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February

1975

FORM:

OM-238

MODEL

P.7

CP-1000

STOCK

NO.

900

860

900

869

MODEL/STOCK

NO.

SERIAL/STYLE

NO.

DATE

PURCHASED

ADDITIONAL

COPY

PRICE

CENTS

Effective

with

Serial

No.

HE819991

q~LLQQ

LLPJ

LtD

LQJJ

LQILLLLLLLW.LLLQ

LLLLP

mmm

OT~T~T~

bTfl

a a

WARRANTY

MILLER

Electric

Mfg.

Co.,

Appleton,

Wisconsin,

warrants

all

new

equipment

free

from

defects

material

and

factory

workmanship

for

the

periods

indicated

below,

provided

the

equipment

installed

and

a a

operated

according

manufacturers

instructions,

MILLER

Electric

Mfg.

Co.s

obligation,

under

this

warranty,

limited

replacingor

repairing

any

defective

part

correcting

any

manufacturing

defect

without

charge

during

the

warranty

period

MILLERS

inspec

tion

confirms

the

existence

such

defects.

MILLERS

option

repair

replacement

will

fob,

factory

Appleton,

Wisconsin

fob,

MILLER

authorized

service

facility,

and

therefore

compensation

for

trans-

portation

costs

any

kind

will

allowed.

The

warranty

period,

beginning

the

date

sale

the

original

purchaser-user

the

equipment,

will

follows:

Arc

welders,

power

sources,

and

components



year

Original

main

power

rectifiers



years

(unconditionally)

MHFC-L1

Feeder,

MHG-35C1,

20E,

20K,

and

all

guns

and

torches



days

All

other

Millermatic

Feeders



year

Mag-Diesel

engine

DEL-200



months

All

other

engines



year

Engine

Warranties

are

covered

the

engine

manufacturers,

subject

their

procedures

and

handled

through

their

authorized

local

Service

Stations

agencies.

warranty

will

made

respect

trade

accessories,

such

being

subject

the

warranties

their

respective

manufacturers.

MILLER

Electric

Mfg.

Co.

will

not

liable

for

any

loss

consequential

damage

expense

accruing

directly

indirectly

from

the

use

equipment

covered

this

warranty.

This

warranty

supersedes

all

MILLER

warranties

and

exclusive

with

other

guarantees

)

warranties

expressed

implied.

LLLO

LQL3~

LLLL0

01P3..0330

033

Qfl.33J3

QQJJ.J,Q,,,

~+~+O~+~

OTO

~OThTh

oTOTh

rnTa~b

OTOTOTTO

SECTION

1-SAFETY

RULES

FOR

OPERATION

ARC

WELDING

POWER

SOURCE

1-1.

INTRODUCTION

learn

experience.

Learning

safety

through

personal

experience

child

touching

hot

stove

harmful,

waste

ful,

and

unwise. Let

the

experience

others

teach

you.

Safe

practices

developed

from

experience

the

use

weld

ing

and

cutting

are

described

this

manual.

Research.

devel

opment,

and

field

experience

have

evolved

reliable

equipment

and

safe

installation,

operation,

and

servicing

practices.

Acci

dents

occur

when

equipment

improperly

used

main

tained.

The

mason

for

the

safe

practices

may

not

always

given.

Some

are

based

common

sense,

others

may

require

technical

volumes

explain.

wiser

the

rules.

Read

and

understand

these

safe

practices

before

attempting

install,

operate,

service

the

equipment

Comply

with

these

procedures

applicable

the

particular

equipment

used

and

their

instruction

manuals,

for

personal

safety

and

for

the

safety

others.

Failure

observe

these

safe

practices

may

cause

serious

jury

death.

When

safety

becomes

habit,

the

equipment

can

used

with

confidence.

Responsibilities

installer,

user,

and

serviceman.

Installa

tion,

operation,

checking,

and

repair

this

equipment

must

done

only

competent

person,

experienced

with

such

equipment.

These

safe

practices

are

divided

into

two

Sections:

General

Precautions,

common

arc

welding

and

cutting;

and

Arc

Welding

(and

CuttingUonly).

Reference

standards:

Published

Standards

safety

are

also

available

for

additional

and

complete

procedures

than

those

given

this

manual.

They

are

listed

the

Standards

Index

these

safety

rules.

ANSI

249.1

the

most

complete.

The

National

Electrical

Code,

Occupation

Safety

and

Health

Administration,

local

industrial

codes,

and

local

inspection

requirements

also

provide

basis

for

equipment

installation,

use,

and

service.

GENERAL

PRECAUTIONS

Burn

Prevention

Wear

protective

clothing

leather

(or

asbestos)

gauntlet

gloves,

hat,

and

high

safety-toe

shoes.

Button

shirt

collar

and

pocket

flaps,

and

wear

cuffless

trousers

avoid

entry

sparks

and

slag.

Wear

helmet

with

safety

goggles

glasses

with

side

shields

underneath,

appropriate

filter

lenses

plates

(protected

clear

cover

glass).

This

MUST

for

welding

cutting,

(and

chipping(

protect

the

eyes

from

radiant

energy

and

flying

metal.

Replace

cover

glass

when

broken,

pitted,

spattered.

See

1-3A.

Avoid

oily

greasy

clothing.

spark

may

ignite

them.

Hot

metal

such

electrode

stubs

and

workpieces

should

never

handled

without

gloves.

Medical

first

aid

and

eye

treatment.

First

aid

facilities

and

qualified

first

aid

person

should

availthle

for

each

shift

unless

medical

facilities

are

for

immediate

treatment

flash

burns

the

eyes

and

skin

burns.

Ear

plugs

should

worn

when

working

overhead

confined

space.

hard

hat

should

worn

when

others

work

overhead.

Flammable

hair

preparations

should

not

used

persons

intending

weld

cut.

Toxic

Fume

Prevention

Adequate

ventilation.

Severe

discomfort

illness

death

can

result

from

fumes,

vapors,

heat

oxygen

enrichment

depletion

that

welding

(or

cutting(

may

produce.

Prevent

them

with

adequate

ventilation

described

ANSI

Stan.

dard

249.1

listed

Standards

index.

NEVER

ventilate

with

oxygen.

Lead,

cadium,

zinc,

mercury,

and

beryllium

bearing

and

simi

lar

materials,

when

welded

(or

cut)

may

produce

harmful

concentrations

toxic

fumes.

Adequate

local

exhaust

venti

lation

must

used,

each

person

the

area

well

the

operator

must

wearan

air-supplied

respirator.

For

beryllium,

both

must

used.

Metals

coated

with

containing

materials

that

emit

toxic

fumes

should

not

heated

unless

coating

removed

from

the

work

surface,

the

area

well

ventilated,

the

operator

wears

air-supplied

respirator.

Work

confined

space

only

while

being

ventilated

and,

necessary,

while

wearing

air-supplied

respirator.

Gas

leaks

confined

space

should

avoided.

Leaked

gas

large

quantities

can

change

oxygen

concentration

danger

ously.

not

bring

gas

cylinders

into

confined

space.

Leaving

confined

space,

shut

OFF

gas

supply

source.

The

space

will

then be

safe

re-enter,

downstream

valves

have

been

accidently

opened

left

open.

Vapors

from

chlorinated

solvents

can

decomposed

the

heat

the

arc

(or

flame)

form

PHOSGENE,

highly

toxic

gas,

and

other

lung

and

eye

irritating

products.

The

ultra

violet

(radiant)

energy

the

arc

can

also

decompose

chloroethylene

and

perchloroethylene

vapors

form

phos

gene.

NOT

WELD

cut

where

solvent

vapors

can

drawn

into

the

welding

cutting

atmosphere

where

the

radiant

energy

can

penetrate

atmospheres

containing

even

minute

amounts

trichlorethylene

perchlorethylene.

Fire

and

Explosion

Prevention

Causes

fire

and

explosion

are:

combustibles

reached

the

arc,

flame,

flying

sparks,

hot

slag

heated

material;

misuse

compressed

gases

and

cylinders;

and

short

circuits.

aware

that

flying

sparks

falling

slag

can

pass

through

cracks,

along

pipes,

through

windows

doors,

and

through

wall

floor

openings,

out

sight

the

goggled

operator.

Sparks

and

slag

can

fly

feet.

prevent

fires

and

explosion:

Keep

equipment

clean

and

operable,

free

oil,

grease.

and

(in

electrical

parts)

metallic

particles

that

can

cause

short

circuits.

combustibles

are

area,

NOT

weld

cut.

Move

the

work

practicable,

area

free

combustibles.

Avoid

paint

spray

rooms,

dip

tanks,

storage

areas,

ventilators.

the

work

can

not

moved,

move

combustibles

least

feet

away

out

reach

sparks

and

heat:

protect

against

ignition

with

suitable

and

snug-fitting,

fire-resistant

covers

shields.

Walls

touching

combustibles

opposite

sides

should

not

welded

(or

cut).

Walls,

ceilings,

and

floor

near

work

should

protected

heat-resistant

covers

shields.

Fire

watcher

must

standing

with

suitable

fire

tinguishing

equipment

during

and

for

some

time

after

weld

ing

cutting

if:

appreciable

combustibles

(including

building

construc

tion)

are

within

feet

appreciable

combustibles

are

further

than

feet

but

can

ignited

sparks

openings

(concealed

visible)

floors

walls

within

feet

may

expose

combustibles

sparks

combustibles

~jacent

walls,

ceilings,

roofs,

metal

partitions

can

ignited

radiant

conducted

heat.

Hot

work

permit

should be

obtained

before

operation

ensure

supervisors

approval

that

adequate

precautions

have

been

taken.

After

work

done,

check

that

area

free

sparks,

glowing

embers,

and

flames.

empty

container

that

held

combustibles,

that

can

pro

duce

flammable

toxic

vapors

when

heated,

must

never

welded

cut,

unless

container

has

first

been

cleaned

described

AWS

Standard

A6.O,

listed

Standards

index.

1-2.

OM-238

Page

possible

leak.

For

fuel

gas,

open

less

than

one

turn

permit quick

emergency

shutoff.

Use

pressure

charts

(available

from

your

supplier)

for

safe

and

efficient,

recommended

pressure

settings

regulators.

will

reduce

backfiring

and

chance

flashbacks.

Check

for

leaks

first

pressurization

and

regularly

there

after.

Brush

with

soap

solution

(capful

Ivory

Liquid

equivalent

per

gallon

water).

Bubbles

indicate

leak.

Clean

off

soapy

water

after

test;

dried

soap

combustible.

User

Responsibilities

Remove

leaky

defective

equipment

from

service

immed

iately

and

repair

them

only

recommended

equipment

instruction

manual.

Send

others

for

repair

manufacturers

designated

repair

center

where

special

techniques

and

tools

are

used

trained

personnel.

Refer

User

Responsibilities

statement

equipment

manual.

Leaving

Equipment

Unattended

gas

supply

source

and

drain

gas.

Rope

Staging-Support

Rope

staging-support

should

not

used

for

welding

cut

ting

operation;

rope

may

burn.

1-3.

ARC

WELDING

Comply

with

precautions

1-2

and

this

section.

Arc

Weld

ing,

properly

done,

safe

process,

but

careless

operator

invites

trouble.

The

equipment

carries

high

currents

signifi

cant

voltages.

The

arc

very

bright

and

hot.

Sparks

fly.

fumes

rise,

ultraviolet

and

infrared

energy

radiates,

weld

ments

are

hot,

and

compressed

gases

may

used.

The

wise

operator

avoids

unnecessary

risks

and

protects

himself

and

others

from

accidents.

Precautions

are

described

here

and

standards

referenced

index.

Burn

Protection

Comply

with

precautions

1-2.

The

welding

arc

intense

and

visibly

bright.

Its

radiation

can

damage

eyes,

penetrate

lightweight

clothing,

reflect

from

light-colored

surfaces,

arid

burn

the

skin

and

eyes.

Skin

burns

resemble

acute

sunburn,

those

from

gas-shielded

arcs

are

severe

and

painful.

DONT

GET

BURNED;

COMPLY

WITH

PRECAUTIONS.

Protective

Clothing

Wear

long-sleeve

clothing

(particularly

for

gas-shielded

arc)

addition

gloves,

hat,

and

shoes

(1-2A).

necessary,

use

additional

protective

clothing

such

leather

jacket

sleeves,

flame-proof

apron,

and

fire-resistant

leggings.

Avoid

outergarments

untreated

cotton.

Bare

skin

protection.

Wear

dark,

substantial

clothing.

Button

collar

protect

chest

and

neck

and

button

pockets

pre

vent

entry

sparks.

Eye

and

Head

Protection

Protect

eyes

from

exposure

arc.

NEVER

look

elec

tric

arc

without

protection.

Welding

helmet

shield

containing

filter

plate

shade

no.9

denser

must

used

when

welding.

Place

over

face

before

striking

arc.

Protect

filter

plate

with

clear

cover

plate.

Cracked

broken helmet

shield

should

NOT

worn;

radiation

can

pass

through

cause

burns.

Cracked,

broken,

loose

filter

plates

must

replaced

MEDIATELY.

Replace

clear

cover

plate

when

broken,

pitted,

spattered.

Flash

goggles

with

side

shields

MUST

worn

under

the

helmet

give

some

protection

the

eyes

should

the

helmet

not

lowered

over

the

face

before

arc

struck.

Looking

arc

momentarily

with

unprotected

eyes

(particularly

high

intensity

gas-shielded

arc)

can

cause

retinal

burn

that

may

leave

permanent

dark

area

the

field

vision.

Protection

Nearby

Personnel

Enclosed

welding

area.

For

production

welding,

separate

room

enclosed

bay

best.

open

areas,

surround

the

operation

with

low-reflective,

non-combustible

screens

panels.

Allow

for

free

air

circulation,

particularly

floor

level.

Viewing

the

weld.

Provide

face

shields

for

all

persons

who

will

looking

directly

the

weld.

Others

working

area.

See

that

all

persons

are

wearing

flash

goggles.

Before

starting

weld,

make

sure

that

screen

flaps

bay

doors

are

closed.

Toxic

Fume

Prevention

Comply

with

precautions

1-28.

Generator

engine

exhaust

must

vented

the

outside

air.

Carbon

monoxide

can

kill.

Fire

and

Explosion

Prevention

Comply

with

precautions

1-2C.

Equipments

rated

capacity.

not

overload

arc

welding

equipment.

may

overheat

cables

and

cause

fire.

Loose

cable

connections

may

overheat

flash

and

cause

fire.

Never

strike

arc

cylinder

other

pressure

vessel.

creates

brittle

area

that

can

cause

violent

rupture

lead

Such

rupture

later

under

rough

handling.

Compressed

Gas

Equipment

Comply

with

precautions

1-2D.

Shock

Prevention

Exposed

hot

conductors

other

bare

metal

the

welding

circuit,

ungrounded,

electrically-HOT

equipment

can

fatally

shock

person

whose

body

becomes

conductor.

NOT

STAND,

SIT,

LIE,

LEAN

ON,

TOUCH

wet

sur

face

when

welding,

without

suitable

protection.

protect

against

shock:

Keep body

and

clothing

dry.

Never

work

damp

area

with

out

adequate

insulation

against

electrical

shock.

Stay

dry

duckboard,

rubber

mat

when

dampness

sweat

can

not

avoided.

Sweat,

sea

water,

moisture

between

body

and

electrically

HOT

part

grounded

metal

reduces

the

body

surface

electrical

resistance,

enabling

dangerous

and

possibly

lethal

currents

flow

through

the

body.

Grounding

the

Equipment

When

installing,

connect

the

frames

each

unit

such

welding

power

source,

control,

work

table,

and

water

circula

tor

the

building

ground.

Conductors

must

adequate

carry

ground

currents

safely.

Equipment

made

electrically

HOT

stray

current

may

shock,

possibly

fatally.

NOT

GROUND

electrical

conduit,

pipe

carrying

ANY

gas

flammable

liquid

such as

oil

fuel.

Three-phase

connection.

Check

phase

requirement

equip

ment

before

installing.

only

3-phase

power

available.

connect

single-phase

equipment

only

two

wires

the

3-phase

line.

NOT

connect

the

equipment

ground

lead

the

third

(live)

wire,

the

equipment

will

become

electri.

cally

HOT

dangerous

condition

that

can

shock,

possibly

fatally.

Before

welding,

check

ground

~or

continuity.

sure

conduc

tors

are

touching

bare

metal

equipment

frames

connec

tions.

line

cord

with

ground

lead

provided

with

the

equip

ment

for

connection

switchbox,

connect

the

ground

lead

the

grounded

switchbox.

three-prong

plug

added

for

connection

grounded

mating

receptacle,

the

ground

lead

must

connected

the

ground

prong

only.

the

line

cord

comes

with

three-prong

plug,

connect

grounded

mating

receptacle.

Never

remove

the

ground

prong

from

plug,

use

plug

with

broken

off

ground

prong.

Trademark

Proctor

Gamble.

OM-238

Page

SECTION

INTRODUCTION

Model

Rated

Welding

Current

Amperes

Open-Circuit

Voltage

Range

Maximum

Open-

Circuit

Voltage

Amperes

Input

Rated

LoadOutput60Hz.

Three

Phase



230

Volts

460

Volts

kva

Dimensions

(Inches)

Weight

(Pounds)

Net

Ship

Amperes

750

Volts

100%

Duty

Cycle

15-49

36.6

33.2

Height

56-1/2

Width

27-1/4

Depth

35-3/4

895

955

1000

Amperes

Volts

100%

Duty

Cycle

15-47

120

47.7

43.5

Height-56.1/2

Width

27-1/4

Depth

1145

1215



 



Figure

2-1.

Specifications

2-1.

GENERAL

This

manual

has

been

prepared

especially

for

use

familiar

izing

personnel

with

the

design,

installation,

operation,

main

tenance,

and

troubleshooting

this

equipment.

All

informa

tion

presented

herein

should

given

careful

consideration

assure

optimum

performance

this

equipment.

2-2.

RECEIVING-HANDLING

Prior

installing

this

equipment,

clean

all

packing

material

from

around

the

unit

and

carefully

inspect

for

any

damage

that

may

have

occurred

during

shipment.

Any

claims

for

loss

damage

that

may

have

occurred

transit

must

filed

the

purchaser

with

the

carrier.

copy

the

bill

lading

________________________________________________________

and

freight

bill

will

furnished

the

carrier

request

occasion

file

claim

arises.

When

requesting

information

concerning

this

equipment,

essential

that

Model

Description

and/or

Stock

Number

and

Serial

(or

Style)

Numbers

the

equipment

supplied.

2-3.

DESCRIPTION

This

Unit

three-phase

welding

power

source

which

pro

duces

welding

current.

This

welding

power

source

________________

designed

specifically

for

use

with

the

Gas

Metal-Arc

)MIG)

Welding

process.

2-4.

SAFETY

Under

this

heading,

explanatory

statements

will

found

that

need

special

emphasis

obtain

the

most

Before the

equipment

put

into

operation,

the

safety

sec-

efficient

operation

the

equipment.

tion

the

front

this

manual

should

reed

completely.

SECTION

INSTALLATION

3-1.

LOCATION

(Figure

3-1)

proper

installation

Site

should

selected

for

the

welding

power

source

the

unit

provide

dependable

service,

and

remain

relatively

maintenance

free.

proper

installation

site

permits

freedom

air

movement

into

and

Out

the

welding

power

source,

and

also

least

subjects

the

unit

dust,

dirt,

moisture,

and

corrosive

vapors.

minimum

inches

unrestricted

space

must

main

tained

between

the

welding

power

source

front

and

rear

panels

and

the

nearest

obstruction.

Also,

the

underside

the

welding

powe(

source

must

kept

completely

free

obstructions.

The

installation

site

should

also

permit

easy

removal

the

welding

power

source

outer

enclosure

for

maintenance

functions.

place

over

the

take

air

pas~ges

the

welding

power

source

this

would

restrict

the

volume

intake

air

and

thereby

subject

the

welding

power

source

internal

components

overheating

condition

and

subsequent

failure.

War-

TB.039

388

ranty

void

any

type

filtering

device

used.

Figure

3-1.

Dimensional

Drawing

This

will

help

avoid

possible

injury

due

misuse

improper

welding

applications.

The

following

definitions

apply

CAUTION,

IMPORTANT,

and

NOTE

blocks

found

throughout

this

manual:

1Irq~i~iiii.i~1

Under

this

heading,

installation,

operating,

and

main

tenance

procedures

practices

will

found

that

not

carefully

followed

may

create

safety

hazard

personnel

~J~=ANT

Under

this

heading,

installation,

operating,

and

main

tenance

procedures

practices

will

found

that

not

carefully

followed

may

result

damage

equip

ment.

NOTE

5-1/2

OM-238

Page

Holes

are

provided

the

welding

power

source

base

for

mounting

purposes.

Figure

3.1

gives

overall

dimensions

and

the

base

mounting

hole

layout.

most

welding

power

sources

lifting

device

provided

for

moving

the

unit.

However,

fork

lift

vehicle

used

for

lifting

the

unit,

sure

that

the

lift

forks

are

long

enough

extend

completely

under

the

base.

IMPORTANT

The

use

lift

forks

too

short

extend

out

the

opposite

side

the

base

will

expose

internal

com

ponents

damage

should

the

tips

the

lift

forks

penetrate

the

bottom

the

unit.

3-2.

ELECTRICAL

INPUT

CONNECTIONS

NOTE

recommended

that

Line

Disconnect

Switch

installed

the

input

Circuit

the

welding

power

source.

This

would

provide

safe

and

convenient

means

completely

remove

all

electrical

power

from

the

welding

power

source

whenever

necessary

perform

any

internal

function

the

unit

CAUTION__j



Before

making

electrical

input

conons

the

welding

power

source,

machinery

lockout

proce

dures

should

employed,

the

connection

made

from

line

disconnect

switch,

the

switch

should

padlocked

the

open

position.

the

connection

made

from

fuse

box,

remove

the

fuses

from

the

box

and

padlock

the

cover

the

closed

position.

lock

ing

facilities

are

not

available,

attach

red

tag

the

line

disconnect

switch

(or

fuse

box)

warn

others

that

the

circuit

being

worked

on.

Input

Electrical

Requirements

This

welding

power

source

designed

operated

from

three

phase,

Hertz,

power

supply

which

has

line

voltage

rating

that

corresponds

with

one

the

primary

volt

ages

shown

the

welding

power

source

nameplate.

Consult

the

local

electric

utility

there

any

question

about

the

type

electrical

system

available

the

installation

site

how

proper

connections

the

welding

power

source

are

made.

Input

Conductor

Connections

CAUTION__I!

not

connect

the

input

conducto~he

three-

phase

power

supply

until

all

input

electrical

connec

~~ions

have

been

made

the

welding

power

source

recommended

that

the

input

conductors

the

heavy

rubber

covered

type

installed

solid

flexible

con

duit.

Select

theproper

size

input

conductors

and

fuse

from

Table

3-1.

Table

3-1.

Input

Conductor

and

Fuse

Size

Input

Conductor

Size.

A6IG

Fuse

Size

(AmperesjJ

Model

208V

230V 460V

575V

208V 230V

460V

575V

750

Amp

(81

181

(8)

175

150

1000

Amp

(8)

(81 181

200

Numbers

are

ground

conductor

sizes

Insert

the

three

input

conductors

plus

one

ground

conductor

through

the

access

hole

the

rear

panel.

This

hole

will

standard

conduit

fittings.

See

Figure

3-2

for

hole

loca

tion

and

size.

NOTE

It is

recommended

that

terminal

lug

adequate

amperage

capacity

attached

the

ends

the

input

and

ground

conductors.

The

hole

diameter

the

terminal

lug

must

proper

size

accommo

date

the

line

and

ground

terminal

studs

the

primary



terminal

board.

Connect

the

three

input

conductors

the

terminals

the

primary

terminal

board

labeled

LINE

and

connect

the

ground

conductor

the

terminal

labeled

GRD

(See

Figure

3-2).

The

remaining

end

the

ground

conductor

should

connected

proper

ground.

Use

whatever

grounding

method

that

acceptable

the

local

electrical

inspection

authority.

CAUTION



The

terminal

labeled

GAD

connecte~e

welding

power

source

chassis

and

for

grounding

purposes

only.

not

connect

conductor

from

the

terminal

labeled

GAD

any

one

the

LINE

terminals~as

this

will

result

electrically

hot

welding

power



source

chassis.

Figure

3-2.

Input

Conductor

Connections

Input

Voltage

Jumper

Links

Matching

The

Welding

Power

Source

The

Avail

able

Input

Voltage

The

input

voltage

umper

links

provided

the

primary

ter

minal

board

permit

the

welding

power

source

operated

from

various

line

voltages.

The

various

voltages

from

which

this

welding

power

source

may

operated

are

stated

the

welding

power

source

nameplate,

and

the

input

voltage

label.

See

Figure

3-2

for

location.

The

input

voltage

jumper

links

this

welding

power

source

are

positioned

for

the

highest

the

voltages

stated

the

nameplate.

the

weld

ing

power

source

operated

from

line

voltage

which

lower

than

the

highest

voltage

for

which

the

unit

was

signed,

the

jumper

links

will

have

moved

the

proper

position

before

operation

the

welding

power

source

com

mences.

Figure

3-3

shows

the

various

positions

for

which

the

jumper

links

may

set

the

standard

welding

power

source.

the

input

voltages

the

welding

power

source

nameplate

differ

from

those

shown

Figure

3-3,

the

input

voltage

jumper

links

must

positioned

shown

the

put

voltage

label.

Ground

Line

Terminals

Terminal

TA-900

872-2A

Page

NOTE

only

one

jumper

link

required

each

the

grouped

terminals,

recommended

that

the

unused

jumper

links

placed

across

the

terminals

which

are

used.

This

will

prevent

losing

the

jumper

links

which

are

not

required

for

this

connection.

G~D.

~Li

~L2

'L3

______

013

922

Figure

3-3.

Input

Voltage

Jumper

Link

Arrangement

3-3.

SECONDARY

CONNECTIONS

The

Positive

and

Negative

secondary

terminals

are

located

behind

the

lower

front

access

panel.

See

Figure

4-1 for

loca

tion

the

terminals.

The

access

panel

which

covers

the

secondary

terminals

secured

two

fasteners.

open

the

access

panel,

rotate

the

fasteners

counterclockwise

one

full

turn.

Likewise,

the

panel,

rotate

the

fasteners

clockwise

one

full

turn.

Welding

Cables

recommended

that

the

welding

cables

kept

short

possible,

placed

together,

and

adequate

current

carrying

capacity.

The

resistance

the

welding

cables

and

connections

cause

voltage

drop

which

added

the

volt.

age

the

arc.

Excessive

cable

resistance

may

result

over

well

reducing

the

maximum

current

output

which

the

welding

power

source

capable.

The

proper

opera

tion

any

arc

welding

power

source

great

extent

dependent

the

use

welthng

cables

and

connections

that

are

good

condition

and

adequate

size.

insulated

electrode

holder

must

used

ensure

the

operators

safety.

Use

Table

3-2

guide

for

selecting

the

correct

welding

cable

size

for

the

anticipated

maximum

weld

current

that

will

used.

Table

3-2

takes

into

account

the

total

cable

length

for

the

weld

circuit.

This

means

the

length

the

Electrode

cable

that

connects

the

wire

feeder

the

welding

power

source

and

the

Work

ground

cable

between

the

welding

power

source

and

the

work

piece.

For

example:

the

Elec

trode

cable

feet

long

and

the

work

ground

cable

feet

long,

select

the

size

cable

from

Table

3-2

that

recom

mended

for

100

feet.

situation

where

maximum

weld

current

150

amperes

anticipated,

No.

weld

cable

recommended

for

both

the

Electrode

and

Work

cables.

WELDING

TOTA

LLEN

GTH

CABLE

(COPPER

WELD

CIRCUIT

250 300 350

400

AMPERES

50

100

150

200

100

1/0 1/0

150

1/0

2/0

3/0

200

1/0

2/0

3/0

4/0

250

1/0 1/0 1/0

2/0 3/0

4/0

2-2/0

300

2/0 2/0 2/0 3/0

4/0 4/0

2-2/0

2.3/0

350

3/0 3/0 2/0

4/0

2-2/0

2-3/0

400

3/0

3/0 3/0 4/0

2-2/0

2-3/0 3.2/0

2-4/0

500

4/0 4/0

4/0

2-2/0

2-3/0

2.3/0

2-4/0

3-3/0

600

2.2/0

2-2/0

2-3/0

3-2/0 2-4/0

3.3/0

3.4/0

700

2-3/0 2.3/0 2.3/0

2-4/0

3-3/0

3-4/0

4-4/0

800

2.3/0

2-3/0

2.4/0

3-3/0

3-4/0

4.4/0 4-4/0

A002

623

NOTE:

FEET

LESS.

8.

CABLE

SIZE

BASED

DIRECT

CURRENT

(DCI,

100%

DUTY

CYCLE

AND

EITHER

VOLTS

LESS

DROP

OR A

CURRENT

DENSITY

NOT

OVER

300

CIRCULAR

MILS

PER

AMP.

WELD

CABLE

INSULATION

WITH

VOLTAGE

RATING

WITHSTAND

THE

OPEN-CIRCUIT

VOLT.

AGE

IOCVI

THE

WELDING

POWER

SOURCE

MUST

USED.

WHILE

MOST

WELDING

POWER

SOURCES

HAVE

OPEN-CIRCUIT

VOLTAGE

LESS

THAN

100

VOLTS.

SOME

WELDING

POWER

SOURCES

SPECIAL

DESIGN

MAY

HAVE

HIGHER

OPEN-CIRCUIT

VOLTAGE.

3-4.

115

VOLTS

RECEPTACLES

(Figure

4-1)

Two

receptacles,

both

labeled

115

VOLTS

AC,

are

provided

the

front

panel.

The

duplex

115

VOLTS

receptacle

intended

used

for

operating

accessory

equipment.

The

three-pole

twistlock,

115

VOLTS

receptacle

intended

be used

for

supplying

operating

power

control/feeder.

secure

the

corresponding

three-pole

plug

into

this

recep

tacle,

rotate

far

will

turn

clockwise

direction.

Both

115

VOLTS

Receptacles

and

CONTACTOR

CONTROL

Circuitry

are

protected

ampere

fuse

(F2)

which

located

the

front

panel.

should

become

necessary

replace

the

fuse,

ensure

that

fuse

the

same

rating

used

for

replace

ment.

fuse

larger

rating

will

permit

overloading

the

115

volts

circuitry

and

thereby

cause

damage

the

welding

power

source.

3-5.

CONTACTOR

CONTROL

CONNECTIONS

The

CONTACTOR

CONTROL

Receptacle

located

the

front

panel,

two-pole,

twistlock,

motor-base,

male

recep

tacle.

The

corresponding

plug

for

this

receptacle

supplied

with

the

welding

power

source

standard

equipment.

The

function

the

CONTACTOR

CONTROL

Receptacle

provide

connection

point

between

the

remote

contactor

control

station

and

the

contactor

the

welding

power

source.

energize

the

contactor

from

remote

station,

the

remote

Station

must

able

supply

115

volts

Hertz

electrical

power

this

receptacle.

connect

the

Remote

Contactor

Control

device

the

CONTACTOR

CONTROL

Receptacle,

insert

the

two-pole

plug

from

the

Remote

Contactor

Control

device

into

the

CONTACTOR

CONTROL

Receptacle

and

rotate

the

plug

far

will

turn

clockwise

direction.

The

plug

will

now

locked

the

receptacle

and

will

not

pull

out

under

stress.

Table

3-2.

Secondary

Cable

Sizes

230

VOLTS

460

VOLTS

OM-238

Pa~

SECTION

FUNCTION

CONTROLS

4-5.

CONTACTOR

CONTROL

RECEPTACLE

(Figure

4-1)

Whenever

Remote

Contactor

Control

used,

make

connections

the

CONTACTOR

CONTROL

Receptacle

the

welding

power

source

instructed

item

3-5.

order

for

Remote

Contactor

Control

operate

the

contactor

the

welding

power

source,

the

Remote

Contactor

Control

must

able

supply

115

volts

the

CONTACTOR

CONTROL

Receptacle

whenever

weld

output

desired.

Also,

whenever

suspension

weld

output

desired,

the

Remote

Contactor

Control

must

able

cut-off

the

115

volts

supply

the

receptacle.

NOTE

thermostat

connected

series

with

the

con

tactor

coil

order

provide

overload

protection.

Should

overload

condition

occur,

the

thermostat

would

open

and

thus

cause

the

contactor

drop

out

and

suspend

weld

output.

Once

the

thermostat

has

opened,

will

not

possible

energize

the

contactor

until

the-

welding

power

source

has

cooled

proper

tempera

ture.

Usually

five

minute

idling

period

sufficient

period-of

time

for

the

welding

power

source

cool

order

permit

the

thermostat

close.

Figure

4-1.

Front

Panel

View

Placing

the

POWER

Switch

the

position

will

energize

the

welding

power

source

fan

and

control

circuitry

and

place

the

welding

power

source

ready-to-weld

status.

Placing

the

POWER

Switch

the

OFF

position

will

shut

the

welding

power

source

down.

Even

though

the

POWER

Switch

the

OFF

posi

tion

and

the

welding

power

source

apparently

elec

trically

shut

down,

electrical

input

power

still

present

all

circuitry

the

POWER

Switch.

completely

cut-off

all

electrical

power

the

welding

power

source,

will

necessary

place

the

line

disconnect

switch

the

OFF

position

remove

the

inputcircuitfuses.

The

Range

Switch

provides

the

capability

being

able

select

from

five

coarse

open-circuit

voltage

ranges.

The

maxi

mum

open-circuit

voltage

that

can

obtained

from

each

switch

position

displayed

the

welding

power

source

nameplate.

chan

the

pos

Switch

while

welding

under

load

this

will

cause

the

contacts

the

switch

arc.

Arcing

across

the

contacts

will

cause

the

contacts~to

become

pitted

and

thereby

eventually

to

become

inoperative.

4-3.

VOLTAGECONTROL(Figure4-1)

The

Voltage

Control

provides

the

capability

being

able

select

the

desired

open-circuit

voltage

within

the

entire

range

the

welding

power

source.

Rotating

the

Voltage

Control

clockwise

direction

will

increase

the

open-circuit

voltage.

4-4.

OPEN-CIRCUIT

VOLTS

INDICATOR

(Figure

4-1)

indicator,

labeled

OPEN-CIRCUIT

VOLTS,

provided

the

front

panel

display

the

open-circuit

voltage

selec

ted.

The

reading

the

OPEN-CIRCUIT

VOLTS

Indicator

will

change

when

the

Voltage

Control

rotated.

4-6.

METERS

(Figure

4-1)

The

welding

power

source

equipped

with

ammeter

and

voltmeter.

These

meters

are

internally

connected

the

welding

power

source

output

welding

terminals.

The

volt

meter

will

indicate

the

voltage

the

secondary

terminals,

but

will

not

necessarily

indicate

the

actual

voltage

the

welding

arc.

the

welding

cables

are

excessively

long,

have

poor,

loose

connections,

the

difference

between

actual

arc

voltage

and

the

voltage

the

welding

power

source

secondary

terminals

may

considerable,

4-7.

DUTY

CYCLE

(Figure

4-2)

zuutJ

Welding

power

sources

are

rated

percent

duty

cycle

based

minute

intervals.

For

example:

percent

duty

cycle

simply

means

that

the

welding

current

off

for

minutes,

again

for

minutes,

and

on.

must

kept

mind

that

time

intervals

other

than

minutes

will

yield

different

test

rating

results.

the

output

reduced

increased,

the

duty

cycle

will

increase

decrease.

Figure

4-2

enables

the

operator

determine

the

safe

output

the

welding

power

source

various

duty

cycles.

,.,~&p

.....



,~5-0L_j_

1000



~__E



u~j

icnn

1~sn

Voltmeter

Ammeter

Fuse

Range

Switch

Open-Circuit

Volts

Indicator

Voltage

Control

Power

Switch

115

Volts

Duplex

Receptacle

115

Volts

Twit

tlock

Receptacle

tactor

Control

Receptacle

TB-039

388

Negative

Secondary

Terminal

PositIve

Secondary

Terminal

4-i.

POWER

SWITCH

(Figure

4-1)

4-2.

RANGE

SWITCH

(Figure

4i)

IMPORTANT

Exceeding

the

indicated

duty

cycle

will

cause

the

welding

power

source

overheat

thereby

causing



damage

the

welding

power

source.

-J

%DUTY

CYCLE

50 60

100

Figure

4-2.

Duty

Cycle

Chart

Page

4-8.

VOLT-AMPERE

CURVE

(Figure

4.3)

The

volt-ampere

curve

shows

the

output

voltage

available

any

given

output

current

within

the

limits

the

minimum

and

maximum

Voltage

Control

setting.

Load

voltage

pre

determined

large

degree

arc

characteristics.

With

the

use

the

volt-ampere

curve,

possible

determine

the

amperage

required

for

Specific

load

voltage.

With

reference

the

volt-ampere

curve

(Figure

4-3(,

the

curve

shows

the

maximum

and

minimum

settings

the

Voltage

Control

only.

Curves

other

settings

will

fall

between

the

maximum

and

minimum

curves

Shown.

Figure

4-3.

Volt-Ampere

Curves

SECTION

SEQUENCE

OPERATION

Never,

under

any

circumstances,

operate

the

welding

power

source

with

any

portion

the

outer

enclosure

removed.

addition

safety

hazard,

improper

cooling

may

result

damage

the

welding

trans

former

and

the

welding

power

source

components.

Warranty

void

the

welding

power

source

opera.

ted

with

any

portion

the

outer

enclosure

removed.

10.

Place

the

POWER

Switch

the

position.

Prior

welding,

imperative

that

proper

protective

clothing

(welding

coat

and

gloves)

and

eye

protection

(glasses

and/or

welding

helmet)

put

on.

Failure

comply

may

result

serious

and

even

permanent

bodily

damage.

5.1.

GAS

METAL-ARC

(MIG)

WELDING

Make

electrical

input

connections

outlined

item

3-2.

Make

secondary

connections

outlined

item

3-3.

Contactor

Control

connections

are

made

the

control/feeder

outlined

item

3-5,

115

volts

required

operate

Wire

Feeder,

see

item

3-4.

Make

shielding

gas

connections

required.

Connect

the

work

clamp

the

work.

Place

the

Range

Switch

the

desired

position.

Rotate

the

Voltage

Control

until

the

desired

voltage

indicated

the

OPEN-CIRCUIT

VOLTS

Indicator.

Make

all

necessary

adjustments

the

Wire

Feeder.

11.

Commence

welding.

The

Voltage

Control

may

adjusted

while

welding.

5-2.

SHUTTING

DOWN

Break

the

arc

and

allow

the

welding

power

source

idle

for

minutes

with

load

applied.

Turn

the

shielding

gas

supply

off.

Place

the

POWER

Switch

the

OFF

position.

1ur~iuIIrs]~ii.uJ

welding

performed

confined

area,

failure

turn

off

the

shielding

gas

supply

could

result

build

shielding

gas

fumes,

thereby

endangering

per

sonnel

re-entering

the

welding

area.

SECTION

MAINTENANCE

IMPORTANT

sure

the

branch

circuit

main

disconnect

switch

open

electrical

input

circuit

fuses

are

removed

before

attempting

any

inspection

work

the

inside

of the

welding

power

source.

Placing

the

POWER

Switch

the

welding

power

source

the

OFF

position

does

not

remove

voltage

from

the

power

terminals

inside

the

welding

power

source.

6-1.

FAN

MOTOR

All

models

are

equipped

with

exhaust

fan

and

rely

forced

draft

for

adequate

cooling.

The

fan

motor

manu

factured

with

lifetime

lubricated

sealed

ball

bearings

and

attention

should

required.

6-2.

TRANSFORMER

Occadonal

blowing

out

the

dust

and

dirt

from

around

the

transformer

recommended.

This

should

done

period.

ically

depending

upon

the

location

the

unit

and

the

200

450 600

000

1000 1200

bOO

OM-238

Page

amount

dust

and

dirt

the

atmosphere.

The

welding

power

source

outer

enclosure

should

removed

and

clean

dry

air

stream

should

used

for

this

cleaning

operation.

6-3.

RECTIFIER

recommended

that

the

rectifier

cleaned

occasionally

blowing

out

with

compressed

air.

This

cleaning

opera

tion

necessary

that

maximum

cooling

will

accom

plished

the

air

stream.

This

should

done

periodically.

depending

upon

the

location

the

unit

and

the

amount

dust

and

dirt

the

atmosphere.

will

necessary

remove

the

outer

enclosure

for

this

cleaning

operation.

6-4.

CONTROL

CIRCUIT

PROTECTION

The

entire

control

circuit

the

welding

power

source

protected

600

volts,

ampere,

cartridge

type

fuse

~F1).

This

fuse

located

behind

the

rear

primary

access

panel,

immediately

the

upper

right.

Should

this

fuse

open

the

welding

power

source

would

completely

shut

down.

IMPORTANT

should

become

necessary

replace

this

fuse

any

other

fuse

the

welding

power

source,

ensure

that

the

proper

size

fuse

used

replacement.

SECTION

TROUBLESHOOTING

The

data

collected

here,

discusses

some

the

common

problems

which

may

occur

this

welding

power

source.

The

assumption

this

data

that

proper

welding

condition

has

been

achieved

and

has

been

used

until

trouble

developed.

all

cases

equipment

malfunction,

the

manufacturers

recommendations

should

strictly

adhered

and

followed.

after

performing

the

following

procedures

the

trouble

still

not

remedied,

recommended

that

serviceman

called.

recommenc~d

that

the

circuit

diagram

used

for

reference

during

troubleshooting.

TROUBLE

PROBABLE

CAUSE

REMEDY

mite

and

low

open.circuit

voltage,

Operation

single

phase.

Open

line

fuse

one

phase.

Check

incoming

three-phase

power

for

correct

voltage.

Replace

fuse

open.

Input

voltage

jumper

links

connected

wrong

terminals,

Connect

jumper

links

for

input

voltage

being

used. See

the

input

voltage

Label

the

rear

panel

hinged

door.

Fan

runs

slow.

Input

voltage

jumper

links

primary

con

nection

board

connected

for

incorrect

voltage.

Connect

jumper

links for

input

voltage

being

used.

See

the

input

voltage

Label

the

rear

panel

hinged

door.

Fan

does

not

run.

Weld

output

available.

Fan

motor

defective.

Check

fan

motor

leads

for

possible

short.

Check

fan

motor

windings

for

continuity.

open,

replace

the

fan

motor.

Rotate

the

fan

check

for

freedom

rotation.

hard

rotate,

replace

the

motor.

Fan

does

not

run

and

weld

output.

Fuse Fl

open.

Replace

fuse.

Line

fuses

open.

Replace

defective

fuses.

Erratic

weld

current.

Incorrect

welding

cable

size.

Use

proper

size

type

cable.

See

item

3-3.

Loose

welding

cable

connections.

Tighten

all

welding

connections.

Incorrect

drive

gear

for

wire

size

the

feeder.

See

wire

feeder

instruction

manual

troubleshooting

guide.

Page