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February

1975

FORM:

OM-238

MODEL

C

P.7

50

CP-1000

STOCK

NO.

900

860

900

869

MODEL/STOCK

NO.

SERIAL/STYLE

NO.

DATE

PURCHASED

ADDITIONAL

COPY

PRICE

40

CENTS

Effective

with

Serial

No.

HE819991

..

q~LLQQ

LU

LLPJ

LtD

U

LQJJ

U

Q

LQILLLLLLLW.LLLQ

~

LLLLP

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bTfl

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~

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~

aa

C)

a

a

C

a

a

Ca

a

a

a

a

Ca

a a

Ca

WARRANTY

C

MILLER

Electric

Mfg.

Co.,

Appleton,

Wisconsin,

warrants

all

new

equipment

to

be

free

from

defects

in

Ca

a

a

material

and

factory

workmanship

for

the

periods

indicated

below,

provided

the

equipment

is

installed

and

a

a

I

a

-

a a

operated

according

to

manufacturers

instructions,

CC

aa

a

a

a

a

C

a

MILLER

Electric

Mfg.

Co.s

obligation,

under

this

warranty,

is

limited

to

replacingor

repairing

any

defective

I

part

or

correcting

any

manufacturing

defect

without

charge

during

the

warranty

period

if

MILLERS

inspec

a

tion

confirms

the

existence

of

such

defects.

MILLERS

option

of

repair

or

replacement

will

be

fob,

factory

at

a

a

C

a

a

Appleton,

Wisconsin

or

fob,

a

MILLER

authorized

service

facility,

and

therefore

no

compensation

for

trans-

c

a

portation

costs

of

any

kind

will

be

allowed.

a

C)

C

a

C

3

C

a

The

warranty

period,

beginning

on

the

date

of

sale

to

the

original

purchaser-user

of

the

equipment,

will

be

as

C

a

a

C

3

a

follows:

3

a

a

1.

Arc

welders,

power

sources,

and

components



1

year

C

C

a

C3

C

a

2.

Original

main

power

rectifiers



3

years

(unconditionally)

3.

MHFC-L1

Feeder,

MHG-35C1,

20E,

20K,

C

(3

and

all

guns

and

torches



90

days

c

C

3

a

~

4.

All

other

Millermatic

Feeders



1

year

5.

Mag-Diesel

engine

on

DEL-200



6

months

C

3

6.

All

other

engines



1

year

C

C)

C)

,

Engine

Warranties

are

covered

by

the

engine

manufacturers,

subject

to

their

procedures

and

to

be

handled

C)

through

their

authorized

local

Service

Stations

or

agencies.

No

warranty

will

be

made

in

respect

to

trade

C)

,

accessories,

such

being

subject

to

the

warranties

of

their

respective

manufacturers.

C

C)

C)

C

C)

C)

a

MILLER

Electric

Mfg.

Co.

will

not

be

liable

for

any

loss

or

consequential

damage

or

expense

accruing

c

~

directly

or

indirectly

from

the

use

of

equipment

covered

in

this

warranty.

C)

C)

C)

C

~

This

warranty

supersedes

all

previous

MILLER

warranties

and

is

exclusive

with

no

other

guarantees

or

C

C)

c

C

)

warranties

expressed

or

implied.

c

a

C)

C

a

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LQL3~

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p

SECTION

1-SAFETY

RULES

FOR

OPERATION

OF

ARC

WELDING

POWER

SOURCE

1-1.

INTRODUCTION

We

learn

by

experience.

Learning

safety

through

personal

experience

like

a

child

touching

a

hot

stove

is

harmful,

waste

ful,

and

unwise. Let

the

experience

of

others

teach

you.

Safe

practices

developed

from

experience

in

the

use

of

weld

ing

and

cutting

are

described

in

this

manual.

Research.

devel

opment,

and

field

experience

have

evolved

reliable

equipment

and

safe

installation,

operation,

and

servicing

practices.

Acci

dents

occur

when

equipment

is

improperly

used

or

main

tained.

The

mason

for

the

safe

practices

may

not

always

be

given.

Some

are

based

on

common

sense,

others

may

require

technical

volumes

to

explain.

It

is

wiser

to

follow

the

rules.

Read

and

understand

these

safe

practices

before

attempting

to

install,

operate,

or

service

the

equipment

Comply

with

these

procedures

as

applicable

to

the

particular

equipment

used

and

their

instruction

manuals,

for

personal

safety

and

for

the

safety

of

others.

Failure

to

observe

these

safe

practices

may

cause

serious

in

jury

or

death.

When

safety

becomes

a

habit,

the

equipment

can

be

used

with

confidence.

Responsibilities

of

installer,

user,

and

serviceman.

Installa

tion,

operation,

checking,

and

repair

of

this

equipment

must

be

done

only

by

a

competent

person,

experienced

with

such

equipment.

These

safe

practices

are

divided

into

two

Sections:

1

General

Precautions,

common

to

arc

welding

and

cutting;

and

2-

Arc

Welding

(and

CuttingUonly).

Reference

standards:

Published

Standards

on

safety

are

also

available

for

additional

and

more

complete

procedures

than

those

given

in

this

manual.

They

are

listed

in

the

Standards

Index

in

these

safety

rules.

ANSI

249.1

is

the

most

complete.

The

National

Electrical

Code,

Occupation

Safety

and

Health

Administration,

local

industrial

codes,

and

local

inspection

requirements

also

provide

a

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

to

avoid

entry

of

sparks

and

slag.

Wear

helmet

with

safety

goggles

or

glasses

with

side

shields

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

1-3A.

Avoid

oily

or

greasy

clothing.

A

spark

may

ignite

them.

Hot

metal

such

as

electrode

stubs

and

workpieces

should

never

be

handled

without

gloves.

Medical

first

aid

and

eye

treatment.

First

aid

facilities

and

a

qualified

first

aid

person

should

be

availthle

for

each

shift

unless

medical

facilities

are

close

by

for

immediate

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

Adequate

ventilation.

Severe

discomfort

illness

or

death

can

result

from

fumes,

vapors,

heat

or

oxygen

enrichment

or

depletion

that

welding

(or

cutting(

may

produce.

Prevent

them

with

adequate

ventilation

as

described

in

ANSI

Stan.

dard

249.1

listed

1

in

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

of

toxic

fumes.

Adequate

local

exhaust

venti

lation

must

be

used,

or

each

person

in

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

removed

from

the

work

surface,

the

area

is

well

ventilated,

or

the

operator

wears

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

concentration

danger

ously.

Do

not

bring

gas

cylinders

into

a

confined

space.

Leaving

confined

space,

shut

OFF

gas

supply

at

source.

The

space

will

then be

safe

to

re-enter,

if

downstream

valves

have

been

accidently

opened

or

left

open.

Vapors

from

chlorinated

solvents

can

be

decomposed

by

the

heat

of

the

arc

(or

flame)

to

form

PHOSGENE,

a

highly

toxic

gas,

and

other

lung

and

eye

irritating

products.

The

ultra

violet

(radiant)

energy

of

the

arc

can

also

decompose

tn

chloroethylene

and

perchloroethylene

vapors

to

form

phos

gene.

DO

NOT

WELD

or

cut

where

solvent

vapors

can

be

drawn

into

the

welding

or

cutting

atmosphere

or

where

the

radiant

energy

can

penetrate

to

atmospheres

containing

even

minute

amounts

of

trichlorethylene

or

perchlorethylene.

C.

Fire

and

Explosion

Prevention

Causes

of

fire

and

explosion

are:

combustibles

reached

by

the

arc,

flame,

flying

sparks,

hot

slag

or

heated

material;

misuse

of

compressed

gases

and

cylinders;

and

short

circuits.

Be

aware

that

flying

sparks

or

falling

slag

can

pass

through

cracks,

along

pipes,

through

windows

or

doors,

and

through

wall

or

floor

openings,

out

of

sight

of

the

goggled

operator.

Sparks

and

slag

can

fly

35

feet.

To

prevent

fires

and

explosion:

Keep

equipment

clean

and

operable,

free

of

oil,

grease.

and

(in

electrical

parts)

of

metallic

particles

that

can

cause

short

circuits.

If

combustibles

are

in

area,

do

NOT

weld

or

cut.

Move

the

work

if

practicable,

to

an

area

free

of

combustibles.

Avoid

paint

spray

rooms,

dip

tanks,

storage

areas,

ventilators.

If

the

work

can

not

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

ex

tinguishing

equipment

during

and

for

some

time

after

weld

ing

or

cutting

if:

a.

appreciable

combustibles

(including

building

construc

tion)

are

within

35

feet

b.

appreciable

combustibles

are

further

than

35

feet

but

can

be

ignited

by

sparks

c.

openings

(concealed

or

visible)

in

floors

or

walls

within

35

feet

may

expose

combustibles

to

sparks

d.

combustibles

~jacent

to

walls,

ceilings,

roofs,

or

metal

partitions

can

be

ignited

by

radiant

or

conducted

heat.

Hot

work

permit

should be

obtained

before

operation

to

ensure

supervisors

approval

that

adequate

precautions

have

been

taken.

After

work

is

done,

check

that

area

is

free

of

sparks,

glowing

embers,

and

flames.

An

empty

container

that

held

combustibles,

or

that

can

pro

duce

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

3

in

Standards

index.

1-2.

A.

OM-238

Page

1

possible

leak.

For

fuel

gas,

open

to

less

than

one

turn

to

permit quick

emergency

shutoff.

Use

pressure

charts

(available

from

your

supplier)

for

safe

and

efficient,

recommended

pressure

settings

on

regulators.

It

will

reduce

backfiring

and

chance

of

flashbacks.

Check

for

leaks

on

first

pressurization

and

regularly

there

after.

Brush

with

soap

solution

(capful

of

Ivory

Liquid

or

equivalent

per

gallon

of

water).

Bubbles

indicate

leak.

Clean

off

soapy

water

after

test;

dried

soap

is

combustible.

E.

User

Responsibilities

Remove

leaky

or

defective

equipment

from

service

immed

iately

and

repair

them

only

if

recommended

in

equipment

instruction

manual.

Send

others

for

repair

to

manufacturers

designated

repair

center

where

special

techniques

and

tools

are

used

by

trained

personnel.

Refer

to

User

Responsibilities

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

cut

ting

operation;

rope

may

burn.

1-3.

ARC

WELDING

Comply

with

precautions

in

1-2

and

this

section.

Arc

Weld

ing,

properly

done,

is

a

safe

process,

but

a

careless

operator

invites

trouble.

The

equipment

carries

high

currents

at

signifi

cant

voltages.

The

arc

is

very

bright

and

hot.

Sparks

fly.

fumes

rise,

ultraviolet

and

infrared

energy

radiates,

weld

ments

are

hot,

and

compressed

gases

may

be

used.

The

wise

operator

avoids

unnecessary

risks

and

protects

himself

and

others

from

accidents.

Precautions

are

described

here

and

in

standards

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,

arid

burn

the

skin

and

eyes.

Skin

burns

resemble

acute

sunburn,

those

from

gas-shielded

arcs

are

more

severe

and

painful.

DONT

GET

BURNED;

COMPLY

WITH

PRECAUTIONS.

1.

Protective

Clothing

Wear

long-sleeve

clothing

(particularly

for

gas-shielded

arc)

in

addition

to

gloves,

hat,

and

shoes

(1-2A).

As

necessary,

use

additional

protective

clothing

such

as

leather

jacket

or

sleeves,

flame-proof

apron,

and

fire-resistant

leggings.

Avoid

outergarments

of

untreated

cotton.

Bare

skin

protection.

Wear

dark,

substantial

clothing.

Button

collar

to

protect

chest

and

neck

and

button

pockets

to

pre

vent

entry

of

sparks.

2.

Eye

and

Head

Protection

Protect

eyes

from

exposure

to

arc.

NEVER

look

at

an

elec

tric

arc

without

protection.

Welding

helmet

or

shield

containing

a

filter

plate

shade

no.9

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

replaced

IM

MEDIATELY.

Replace

clear

cover

plate

when

broken,

pitted,

or

spattered.

Flash

goggles

with

side

shields

MUST

be

worn

under

the

helmet

to

give

some

protection

to

the

eyes

should

the

helmet

not

be

lowered

over

the

face

before

an

arc

is

struck.

Looking

at

an

arc

momentarily

with

unprotected

eyes

(particularly

a

high

intensity

gas-shielded

arc)

can

cause

a

retinal

burn

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,

surround

the

operation

with

low-reflective,

non-combustible

screens

or

panels.

Allow

for

free

air

circulation,

particularly

at

floor

level.

Viewing

the

weld.

Provide

face

shields

for

all

persons

who

will

be

looking

directly

at

the

weld.

Others

working

in

area.

See

that

all

persons

are

wearing

flash

goggles.

Before

starting

to

weld,

make

sure

that

screen

flaps

or

bay

doors

are

closed.

B.

Toxic

Fume

Prevention

Comply

with

precautions

in

1-28.

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

welding

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

later

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

welding

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

sur

face

when

welding,

without

suitable

protection.

To

protect

against

shock:

Keep body

and

clothing

dry.

Never

work

in

damp

area

with

out

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

between

body

and

an

electrically

HOT

part

-

or

grounded

metal

.

reduces

the

body

surface

electrical

resistance,

enabling

dangerous

and

possibly

lethal

currents

to

flow

through

the

body.

1.

Grounding

the

Equipment

When

installing,

connect

the

frames

of

each

unit

such

as

welding

power

source,

control,

work

table,

and

water

circula

tor

to

the

building

ground.

Conductors

must

be

adequate

to

carry

ground

currents

safely.

Equipment

made

electrically

HOT

by

stray

current

may

shock,

possibly

fatally.

Do

NOT

GROUND

to

electrical

conduit,

or

to

a

pipe

carrying

ANY

gas

or

a

flammable

liquid

such as

oil

or

fuel.

Three-phase

connection.

Check

phase

requirement

of

equip

ment

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

electri.

cally

HOT

-

a

dangerous

condition

that

can

shock,

possibly

fatally.

Before

welding,

check

ground

~or

continuity.

Be

sure

conduc

tors

are

touching

bare

metal

of

equipment

frames

at

connec

tions.

If

a

line

cord

with

a

ground

lead

is

provided

with

the

equip

ment

for

connection

to

a

switchbox,

connect

the

ground

lead

to

the

grounded

switchbox.

If

a

three-prong

plug

is

added

for

connection

to

a

grounded

mating

receptacle,

the

ground

lead

must

be

connected

to

the

ground

prong

only.

If

the

line

cord

comes

with

a

three-prong

plug,

connect

to

a

grounded

mating

receptacle.

Never

remove

the

ground

prong

from

a

plug,

or

use

a

plug

with

a

broken

off

ground

prong.

Trademark

of

Proctor

&

Gamble.

OM-238

Page

3

SECTION

2-

INTRODUCTION

Model

Rated

Welding

Current

Amperes

Open-Circuit

Voltage

Range

Maximum

Open-

Circuit

Voltage

Amperes

Input

At

Rated

LoadOutput60Hz.

Three

Phase



230

Volts

460

Volts

kva

kw

.

Dimensions

(Inches)

Weight

(Pounds)

Net

Ship

Amperes

750

@

35

Volts

100%

Duty

Cycle

15-49

49

92

46

36.6

33.2

Height

-

56-1/2

Width

-

27-1/4

Depth

-

35-3/4

895

955

1000

Amperes

30

Volts

100%

Duty

Cycle

15-47

47

120

60

47.7

43.5

Height-56.1/2

Width

-

27-1/4

Depth

-

38

1145

1215



 



Figure

2-1.

Specifications

2-1.

GENERAL

This

manual

has

been

prepared

especially

for

use

in

familiar

izing

personnel

with

the

design,

installation,

operation,

main

tenance,

and

troubleshooting

of

this

equipment.

All

informa

tion

presented

herein

should

be

given

careful

consideration

to

assure

optimum

performance

of

this

equipment.

2-2.

RECEIVING-HANDLING

Prior

to

installing

this

equipment,

clean

all

packing

material

from

around

the

unit

and

carefully

inspect

for

any

damage

that

may

have

occurred

during

shipment.

Any

claims

for

loss

or

damage

that

may

have

occurred

in

transit

must

be

filed

by

the

purchaser

with

the

carrier.

A

copy

of

the

bill

of

lading

________________________________________________________

and

freight

bill

will

be

furnished

by

the

carrier

on

request

if

occasion

to

file

claim

arises.

When

requesting

information

concerning

this

equipment,

it

is

essential

that

Model

Description

and/or

Stock

Number

and

Serial

(or

Style)

Numbers

of

the

equipment

be

supplied.

2-3.

DESCRIPTION

This

Unit

is

a

three-phase

welding

power

source

which

pro

duces

dc

welding

current.

This

welding

power

source

is

________________

designed

specifically

for

use

with

the

Gas

Metal-Arc

)MIG)

Welding

process.

2-4.

SAFETY

Under

this

heading,

explanatory

statements

will

be

found

that

need

special

emphasis

to

obtain

the

most

Before the

equipment

is

put

into

operation,

the

safety

sec-

efficient

operation

of

the

equipment.

tion

at

the

front

of

this

manual

should

be

reed

completely.

SECTION

3

-

INSTALLATION

3-1.

LOCATION

(Figure

3-1)

A

proper

installation

Site

should

be

selected

for

the

welding

power

source

if

the

unit

is

to

provide

dependable

service,

and

remain

relatively

maintenance

free.

A

proper

installation

site

permits

freedom

of

air

movement

into

and

Out

of

the

welding

power

source,

and

also

least

subjects

the

unit

to

dust,

dirt,

moisture,

and

corrosive

vapors.

A

minimum

of

18

inches

of

unrestricted

space

must

be

main

tained

between

the

welding

power

source

front

and

rear

panels

and

the

nearest

obstruction.

Also,

the

underside

of

the

welding

powe(

source

must

be

kept

completely

free

of

obstructions.

The

installation

site

should

also

permit

easy

removal

of

the

welding

power

source

outer

enclosure

for

maintenance

functions.

place

an

r;

over

the

in

take

air

pas~ges

of

the

welding

power

source

as

this

would

restrict

the

volume

of

intake

air

and

thereby

subject

the

welding

power

source

internal

components

to

an

overheating

condition

and

subsequent

failure.

War-

TB.039

388

ranty

is

void

if

any

type

of

filtering

device

is

used.

i

Figure

3-1.

Dimensional

Drawing

This

will

help

avoid

possible

injury

due

to

misuse

or

improper

welding

applications.

The

following

definitions

apply

to

CAUTION,

IMPORTANT,

and

NOTE

blocks

found

throughout

this

manual:

1Irq~i~iiii.i~1

I

Under

this

heading,

installation,

operating,

and

main

tenance

procedures

or

practices

will

be

found

that

if

not

carefully

followed

may

create

a

safety

hazard

to

personnel

I

~J~=ANT

U

Under

this

heading,

installation,

operating,

and

main

tenance

procedures

or

practices

will

be

found

that

if

not

carefully

followed

may

result

in

damage

to

equip

ment.

U

NOTE

1

U

U

U

5-1/2

OM-238

Page

5

Holes

are

provided

in

the

welding

power

source

base

for

mounting

purposes.

Figure

3.1

gives

overall

dimensions

and

the

base

mounting

hole

layout.

On

most

welding

power

sources

a

lifting

device

is

provided

for

moving

the

unit.

However,

if

a

fork

lift

vehicle

is

used

for

lifting

the

unit,

be

sure

that

the

lift

forks

are

long

enough

to

extend

completely

under

the

base.

IMPORTANT

The

use

of

lift

forks

too

short

to

extend

out

of

the

opposite

side

of

the

base

will

expose

internal

com

ponents

to

damage

should

the

tips

of

the

lift

forks

~

penetrate

the

bottom

of

the

unit.

3-2.

ELECTRICAL

INPUT

CONNECTIONS

NOTE

It

is

recommended

that

a

Line

Disconnect

Switch

be

installed

in

the

input

Circuit

to

the

welding

power

source.

This

would

provide

a

safe

and

convenient

means

to

completely

remove

all

electrical

power

from

the

welding

power

source

whenever

it

is

necessary

to

~

perform

any

internal

function

on

the

unit

CAUTION__j



Before

making

electrical

input

conons

to

the

welding

power

source,

machinery

lockout

proce

dures

should

be

employed,

If

the

connection

is

to

be

made

from

a

line

disconnect

switch,

the

switch

should

be

padlocked

in

the

open

position.

If

the

connection

is

made

from

a

fuse

box,

remove

the

fuses

from

the

box

and

padlock

the

cover

in

the

closed

position.

If

lock

ing

facilities

are

not

available,

attach

a

red

tag

to

the

line

disconnect

switch

(or

fuse

box)

to

warn

others

that

the

circuit

is

being

worked

on.

A.

Input

Electrical

Requirements

This

welding

power

source

is

designed

to

be

operated

from

a

three

phase,

60

Hertz,

ac

power

supply

which

has

a

line

voltage

rating

that

corresponds

with

one

of

the

primary

volt

ages

shown

on

the

welding

power

source

nameplate.

Consult

the

local

electric

utility

if

there

is

any

question

about

the

type

of

electrical

system

available

at

the

installation

site

or

how

proper

connections

to

the

welding

power

source

are

to

be

made.

B.

Input

Conductor

Connections

CAUTION__I!

1

Do

not

connect

the

input

conducto~he

three-

phase

power

supply

until

all

input

electrical

connec

~~ions

have

been

made

to

the

welding

power

source

It

is

recommended

that

the

input

conductors

be

of

the

heavy

rubber

covered

type

or

be

installed

in

solid

or

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

70

60

1000

Amp

(8)

(81 181

200

200

90

80

Numbers

in

I

I

are

ground

conductor

sizes

Insert

the

three

input

conductors

plus

one

ground

conductor

through

the

access

hole

on

the

rear

panel.

This

hole

will

accept

standard

conduit

fittings.

See

Figure

3-2

for

hole

loca

tion

and

size.

NOTE

J

I

It is

recommended

that

a

terminal

lug

of

adequate

1

amperage

capacity

be

attached

to

the

ends

of

the

input

and

ground

conductors.

The

hole

diameter

in

the

terminal

lug

must

be

of

proper

size

to

accommo

date

the

line

and

ground

terminal

studs

on

the

primary



terminal

board.

Connect

the

three

input

conductors

to

the

terminals

on

the

primary

terminal

board

labeled

L

or

LINE

and

connect

the

ground

conductor

to

the

terminal

labeled

GRD

(See

Figure

3-2).

The

remaining

end

of

the

ground

conductor

should

be

connected

to

a

proper

ground.

Use

whatever

grounding

method

that

is

acceptable

to

the

local

electrical

inspection

authority.

CAUTION



The

terminal

labeled

GAD

is

connecte~e

welding

power

source

chassis

and

is

for

grounding

purposes

only.

Do

not

connect

a

conductor

from

the

terminal

labeled

GAD

to

any

one

of

the

L

or

LINE

terminals~as

this

will

result

in

an

electrically

hot

welding

power



source

chassis.

Figure

3-2.

Input

Conductor

Connections

Input

Voltage

Jumper

Links

C.

Matching

The

Welding

Power

Source

To

The

Avail

able

Input

Voltage

The

input

voltage

umper

links

provided

on

the

primary

ter

minal

board

permit

the

welding

power

source

to

be

operated

from

various

line

voltages.

The

various

voltages

from

which

this

welding

power

source

may

be

operated

are

stated

on

the

welding

power

source

nameplate,

and

on

the

input

voltage

label.

See

Figure

3-2

for

location.

The

input

voltage

jumper

links

on

this

welding

power

source

are

positioned

for

the

highest

of

the

voltages

stated

on

the

nameplate.

If

the

weld

ing

power

source

is

to

be

operated

from

a

line

voltage

which

is

lower

than

the

highest

voltage

for

which

the

unit

was

de

signed,

the

jumper

links

will

have

to

be

moved

to

the

proper

position

before

operation

of

the

welding

power

source

com

mences.

Figure

3-3

shows

the

various

positions

for

which

the

jumper

links

may

be

set

on

the

standard

welding

power

source.

If

the

input

voltages

on

the

welding

power

source

nameplate

differ

from

those

shown

in

Figure

3-3,

the

input

voltage

jumper

links

must

be

positioned

as

shown

on

the

in

put

voltage

label.

Ground

Line

Terminals

Terminal

TA-900

872-2A

Page

6

NOTE

If

only

one

jumper

link

is

required

on

each

of

the

grouped

terminals,

it

is

recommended

that

the

unused

jumper

links

be

placed

across

the

terminals

which

are

to

be

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

of

the

terminals.

The

access

panel

which

covers

the

secondary

terminals

is

secured

by

two

fasteners.

To

open

the

access

panel,

rotate

the

fasteners

counterclockwise

one

full

turn.

Likewise,

to

close

the

panel,

rotate

the

fasteners

clockwise

one

full

turn.

A.

Welding

Cables

It

is

recommended

that

the

welding

cables

be

kept

as

short

as

possible,

placed

close

together,

and

be

of

adequate

current

carrying

capacity.

The

resistance

of

the

welding

cables

and

connections

cause

a

voltage

drop

which

is

added

to

the

volt.

age

of

the

arc.

Excessive

cable

resistance

may

result

in

over

loading

as

well

as

reducing

the

maximum

current

output

of

which

the

welding

power

source

is

capable.

The

proper

opera

tion

of

any

arc

welding

power

source

is

to

a

great

extent

dependent

on

the

use

of

welthng

cables

and

connections

that

are

in

good

condition

and

of

adequate

size.

An

insulated

electrode

holder

must

be

used

to

ensure

the

operators

safety.

Use

Table

3-2

as

a

guide

for

selecting

the

correct

welding

cable

size

for

the

anticipated

maximum

weld

current

that

will

be

used.

Table

3-2

takes

into

account

the

total

cable

length

for

the

weld

circuit.

This

means

the

length

of

the

Electrode

cable

that

connects

the

wire

feeder

to

the

welding

power

source

and

the

Work

or

ground

cable

between

the

welding

power

source

and

the

work

piece.

For

example:

If

the

Elec

trode

cable

is

75

feet

long

and

the

work

Or

ground

cable

is

25

feet

long,

select

the

size

cable

from

Table

3-2

that

is

recom

mended

for

100

feet.

In

a

situation

where

a

maximum

weld

current

of

150

amperes

is

anticipated,

No.

2

weld

cable

is

recommended

for

both

the

Electrode

and

Work

cables.

WELDING

TOTA

LLEN

GTH

OF

CABLE

(COPPER

I

IN

WELD

CIRCUIT

250 300 350

400

AMPERES

50

100

150

200

100

4

4

22

2

1

1/0 1/0

150

22

2

1

1/0

2/0

3/0

3/0

200

1

1

1

1/0

2/0

3/0

4/0

4/0

250

1/0 1/0 1/0

2/0 3/0

4/0

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

4/0

2-2/0

2-3/0

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

2-2/0

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

4-4/0

800

2.3/0

2-3/0

2-3/0

2.4/0

3-3/0

3-4/0

4.4/0 4-4/0

A002

623

NOTE:

A.

50

FEET

OR

LESS.

8.

CABLE

SIZE

IS

BASED

ON

DIRECT

CURRENT

(DCI,

100%

DUTY

CYCLE

AND

EITHER

A

4

VOLTS

OR

LESS

DROP

OR A

CURRENT

DENSITY

OF

NOT

OVER

300

CIRCULAR

MILS

PER

AMP.

C.

WELD

CABLE

INSULATION

WITH

A

VOLTAGE

RATING

TO

WITHSTAND

THE

OPEN-CIRCUIT

VOLT.

AGE

IOCVI

OF

THE

WELDING

POWER

SOURCE

MUST

BE

USED.

WHILE

MOST

WELDING

POWER

SOURCES

HAVE

AN

OPEN-CIRCUIT

VOLTAGE

OF

LESS

THAN

100

VOLTS.

SOME

WELDING

POWER

SOURCES

OF

SPECIAL

DESIGN

MAY

HAVE

HIGHER

OPEN-CIRCUIT

VOLTAGE.

3-4.

115

VOLTS

AC

RECEPTACLES

(Figure

4-1)

Two

receptacles,

both

labeled

115

VOLTS

AC,

are

provided

on

the

front

panel.

The

duplex

115

VOLTS

AC

receptacle

is

intended

to

be

used

for

operating

accessory

equipment.

The

three-pole

twistlock,

115

VOLTS

AC

receptacle

is

intended

to

be used

for

supplying

operating

power

to

a

control/feeder.

To

secure

the

corresponding

three-pole

plug

into

this

recep

tacle,

rotate

it

as

far

as

it

will

turn

in

a

clockwise

direction.

I

Both

115

VOLTS

AC

Receptacles

and

CONTACTOR

CONTROL

Circuitry

are

protected

by

a

15

ampere

fuse

(F2)

which

is

located

on

the

front

panel.

If

it

should

become

necessary

to

replace

the

fuse,

ensure

that

a

fuse

of

the

same

rating

is

used

for

a

replace

ment.

A

fuse

of

a

larger

rating

will

permit

overloading

of

the

115

volts

circuitry

and

thereby

cause

damage

to

the

welding

power

source.

3-5.

CONTACTOR

CONTROL

CONNECTIONS

The

CONTACTOR

CONTROL

Receptacle

located

on

the

front

panel,

is

a

two-pole,

twistlock,

motor-base,

male

recep

tacle.

The

corresponding

plug

for

this

receptacle

is

supplied

with

the

welding

power

source

as

standard

equipment.

The

function

of

the

CONTACTOR

CONTROL

Receptacle

is

to

provide

a

connection

point

between

the

remote

contactor

control

station

and

the

contactor

in

the

welding

power

source.

To

energize

the

contactor

from

a

remote

station,

the

remote

Station

must

be

able

to

supply

115

volts

ac

60

Hertz

electrical

power

to

this

receptacle.

To

connect

the

Remote

Contactor

Control

device

to

the

CONTACTOR

CONTROL

Receptacle,

insert

the

two-pole

plug

from

the

Remote

Contactor

Control

device

into

the

CONTACTOR

CONTROL

Receptacle

and

rotate

the

plug

as

far

as

it

will

turn

in

a

clockwise

direction.

The

plug

will

now

be

locked

in

the

receptacle

and

will

not

pull

out

under

stress.

Table

3-2.

Secondary

Cable

Sizes

230

VOLTS

460

VOLTS

I

I

OM-238

Pa~

7

SECTION

4-

FUNCTION

OF

CONTROLS

4-5.

CONTACTOR

CONTROL

RECEPTACLE

(Figure

4-1)

Whenever

a

Remote

Contactor

Control

is

to

be

used,

make

connections

to

the

CONTACTOR

CONTROL

Receptacle

on

the

welding

power

source

as

instructed

in

item

3-5.

In

order

for

a

Remote

Contactor

Control

to

operate

the

contactor

in

the

welding

power

source,

the

Remote

Contactor

Control

must

be

able

to

supply

115

volts

ac

to

the

CONTACTOR

CONTROL

Receptacle

whenever

weld

output

is

desired.

Also,

whenever

suspension

of

weld

output

is

desired,

the

Remote

Contactor

Control

must

be

able

to

cut-off

the

115

volts

ac

supply

to

the

receptacle.

NOTE

A

thermostat

is

connected

in

series

with

the

con

tactor

coil

in

order

to

provide

overload

protection.

Should

an

overload

condition

occur,

the

thermostat

would

open

and

thus

cause

the

contactor

to

drop

out

and

suspend

weld

output.

Once

the

thermostat

has

opened,

it

will

not

be

possible

to

energize

the

contactor

until

the-

welding

power

source

has

cooled

to

a

proper

tempera

ture.

Usually

a

five

minute

idling

period

is

a

sufficient

period-of

time

for

the

welding

power

source

to

cool

in

order

to

permit

the

thermostat

to

close.

Figure

4-1.

Front

Panel

View

Placing

the

POWER

Switch

in

the

ON

position

will

energize

the

welding

power

source

fan

and

control

circuitry

and

place

the

welding

power

source

in

a

ready-to-weld

status.

Placing

the

POWER

Switch

in

the

OFF

position

will

shut

the

welding

power

source

down.

Even

though

the

POWER

Switch

is

in

the

OFF

posi

tion

and

the

welding

power

source

is

apparently

elec

trically

shut

down,

electrical

input

power

is

still

present

on

all

circuitry

up

to

the

POWER

Switch.

To

completely

cut-off

all

electrical

power

to

the

welding

power

source,

it

will

be

necessary

to

place

the

line

disconnect

switch

in

the

OFF

position

or

remove

the

inputcircuitfuses.

The

Range

Switch

provides

the

capability

of

being

able

to

select

from

five

coarse

open-circuit

voltage

ranges.

The

maxi

mum

open-circuit

voltage

that

can

be

obtained

from

each

switch

position

is

displayed

on

the

welding

power

source

nameplate.

chan

ge

the

pos

in

A

an

ge

Switch

while

welding

or

under

load

as

this

will

cause

the

contacts

of

the

switch

to

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

of

being

able

to

select

the

desired

open-circuit

voltage

within

the

entire

range

of

the

welding

power

source.

Rotating

the

Voltage

Control

in

a

clockwise

direction

will

increase

the

open-circuit

voltage.

4-4.

OPEN-CIRCUIT

VOLTS

INDICATOR

(Figure

4-1)

An

indicator,

labeled

OPEN-CIRCUIT

VOLTS,

is

provided

on

the

front

panel

to

display

the

open-circuit

voltage

selec

ted.

The

reading

on

the

OPEN-CIRCUIT

VOLTS

Indicator

will

change

when

the

Voltage

Control

is

rotated.

4-6.

METERS

(Figure

4-1)

The

welding

power

source

is

equipped

with

a

dc

ammeter

and

a

dc

voltmeter.

These

meters

are

internally

connected

to

the

welding

power

source

output

welding

terminals.

The

volt

meter

will

indicate

the

dc

voltage

at

the

secondary

terminals,

but

will

not

necessarily

indicate

the

actual

voltage

at

the

welding

arc.

If

the

welding

cables

are

excessively

long,

or

have

poor,

loose

connections,

the

difference

between

actual

arc

voltage

and

the

voltage

at

the

welding

power

source

secondary

terminals

may

be

considerable,

4-7.

DUTY

CYCLE

(Figure

4-2)

zuutJ

Welding

power

sources

are

rated

on

a

percent

duty

cycle

based

on

10

minute

intervals.

For

example:

A

60

percent

duty

cycle

simply

means

that

the

welding

current

is

off

for

4

minutes,

on

again

for

6

minutes,

and

so

on.

It

must

be

kept

in

mind

that

time

intervals

of

other

than

10

minutes

will

yield

different

test

rating

results.

As

the

output

is

reduced

or

increased,

the

duty

cycle

will

increase

or

decrease.

Figure

4-2

enables

the

operator

to

determine

the

safe

output

of

the

welding

power

source

at

various

duty

cycles.

,.,~&p

.....



,~5-0L_j_

E

1000



~__E



E



E



E

I

I

u~j

icnn

1~sn

-~

r

~-

DC

Voltmeter

DC

Ammeter

\

Fuse

F2

Range

Switch

Open-Circuit

Volts

Indicator

Voltage

Control

Power

Switch

115

Volts

AC

Duplex

Receptacle

115

Volts

AC

Twit

tlock

Receptacle

tactor

Control

Receptacle

TB-039

388

Negative

Secondary

Terminal

PositIve

Secondary

Terminal

I

I

4-i.

POWER

SWITCH

(Figure

4-1)

U

I

4-2.

RANGE

SWITCH

(Figure

4i)

IMPORTANT

Exceeding

the

indicated

duty

cycle

will

cause

the

welding

power

source

to

overheat

thereby

causing



damage

to

the

welding

power

source.

LU

LU

0~

5

(3

0

-J

LU

0

15

20

25

30

%DUTY

CYCLE

40

50 60

70

80

100

Figure

4-2.

Duty

Cycle

Chart

Page

8

4-8.

VOLT-AMPERE

CURVE

(Figure

4.3)

The

volt-ampere

curve

shows

the

output

voltage

available

at

any

given

output

current

within

the

limits

of

the

minimum

and

maximum

Voltage

Control

setting.

Load

voltage

is

pre

determined

to

a

large

degree

by

arc

characteristics.

With

the

use

of

the

volt-ampere

curve,

it

IS

possible

to

determine

the

amperage

required

for

a

Specific

load

voltage.

With

reference

to

the

volt-ampere

curve

(Figure

4-3(,

the

curve

shows

the

maximum

and

minimum

settings

of

the

Voltage

Control

only.

Curves

of

other

settings

will

fall

between

the

maximum

and

minimum

curves

Shown.

Figure

4-3.

Volt-Ampere

Curves

SECTION

5

-

SEQUENCE

OF

OPERATION

!

Never,

under

any

circumstances,

operate

the

welding

power

source

with

any

portion

of

the

outer

enclosure

removed.

In

addition

to

a

safety

hazard,

improper

cooling

may

result

in

damage

to

the

welding

trans

former

and

the

welding

power

source

components.

Warranty

is

void

if

the

welding

power

source

is

opera.

ted

with

any

portion

of

the

outer

enclosure

removed.

10.

Place

the

POWER

Switch

in

the

ON

position.

!

Prior

to

welding,

it

is

imperative

that

proper

protective

clothing

(welding

coat

and

gloves)

and

eye

protection

(glasses

and/or

welding

helmet)

be

put

on.

Failure

to

comply

may

result

in

serious

and

even

permanent

bodily

damage.

5.1.

GAS

METAL-ARC

(MIG)

WELDING

1.

Make

electrical

input

connections

as

outlined

in

item

3-2.

2.

Make

secondary

connections

as

outlined

in

item

3-3.

3.

Contactor

Control

connections

are

to

be

made

to

the

control/feeder

as

outlined

in

item

3-5,

4.

If

115

volts

ac

is

required

to

operate

a

Wire

Feeder,

see

item

3-4.

5.

Make

shielding

gas

connections

as

required.

6.

Connect

the

work

clamp

to

the

work.

7.

Place

the

Range

Switch

in

the

desired

position.

8.

Rotate

the

Voltage

Control

until

the

desired

voltage

is

indicated

on

the

OPEN-CIRCUIT

VOLTS

Indicator.

9.

Make

all

necessary

adjustments

on

the

Wire

Feeder.

11.

Commence

welding.

The

Voltage

Control

may

be

adjusted

while

welding.

5-2.

SHUTTING

DOWN

1.

Break

the

arc

and

allow

the

welding

power

source

to

idle

for

3

minutes

with

no

load

applied.

2.

Turn

the

shielding

gas

supply

off.

3.

Place

the

POWER

Switch

to

the

OFF

position.

1ur~iuIIrs]~ii.uJ

If

welding

is

performed

in

a

confined

area,

failure

to

turn

off

the

shielding

gas

supply

could

result

in

a

build

up

of

shielding

gas

fumes,

thereby

endangering

per

sonnel

re-entering

the

welding

area.

SECTION

6-

MAINTENANCE

IMPORTANT

Be

sure

the

branch

circuit

or

main

disconnect

switch

is

open

or

electrical

input

circuit

fuses

are

removed

before

attempting

any

inspection

or

work

on

the

inside

of the

welding

power

source.

Placing

the

POWER

Switch

on

the

welding

power

source

in

the

OFF

position

does

not

remove

voltage

from

the

power

terminals

inside

of

the

welding

power

source.

6-1.

FAN

MOTOR

All

models

are

equipped

with

an

exhaust

fan

and

rely

on

forced

draft

for

adequate

cooling.

The

fan

motor

is

manu

factured

with

lifetime

lubricated

sealed

ball

bearings

and

no

attention

should

be

required.

6-2.

TRANSFORMER

Occadonal

blowing

out

of

the

dust

and

dirt

from

around

the

transformer

is

recommended.

This

should

be

done

period.

ically

depending

upon

the

location

of

the

unit

and

the

0

200

450 600

000

1000 1200

bOO

I

I

I

I

I

I

I

I

I

OM-238

Page

9

amount

of

dust

and

dirt

in

the

atmosphere.

The

welding

power

source

outer

enclosure

should

be

removed

and

a

clean

dry

air

stream

should

be

used

for

this

cleaning

operation.

6-3.

RECTIFIER

It

is

recommended

that

the

rectifier

be

cleaned

occasionally

by

blowing

it

out

with

compressed

air.

This

cleaning

opera

tion

is

necessary

so

that

maximum

cooling

will

be

accom

plished

by

the

air

stream.

This

should

be

done

periodically.

depending

upon

the

location

of

the

unit

and

the

amount

of

dust

and

dirt

in

the

atmosphere.

It

will

be

necessary

to

remove

the

outer

enclosure

for

this

cleaning

operation.

6-4.

CONTROL

CIRCUIT

PROTECTION

The

entire

control

circuit

of

the

welding

power

source

is

protected

by

a

600

volts,

10

ampere,

cartridge

type

fuse

~F1).

This

fuse

is

located

behind

the

rear

primary

access

panel,

immediately

to

the

upper

right.

Should

this

fuse

open

the

welding

power

source

would

completely

shut

down.

I

I

IMPORTANT

U

If

it

should

become

necessary

to

replace

this

fuse

or

any

other

fuse

in

the

welding

power

source,

ensure

that

the

proper

size

fuse

is

used

as

a

replacement.

.

SECTION

7

-

TROUBLESHOOTING

The

data

collected

here,

discusses

some

of

the

common

problems

which

may

occur

in

this

welding

power

source.

The

assumption

of

this

data

is

that

a

proper

welding

condition

has

been

achieved

and

has

been

used

until

trouble

developed.

In

all

cases

of

equipment

malfunction,

the

manufacturers

recommendations

should

be

strictly

adhered

to

and

followed.

If

after

performing

the

following

procedures

the

trouble

is

still

not

remedied,

it

is

recommended

that

a

serviceman

be

called.

It

is

recommenc~d

that

the

circuit

diagram

be

used

for

reference

during

troubleshooting.

TROUBLE

PROBABLE

CAUSE

REMEDY

Li

mite

d

o

u

t

pu

t

and

low

open.circuit

voltage,

Operation

on

single

phase.

Open

line

fuse

on

one

phase.

Check

incoming

three-phase

power

for

correct

voltage.

Replace

fuse

if

open.

Input

voltage

jumper

links

connected

to

wrong

terminals,

Connect

jumper

links

for

input

voltage

being

used. See

the

input

voltage

Label

on

the

rear

panel

hinged

door.

Fan

runs

slow.

~

Input

voltage

jumper

links

on

primary

con

nection

board

connected

for

incorrect

voltage.

Connect

jumper

links for

input

voltage

being

used.

See

the

input

voltage

Label

on

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.

If

open,

replace

the

fan

motor.

Rotate

the

fan

to

check

for

freedom

of

rotation.

If

hard

to

rotate,

replace

the

motor.

Fan

does

not

run

and

no

weld

output.

Fuse Fl

open.

Replace

fuse.

Line

fuses

open.

Replace

defective

fuses.

Erratic

weld

current.

Incorrect

welding

cable

size.

Use

proper

size

&

type

of

cable.

See

item

3-3.

Loose

welding

cable

connections.

Tighten

all

welding

connections.

Incorrect

drive

gear

for

wire

size

on

the

feeder.

See

wire

feeder

instruction

manual

troubleshooting

guide.

Page

10