected by a manual reset CON

TROL CIRCUIT OVERLOAD BREAKER. If this circuitryis overloaded, the overload breaker opens shuttingdown the welding power source. See Section 7-2 for re

setting procedures.

OM-317 Page 13

SECTION 6 � SEQUENCE OF OPERATION

4A WARNING: ELECTRIC SHOCK can kill;MOVING PARTS can cause serious Injury;IMPROPER AIRFLOW AND EXPOSURE TOENVIRONMENT can damage Internal parts.� Do not touch live electrical parts.

� Keep all covers andpanels in place while op

erating.

Warranty is void if the welding power source is

operated with any portion of the outer enclosure

removed.

ARC RAYS, SPARKS, AND HOT SURFACES

can burn eyes and skin; NOISE can damagehearing.� Wear correct eye, ear, and body protection.

FUMES AND GASES can seriously harm

your health.

� Keep your head out of the fumes.

� Ventilate to keep from breathing fumes and

gases.

� If ventilation is madequate, use approvedbreathing device.

HOT METAL, SPATTER, AND SLAG can

cause fire and burns.

� Watch for fire.

� Keep a fire extinguisher nearby, and know

how to use it.

� Do not use near flammable material.

� Allow work and equipment to cool before han

dung.

MAGNETIC FIELDS FROM HIGH CURRENTScan affect pacemaker operation.� Wearers should consult their doctor before

going neararc welding, gouging, or spot weldingoperations.

See Section 1 - Safety Rules For Operation OfArc Welding Power Source for basic weldingsafety information.

6-1. SHIELDED METAL ARC WELDING (SMAW)

1. install and connect unit according to Section 4.

2. Place the Range switch in desired position (seeSection 4-2).


� In wet or confined areas, use only DC outputor remote output control.

� Read Safety Rules at beginning of this man

ual.

3. Place the AC/DC Selector switch in desired position(see Figure 5-1).

4. If remote amperage control is not used, place the

REMOTE AMPERAGE switch in the OFF position.If remote amperage control is to be used, place the

REMOTE AMPERAGE switch in the ON position(see Section 5-5).

5. Rotate the AMPERAGE ADJUSTMENT control or

the Remote Amperage Control, if applicable, to the

desired position (see Figure 5-1).

6. Wear dry insulating gloves and clothing, and wear

welding helmet with proper filter lens according to

ANSI Z49.1.

7. Prepare for welding as follows:

a. Connect work clamp to clean, bare metal at

workpiece.

b. Select and obtain proper electrode, and insert

into electrode holder.

8. Depress the POWER switch ON push button (seeSection 5-1).

9. Begin welding.

6-2. SHUTTING DOWN

1. Stopwelding.

2. Depress the POWER switch OFF button.

SECTION 7� MAINTENANCE & TROUBLESHOOTING

WARNING: ELECTRIC SHOCK can kill.



connect input power employing lockout/taggingprocedures before inspecting, maintaining, or

servicing.

Lockout/tagging procedures consist of padlocking line disconnect switch in open position,removing fuses from fuse box, or shutting offand red-tagging circuit breaker or other discon

necting device.

7-1. ROUTINE MAINTENANCE (Table 7-1)

IMPORTANT: Every six months inspect the labels on

this unit for legibility. All precautionary labels must be

maintained in a clearly readable state and replacedwhen necessary. See Parts List for part number of

precautionary labels.

OM-317 Page 14

MOVING PARTS can cause serious injury. 7-3. THERMAL PROTECTION (FIgure 5-1)� Keep away from moving parts.

HOT SURFACES can cause severe burns.

� Allow cooling period before servicing.

Maintenance to be performed only by qualifiedpersons.

Table 7-1. MaIntenance Schedule

Frequency� Maintenance

Every month. Units in heavy service environ

ments:

Check labels, weld cables, clean

internal parts.

Every 3 months. Check weld cables (see Section

7-1B).

Every 6 months. Check all labels (see iMPORTANT block, Section 7-1). Clean

internal parts (see Section 7-IC).

�Frequency of service is based on units operated40 hours per week. Increase frequency of maint

enance it usage exceeds 40 hours per week.

A. Fan Motor

This unit is equipped with an exhaust fan and relies on

forced draft for adequate cooling. The fan motor is

manufactured with lifetime sealed bearings and re

quires no maintenance.

B. Weld Cables

a WARNING: Read and follow safety Information at beginning of entire SectIon 7-1 before proceeding.

Every three months inspect cables for breaks in insula

tion. Repair or replace cables it insulation breaks are

present. Clean and tighten connections at each inspection.

C. Internal Cleaning

a WARNING: Read and follow safety Information at beginning of entire Section 7-1 before proceeding.

Every six months blow Out or vacuum dust and dirt from

the inside of the welding power source. Remove the

outer enclosure, and use a clean, dry airstream or vac

uum suction for the cleaning operation. If dusty or dirtyconditions are present, clean the unit monthly.

7-2. OVERLOAD PROTECTION (Figure 5-1)

Control circuit overload protection is provided by the

CONTROL CIRCUIT OVERLOAD BREAKER CB1.

Should an overload occur, CB1 would open and the contactor W would drop out (deenergize) stopping all out

put. Manually depress the circuit breaker to reset it.

The main transformer is protected by a thermostat TP1.

The thermostat opens it the transformer overheats,

shutting down the welding power source. The thermo

stat will automatically reset after cooling period of approximately fifteen minutes. Depress the POWER

switch ON push button to reset the welding powersource.

7-4. VOLTAGE REDUCER CIRCUIT OPERATION

A voltage reducer circuit board PC2 and related components in the unit automatically reduce open-circuit volt

age when no welding arc is present. Before starting or

after breaking a welding arc, the unit open-circuit volt

age is automatically reduced to 36 volts ac or 32 volts

dc. Once the electrode makes contact with the

workpiece, the voltage reducer circuitry disengages al

lowing the unit to provide rated weld output for normal

arc starting.Circuit Board

enclosure

TB- 112 202

Figure 7-1. Voltage Reducer ComponentLocations

7-5. CIRCUIT BOARD HANDLING PRECAUTIONS


� Do not touch live electrical parts.� Shut down welding power source, and disconnect input power employing lockout/taggingprocedures before inspecting, maintaining, or

servicing.

Lockoutltagging procedures consist of padlocking line disconnect switch in open position,removing fuses from fuse box, or shutting offand red-tagging circuit breaker or other discon

necting device.

Receptacles RC6O

And RC61 Located

On Lower Portion

Of

N. P. R And S Located

On Lower Portion Of

PC2

FrontLocation

PanelOf Receptacle

RC5O

OM-317 Page 15

aCAUTION: ELECTROSTATIC DISCHARGE

(ESD) can damage cIrcuIt boards.

� Put on properly grounded wrist strap BEFORE handling circuit boards.

� Transport circuit boards in proper static-

shielding carriers or packages.

� Perform work only at a static-safe work area.

INCORRECT INSTALLATION or misalignedplugs can damage circuit board.

� Be sure that plugs are properly installed and

aligned.

EXCESSIVE PRESSURE can break circuit

board.

� Use only minima! pressure and gentle movement when disconnecting or connecting board

plugs and removing or installing board.

7-6. TROUBLESHOOTING CHART (Table 7-2)




connect input power employing lockout/taggingprocedures before inspecting, maintaining, or

servicing.

Lockoutltagging procedures consist of padIockin9 line disconnect switch in open position,removing fuses from fuse box, or shutting off

and red-tagging circuit breaker or other discon

necting device.

MOVING PARTS can cause serious injury.� Keep away from moving parts.

HOT SURFACES can cause severe burns.

� Allow cooling period before servicing.

Troubleshooting to be performed only by qualified persons.

It is assumed that the unit was properly installed accord

ing to Section 4 of this manual, the operator is familiar

with the function of controls, the welding power source

was working properly, and that the trouble is not related

to the welding process. The following chart is designedto diagnose and provide remedies for some of the troub

les that may develop in this welding power source.

Use this chart in conjunction with the circuit diagramwhile performing troubleshooting procedures. If the

trouble is not remedied after performing these proce

dures, the nearest Factory Authorized Service Station

should be contacted. in all cases of equipment maltunc

tion, the manufacturers recommendations should be

strictly followed.

Table 7-2. Troubleshooting Chart

TROUBLE PROBABLE CAUSE REMEDY

No welding output; fan

motor FM does not run.

~

Open line disconnect fuses(s). Replace line fuse(s).

Poor and/or improper inputconnections.

See Section 4-5 for proper input connections.

Thermostat TP1 open(thermal shutdown).

Restart unit after a cooling period of approximately fifteen minutes (see Section 7-3).

Circuit breaker CBI open. Reset CB1 (see Sections 5-6 and 7-2).

Power switch PB1. Replace PBI.

Low or erratic weld output. Poor and/or improper inputor output

See Section 4-5 or 4-3 for proper connections.

Incorrect welding cable size. Use proper size and type of weld cable

(see Section 4-3).

Low output with no control. REMOTE AMPERAGE control

switch Si in ON position with no

Remote Amperage Control

connected to RC1.

Place Si in the OFF position or connect

Remote Amperage Control to RC1

(see Sections 4-4 and 5-5).

Firing Board PCi. Replace PCi (see Section 7-5).

Fan FM does not run; weld

output available.

Fan motor FM. Replace FM.

Limited output and low

open-circuit voltage at all

times.

Voltage Reducer Board PC2. Replace PC2 (see Section 7-5).

High output and high open-circuit voltage at all times.

Voltage Reducer Board PC2

and related components.

Contact nearest Factory Authorized ServiceStation.

OM-317 Page 16

SECTION 8 - ELECTRICAL DIAGRAMS

Circuit Diagram No. B-112 067

N

p

Circuit Diagram No. A-093 341

Diagram 8-1. Circuit Diagram

I

RC6o-P~NSA-F

RC61 -P~N5C-p

+~5V.

+15V.

+24 *24

B

C,

F

Diagram 8-2. CIrcuit Diagram For Firing Board PCi

OM-317 Page 17

K

E

P

S

I_7-

cR50

>c

>0

8-I 12439-A

Circuit Diagram No. B-112 439-A

Diagram 8-3. Circuit Diagram For Voltage Reducer Board PC2

OM-317 Page 18

SECTION 9� PARTS LIST

OM-317 Page 19

Figure9-1.

MaIn

Assembly

19

TD-087276

Replace Coils At Factory Or Factory Authorized Service Station

Item Dia. PartNo. Mkgs. No. Description Quantity

Figure 9-1. MaIn Assembly

1 Z 072 533 STABILIZER 1

2 086 439 BUS BAR, stabilizer to rect I

3 CT1 035 454 TRANSFORMER, current 500/1 1

4 072 531 FRAME, upright-base 1

5 026 627 GASKET, lifting-eye 1

6 SRi 071 001 RECTIFIER, si diode (Fig 9-8) 1

TP1 026 181 THERMOSTAT, NC 1

7 072 544 PANEL, side LH i

8 +072 532 COVER, top 1

9 123 154 LABEL, warning general precautionary 1

10 Fig 9-9 PANEL, rear-w/components 1

11 072545 PANEL,siØeRH 1

109 035 LABEL, warning electric shock 1

12 SCR1,2,TE2 Fig 9-10 SCR CONTACTOR & PRIMARY TERMINAL 1

13 TEl 072 547 TERMINAL ASSEMBLY, pn (consisting of) 1

14 601 837 NUT, brs-hex jam .375-16 6

15 602 213 WASHER, lock sti split .375 2

16 602 243 WASHER, fIat .375 2

17 072546 ~TERMINALBOARD 1

18 038891 ~STUD,brs.375-i6x2.125 2

19 MA1 072 536 AMPLIFIER, magnetic (consisting of) I

20 072 290 COIL, control ac 4

21 072 291 COIL, control dc 1

22 082 456 DIODE ASSEMBLY, (consisting of) 1

D5,6 070 250 DIODE, 3A 600V 2

112 070 DIODE ASSEMBLY, (consisting of) 1~

D7-9 070 250 DIODE, 3A 600V 3

23 035 049 LINK, connector-contactor 1

24 W 009 859 CONTACTOR, 50A 3P (consisting of) 1

028 982 COIL 1

003567 ~KiT,point 325 081 016 BRACKET, mtg-contactor cable 1

26 Included w/ltem 4 (Fig 9-2) 1

27 072530 BASE 1

28 045 852 CLIP, component 1i/i6dia 2

29 086 437 BUS BAR, rect to sec Ti 2

30 Fig 9-2 PANEL, front - w/components 1

31 086440 BUS BAR, rect to plrt switch 1

32 086441 BUS BAR, plrt switch thru CT to rect 1

33 TI 072 538 TRANSFORMER, pwr-main (230/460) (consisting of) 1

33 Ti 087314 TRANSFORMER, pwr-main (230/460/575) 1

33 Ti 087 315 TRANSFORMER, pwr-main (200/230/460) (consisting of) I

34 072 289 COIL, pn/sec RH (230/460) 1

34 086 400 COIL, pri/sec RH (230/460/575) I34 087 185 COIL, pn/sec RH (200/230/460) 1

35 072 288 COIL, pri/sec LH (230/460) 1

35 086 401 COIL, pri/sec LH (230/460/575) 135 087 186 COIL, pri/sec LH (200/230/460) 1

36 086 438 BUS BAR, stabilizer to pirt switch 1

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

Recommended Spare Parts.

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-317 Page 21

1.

FIg9-3

2

Fig9-7

9

12

8

34 33 32

13�Fig9-5

Fig9-6

~1516

23

31

23

30

29

TD-087271-8

Figure9-2.

Panel,Front

-

w/Components

Item Dia. PartNo. Mkgs. No. Description Quantity

Figure 9-2. Panel, Front - w/Components

1 072 529 PANEL, front 1

2 S3 084 228 SWITCH, p1,1 (Fig 9-3) 1

3 S2 070 200 SWITCH, range (Fig 9-4) 1

4 PB1 046 745 SWITCH, PB (Fig 9-7) 1

5 092353 ENCLOSURE,circuit card 1

6 R2 091 685 RESISTOR, WW fxd 50W 25 ohm 1

7 SR3 035 704 RECTIFIER, integ 30A 600V 1

8 092 344 HEAT SINK 1

9 SR2,VR3 080 907 DIODE/SCR, bridge 1

10 R4 096 157 RESISTOR, WW fxd 5W 220 ohm I

11 iT 038 894 BLOCK, term 30A 4P 1

12 Shunt 044968 SHUNT 1

13 PCi 093 313 CIRCUIT CARD, MA control (Fig 9-5) 1

RC6O 084 198 HOUSING,~term header 6 pin (PCi) I

RC61 072 566 HOUSING, term header 8 pin (PCI) 1

14 PC2 112 438 CIRCUIT CARD, voltage reducer (Fig 9-6) 1

15 079 760 HOUSING, term header 12 pin 1

16 080509 GROMMET,scrNo.8/10 12

17 Ri 072 623 POTENTIOMETER, iT 2W 100 ohm 1

18 CBI 079 560 CIRCUIT BREAKER, reset 25A 1P 1

19 Si 011 609 SWITCH, tgl SPDT 15A 125V 1

20 C8-10 031 670 CAPACITOR,cer.O5uI500VDC 3

21 RC1 035 523 RECEPTACLE, 5 skt MS-3102A-16S-8S 1

22 C6,7 087 209 CAPACITOR, cer .OO3uf 2000V 2

23 039 047 TERMINAL, pwr output (consisting of) 2

24 601 976 SCREW, cap-hex hd .500-13 x 1.500 1

25 039 049 TERMINAL BOARD, red 1

26 601 880 NUT, hex-jam .500-13 1

27 039 044 BUS BAR 1

28 601 879 NUT, hex-full .500-13 1

29 605 583 CATCH, spring loaded 1

30 072 539 DOOR, access-front 1

31 039684 CAP,dust(RC1) 1

32 097 926 KNOB, pointer 1

33 072 590 LOCK, shaft-pot I

34 NAMEPLATE, (order by model & serial number) 1


OM-317 Page 23

Figure 9-3. SwItch, PIrt


OM-317 Page 24

Item PartNo. No. Descnption Quantity

084 228 FIgure 9-3. SwItch, Plfl (Fig 9-2 Item 2)

011 645 CONTACT ASSEMBLY, movable (consisting of)1

2

3

4

5

6

7

8

9

10

11

12

13

14

011 074

011 953

011 075

011 644

072 028

086322

070204

010 486

084 673

072 082

072 027

005558

084226

SPRING, pressure-contactCONTACT, switch

SPRING, pressure-contactCONTACT, stationary switch

GUIDE, contact switch

BRACKET, mtg-switchLINK, jumper - U shapedTUBING, stl .275 x .750

LINK, jumperBUSHING, .265 ID x .484 OD x .593 IgLEVER, switch

SPRING, selector switch

SPACER, handle-switch

4

1

2

1

12

4

2

2

4

1

2

2

2

1

1

5

11

8

9

5

10

1

13 12

TC.087 2~

Descnption Quantity

070 200 FIgure 9.4. SwItch, Range (FIg 9-2 Item 3)


OM-317 Page 25

ItemNo.

PartNo.

1 011 645 CONTACT ASSEMBLY, movable (consisting of)2 011 074 SPRING, pressure-contact3 011 953 CONTACT, switch

4 011 075 SPRING, pressure-contact5 011 644 CONTACT, stationary-switch6 072 028 GUIDE, contact-switch

7 072 026 BRACKET, mtg-switch8 005 558 SPRING, selector-switch

9 072 027 LEVER, switch

10 072 082 BUSHING, .265 ID x .484 OD x .593 ig

1

5

10

6

7

9

I

1

2

1

3

1

1

1

1

1

TC.087 340

Figure 9-4. SwItch, Range

Figure 9-5. Circuit Card, MA Control PCi

set. C-093 312

N ~

0 VR5O

~j°I0

~i~aQ5Iosi �c~�

D50

D53

D52 �~=J-

R62

R61

C53

R59

R52

0RC6O~~a 00 a~

A

ASSY 093313

-cJ~75

0

OM-317 Page 26

Dia. Part

Mkgs. No. Description Quantity

Pci 093 313 Figure 9-5. CircuIt Card, MA Control (Fig 9-2 Item 13)

A50 052133 IC,Iinear4l36 1

C50,51 039 482 CAPACITOR, electlt lOOuf 35VDC 2

C52 000 348 CAPACITOR, tantim .47uf 35V 1

C53 005 023 CAPACITOR, tantlm 2.2uf 20V I

C54,59,60 031 643 CAPACITOR,cer.O1uf500VDC 3

C55,56 073 739 CAPACITOR, cer .luf 50V 2

C57 072 130 CAPACITOR, tantim luf 35VDC 1

C58 053 992 CAPACITOR, cer .OOluf 1000V 1

C61 035 835 CAPACITOR, electlt 4.7uf 35V 1

D50-54 026 202 DIODE, 1A 400V SP 5

D55 037449 DIODE,zenerl5VlW 1

D56,57 028 351 DIODE, .020A 75V SP 2

050,52 037 200 TRANSISTOR, 200MA 40V NPN 2

Q51 039 355 TRANSISTOR, 15MA 40V 1

053 035 842 TRANSISTOR, PNP .6A 40V 1

R50 030 711 RESISTOR, C 1W 330 ohm 1

R51 ,62,69,72 035 825 RESISTOR, CF .25W 1K ohm 4

R52 052 138 RESISTOR, CF .25W 20K ohm 1

R53,58,67 000 885 RESISTOR, CF .25W 10K ohm 3

R54,60 039 333 RESISTOR, CF .25W 18K ohm 2

R55,65 039 332 RESISTOR, CF .25W 15K ohm 2

R56 039 330 RESISTOR, CF .25W 3900 ohm 1

R57 009 173 POTENTIOMETER, cermet 20/T .5W 5K ohm 1

R59,66 052 137 RESISTOR, CF .25W 5.1K ohm 2



R64 605 919 RESISTOR, C .25 4.7K ohm 1


R70 039 331 RESISTOR, CF .25W 4.7K ohm 1


R73,75 030 090 RESISTOR, C .5W 47 ohm 2

R74,76 039 106 RESISTOR, CF .25W 470 ohm 2

092 648 RESISTOR, CF .25W zero ohm 1

RC6O 084 196 TERMINAL, header 6 pin 1

RC61 084 197 TERMINAL, header 8 pin 1

VR5O 081 832 IC, linear 78M15 1


OM-317 Page 27

FIgure 9-6. CIrcuit Card, Voltage Reducer PC2

Rel. D~O72 188

0ASSEMBLY 072187

T50

�

151

D56D~4

053

R 76

0

I �1C57

.A 65

C

OM-317 Page 28


Dia.

Mkgs.PartNo. Description

PC2 112 438 Figure 9-6. CircuIt Card, Voltage Reducer (Fig 9-2 Item 14)

Quantity

A50 009159 IC,Iinear358 1

C50 074 001 CAPACITOR, electit 2Ouf 150V 1

C51,60 053 992 CAPACITOR, cer .OOluf 1000V 2

C52 072 130 CAPACITOR, tantlm luf 35VDC 1

C53 031 638 CAPACITOR, electit luf 15OVDC 1

C54 005 023 CAPACITOR, tantim 2.2uf 20V 1

C55 031 643 CAPACITOR,cer.O1uf500VDC 1

C56-58,65 073 739 CAPACITOR, cer .luf 50V 4

C59 031 699 CAPACITOR, polye film .0022uf 200VDC....

1

C61 ,62 035 522 CAPACITOR, poiye film .047uf 100V 2

C63,64 039 482 CAPACITOR, electit lOOuf 35VDC 2

CR50 039 486 RELAY, end 24VDC SPDT 1

D50-57 026 202 DIODE, 1A 400V SP 8

D58-61 028 351 DIODE, sig 020A 75V 4

D62 072 423 DIODE, zener 56V 1W 1

D63 037449 DIODE,zenerl5VlW 1

D64 037 250 DIODE, zener 24V 1W 1

IC5O 072 433 IC, interface 555 1

0C50 047 034 IC, interface 4N26 1

Q50-54 037 200 TRANSISTOR, 200MA 40V NPN 5

Q55 035 842 TRANSISTOR, 6A 40V PNP 1

R50 605 919 RESISTOR, C .25W 47 ohm 1

R51 030 712 RESISTOR, C 1W 1000 ohm 1


R53,68 030 707 RESISTOR, C 1W 47 ohm 2



R56,66 003 272 RESISTOR, CF .25W 1 meg ohm 2

R57-59,64 039 333 RESISTOR, CF .25W 18K ohm 4

R60,63,76,78 039 330 RESISTOR, CF .25W 3900 ohm 4

R61 73 039 332 RESISTOR, CF .25W 15K ohm 2


R65,69,70 035 825 RESISTOR, CF .25W 1K ohm 3


R71 030 105 RESISTOR, C .5W 680 ohm 1

R72 052 137 RESISTOR, CF .25W 5.1K ohm 1



R77 074 060 RESISTOR, C .5W 1000 ohm 1

R79 039 331 RESISTOR, CF .25W 4.7K ohm I

RC5O 079 759 TERMINAL, header 12 pin 1

T50,51 072432 TRANSFORMER, pulse 2

OM-317 Page 29

1

4

Figure 9-7. SwItch, PB

TA-080 214-A

TA-087 317

Item Dia.No. Mkgs.

PartNo.

031 688

037 157

031 689

046819

FIgure 9-8. RectIfier, Si DIode

2

4

1

1

ItemNo.

PartNo. Description Quantity

046 745 Figure 9-7. SwItch, PB (Fig 9-2 Item 4)

1 059 885 BUTTON, push-reset red 1

2 018 606 SPRING, compression 1

3 045 546 PUSH BUTTON SET, w/cable & housing I

4 081 008 BRACKET, mtg-switch PB 1

5 027 878 SWITCH, iimit-ieaf actuating SPDT 1

5

Description

071 001 FIgure 9-8. Rectifier, Si DIode (FIg 9-1 Item 6)

Quantity

1 CAPACITOR, cer .Oluf 1000VDC 3/16 term

2 D1-4 DIODE,275A250VSP3 CAPACITOR, cer .Oluf 1000VDC 3/16 & 1/4 term

4 R3,VR1 SUPPRESSOR


OM-317 Page 30

1

2

3

4

5

6

Description~ ~ ~_____ ~ ~

Quantity

Figure 9-9. Panel, Rear w/Components (Fig 9-1 Item 10)


1

1

1

2

1

1

Item Dia.No. MkQs.

PartNo.

132 260

605 799

072 528

C5 107211

025 141

FM 032605

CHAMBER, plenum 141n

BLADE, fan l4in 5wg 30 degPANEL, rear

CAPACITOR, polyp MF 35uf 48OVAC

BRACKET, mtg-capacitorMOTOR, cap perm SP 1/4HP 230VAC 1625RPM

Figure 9-9. Panel, Rear - w/Components

TC.087 278

OM-317 Page 31

1

2

3

4

5

6

7

8

9

10

11

12

13

14

SCR1,2VR2

vS1

TE2

Description Quantity

Figure 9-10. SCR Contactor & Primary Terminal (Fig 9-1 Item 12)

1

2

2

2

1

1

1

1

16

4

8

8

1

8

Item Dia.No. Mkgs.

PartNo.

070 116

072 085

025 248

072 131

091 033

020 225

071 047

072 540

601 835

038 618

010913

038 887

072 548

026 754

SCR CONTACTOR, (consisting of)�HEATSINK� STAND-OFF, insul .250-20 x 1.250 ig x .437thd

THYRISTOR, SCR 70A 1600V

VARISTOR, .5uf 575VAC

CLAMP, nyl .875c1p dia x .500 wide� SUPPRESSOR, .5uf 575V

TERMINAL ASSEMBLY, pri (consisting of)NUT, brs-hex 10-32

LINK, jumperWASHER, flat-brs .187 x .500 OD x .O3lthk

� STUD, pri bd brs 10-32 x 1.375

TERMINAL BOARD

INSULATION, barrier

1

8

Figure 9-10. SCR Contactor & Primary Terminal


OM-31 7 Page 32

18.087 281-A

ERRATA SHEET


AMENDMENT TO SECTION 9 � PARTS LIST


Dia. Part

Mkgs. No.Replaced

With Description Quantity

�

21-4. .. .

W...

009 859..

137 900�. KIT, contactor (Eff w/KB022071) 1

21-25 081 016�.

Deleted�.

Effw/KB022071 1

**First digit represents page no � digits following dash represent item no.


~

ERRATA SHEET


Replace warranty with the following:

Ui

FILE C'PV~TO F@~~

MILLER�S TRUE BLUETM LIMITED WARRANTY

Effective January 1, 1992

(Equipment with a serial number preface of �KC� or newer)

This limited warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.

~~1

LIMITED WARRANTY � Subjectto the terms arid conditions below. MILLER Electric

Mfg. Co.. Appleton. Wisconsin. warrants to its original retail purchaser that new

MILLER equipment sold after the affective date of this limited warranty is free of de

fects in material and workmanship at the time it is shipped by MILLER. THIS WAR.

RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR

IMPLIED. INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT

NESS.

Within the warranty periods listed below, MILLER will repair or replace any war

ranted parts or components that fail due to such defects in material or workmanship.MILLER must be notified in writing within thirty (30) days of such defect or failur., at

which time MILLER will provide instructions on the warranty claim procedures to be

followed.

MILLER shall honor warranty claims on warranted equipment listed below in the

event of such a failure within the warranty time periods. All warranty time periodsstart on the date that the equipment was delivered to the original retail purchaser.and are as follows:

1.. 5 YearS Parts - 3 Years Labor

� Original main power rectifiers

2.. 3 Yeats � Parts and Labor

� TransformeifRectifler Power Sources

� Plasma Arc Cutting Power Source.* Semi-Automatic and Automatic Wire Feeders

� Robots

3.. 2 Yeats � Parts and Labor

� Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer.)

4.. 1 Year � Parts and Labor

� Motor DrivenGuns

� Process Confroflerl

� Water Coolant Systems� HFUnits

� Grids

� Spot Welders

� Load Banks

� SOX Transformers� Running Gear/Trailers� Field Options

(NOTE: Field options are covered under True BIuTe for the remainingwarranty period of the product they are Instalted in. or for a minimum of

one year � whichever is graat~.)

5.. 8 Months � Batteries

8.. 90 Days � Parts and Labor

� MIG Guns/TIG Torches� Plasma Cutting Torches

� Remote Controls

� Accessory Kits

� Replacement Parts

MILLER�S True Bluere

LImited Warranty shall not apply to:

1.. Items furnished by MILLER. but manufactured by others, such as engine. or

trade accessories. These itsms are covered by the manufacturer�s warranty, if

any.

2.. Consumable components; such as contact tips, cutting nozzles. contactore

and relays.

3.. Equipment that has been modifIed by any party other Ituan MILLER. or equipment that has been Improperly Installed, improperly operated or misused

based upon Industry standards, or equipment which has not had reasonable

and necessary maintenance, or equipment which has been used for operationoutside of the specifications for the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN

THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

In the event ole warranty claim covered by this warranty, the exclusive remedies

shall be, at MILLER�S option: (1) repaIr; or (2) replacement; or, where authorized in

writing by MILLER in appropriate case.. (3) the reasonable coat of repair or replacement stan authorized MILLER sstv$ce station; or (4) payment of or credit for the purchase pric, (lisa reasonabl, depreciation based upon actual use) upon return of the

goods at customer�s risk and expense. MILLER�S option of repair or replacementwill be FOB., Factory atAgØeton. Wisconsin. or FOB. ate MILLER authorized ser

vice facility as determined by MILLER. Ther01~rs no compensation or reimburse

ment for franaportatlon costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROViDED HEREIN

ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE

LIABLE FOR DIRECt INOIRECt SPECIAL. INCIDENTAL OR CONSEQUENTIALDAMAGES (INCLUDING LOSS OF PROFIT). WHETHER BASED ON CON

TRACT, TORT OR ANY OThER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR

RANTY. GUARANTY OR REPRESENTATION AS TO PERFORMANCE. AND ANYREMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGALTHEORY WHICH, BUT FOR THIS PROVISION. MIGHT ARISE BY IMPLICATION,OPERATION OF LAW. CUSTOM OF TRADE OR COURSE OF DEALING. IN

CLUDING ANY IMPUED WARRANTY OF MERCHANTABILITY OR FITNESS

FOR PARTICULAR PURPOSE. WITH RESPECT TO ANY AND AU. EQUIPMENT

FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.

Sam. stataa in the USA. do not allow lImItitlon. 01110w long an implied warrunutylasts, or the exclusion of incIdental. indirect, special or cons.quentfai damages. so

the above limitation or exclusion may not apply to you. 1111 warranty provides specific legal rights, and other rights may be available, but may vary from stile to state.

In Canada, legislation In some provinces provide. for certain additional wvrantles

or remedies Other than U stated herein, and to the extant that they may riot be

waived, the tmltstlona and exclusions sat Out above may not apply. This Limited

Warranty provides specific legal rights, and other rights may b available, but may

vary from province to province.

�I

AMENDMENT TO SECTION 9- PARTS LIST


Dia. Part ReplacedMkgs. No. With Description Quantity

�

21-4....

W...

009 859..

137 900.. KIT, contactor (Effw/KB022071) 1

21-25 081 016..

Deleted..

Effw/KB022071



OM-317B Page 2

ERRATA SHEET

W 009 859 137 900 KIT, contactor (Eff w/KB022071) 1

081 016 Deleted Effw/KB022071 1



~

After this manual was printed, refinements In equipment design occurred. This sheet lists exceptionsto data appearing later In this manual.

AMENDMENT TO SECTION 9 � PARTS LIST


Dia. Part

Mkgs. No.Replaced

With Description Quantity

21-4

21-25

Miller February - Norco Medical€¦ · ERRATASHEET Afterthismanualwasprinted, refinementsin...

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