Miller Two Fifty Twin Manuel utilisateur

August

1973

FORM:

OM-313

Effective

with

serial

No.

72-61

2483

MODEL

Two

Fifty

Twin

Two

Fifty

Twin-P

STOCK

NO.

901

973

901

976

ADDITIONAL

COPY

PRICE

CENTS

MODEL/STOCK

NO.

SERIAL/STYLE

NO.

DATE

PURCHASED

OWNERS

MANUAL

MILLER

ELECTRIC

MFG.

CO.

APPLETON,

WISCONSIN,

USA

54911

NWSA

CODE

NO.

4579

U.S

...

TABLE

CONTENTS

Paragraph

No.

Page

No.

SECTION



SAFETY

RULES

FOR

OPERATION

ARC

WELDING MACHINE

1-1.

General

-2.

-3.

-5.

1-7.

1-10.

1-11.

1-12.

1-13.

Welding

Cables

Electrode

Holder

Code

Conformance

Parallel

Connections

Power

Disconnect

Switch

Polarity

Switch

Range

Switch

Exhaust

Gases

Power

Circuit

Ground

Containers

Which

Held

Combustibles

Hollow

Castings

(Welding

of)

Explosion

Hazards

1-14.

Ventilation

1-15.

Solvents

1-16.

Fire

Hazards

1-17.

Electrical

Shock-Voltage

1-18.

Electrical

Shock-Dampness

1-19.

Starting

Under

Load

1-20.

Face

Protection

1-21.

Eye

Protection

1-22.

Clothing

1-23.

Hot

Metal

Burns

1-24.

Grinding

and

Chipping

1-25.

Compressed

Gas

Cylinder

SECTION

2

INTRODUCTION

2-1.

-4.

SECTION

3-1.

General

Receiving-Handling

Description

Safety



INSTALLATION

Line

Disconnect

Switch

Location

Primary

Connections

Secondary

Welding

Connections

SECTION

4

OPERATION

Range

Selector

Switch

4-2.

Fine

Current

Control

Current

Indicator

On-Off

Power

Switch

Duty

Cycle

Volt-Ampere

Curve

SECTION



SEQUENCE

OPERATION

Shielded

Metal-Arc

Welding

(SMAW)

SECTION

6

MAINTENANCE

Power

Factor

Correction

Capacitors

Transformer

Fan

Motor

Input

Power

Welding

Cables

SECTION

7

TROUBLESHOOTING

PARTS

LIST

SECTION

SAFETY

RULES

FOR

OPERATION

ARC

WELDING

MACHINE

GENERAL

These

rules

apply

and

welding

generators.

trans

former

and

ac/dc

welding

machines,

and

transformer

recti

fier

welding

machines.

arc-welding

operations,

where

electrically

energized

parts

are

exposed,

observe

the

following

safety

rules

insure

max

imum

personal

safety

and

protect

nearby

persons.

Failure

observe

these

safety

precautions

may

expose

not

only

you,

but

fellow

workers

well,

serious

injuries.

Once

these

rules

are

learned

and

kept

mind,

proceed

with

maxi

mum

assurance.

-2.

WELDING

CABLES

Figure

1-1.

Dont

overload

cables

NEVER

use

welding

cables

currents

excess

their

rated

capacity.

will

cause

overheating

and

rapid

deterioration

the

insulation.

also

uneconomical.

DONT

use

worn

poorly

connected

cables.

)Figure

1-2)

Inspect

the

cables

frequently.

Immediately

repair

all

breaks

the

insulation

with rubber

and

friction

tapes.

Tighten

all

cable

connections

and

adequately

insulate

any

joints

where

connector

may

have

exposed

conductive

part.

addition

the

potential

hazard

life,

hazard

occurs

when

exposed

sections

cable

come

contact

with

grounded

metallic

objects,

causing

arc.

Unprotected

eyes

may

injured

and

fire

may

result

combustible

materials

such

oil

grease

are

the

vicinity.

The

efficiency

and

quality

welding

will

improved

elimination

these

dangerous

grounds,

and

keeping

connections

tight.

ELECTRODE

HOLDER

DONT

use

electrode

holders

with

defective

jaws.

(Figure

1-3)

Keep

the

jaws

of the

electrode

holder

tight

and

the

gripping

surfaces

good

condition

provide

contact

with

the

electrodes.

Defective

jaws

will

permit

the

electrode

wob

ble,

making

control

the

welding

operations

difficult.

Figure

1-3.

Dont

use

Electrode

Holder

with

defective

jaws

DONT

use

electrode

holder

with

loose

cable

connections.

Keep

the

connections

the

electrode

lead

the

holder

tight

all

times.

Use

only

fully

insulated

electrode

holders

(and

without

pro

truding

screwheads.)

Never

touch

two

electrode

holders

from

two

separate

welding

machines

the

same

time.

-4.

CODE

CONFORMANCE

The

machine

and

its

equipment

must

installed

and

main

tained

accordance

with

the

National

Electrical

Code

and

local

requirements.

-5.

PARALLEL

CONNECTIONS

See

diagrams

the

instruction

manual

applying

the

weld

ing

machine

used.

POWER

DISCONNECT

SWITCH

the

welding

machine

does

not

include

power

disconnect

switch,

install

one

near

the

machine.

.7.

POLARITY

SWITCH

DONT

operate

the

polarity

switch

under

load.

The

polarity

switch

(when

supplied)

provided

for

changing

the

electrode

lead

from

positive

(reverse

polarity)

negative

(straight

polarity).

Never

move

while

under

the

load

welding

current.

Operate

this

switch

only

while

the

machine

idling

and

the

welding

Circuit

open.

The

potential

dan

gers

opening

the

Circuit

while

carrying

high

current

are:

arc

will

form

between

the

contact

surfaces

the

switch

and

severely

burn

them.

The

person

throwing

the

switch

may

receive

severe

burn

from

this

arcing.

RANGE

SWITCH

DONT

operate

the

range

switch

under

load.

The

range

switch

lwhen

supplied)

provided

for

obteining

required

current

settings.

must

never

operated

while

the

machine

under

the

load

welding

current.

Operate

the

range

switch

only

while

the

machine

idling

and

the

welding

circuit

open.

The

potential

danger

switching

the

Circuit

while

carrying

high

current

the

formation

arc

tween

the

contact

surface

which

will

severely

burn

them.

Repeated

occurrences

this

arcing

will

eventually

prevent

operation

the

contacts.

EXHAUST

GASES

DONT

use

gas

engine

units

Confined

spaces

without

vent

ing

the

exhaust

gases.

)Figure

1-4)

gasoline

other

fuel

driven

welding

machines

are

operated

indoors,

provide

means

pipe

the

exhaust

gases

the

Out

side

air

avoid

carbon

monoxide

poisoning.

DONT

overload

cables,

(Figure

1-1)

Figure

1-2.

Dont

use

worn

poorly

connected

cables

OM-313

Page

Figure

1-4.

Vent

exhaust

gases

1-10.

POWER

CIRCUIT

GROUND

DONT

use

welding

machine

without

grounding

frame

case.

(Figure

1-5)

Figure

1-5.

Ground

frame

case

Ground

the

ground

cable

every

power

Circuit

prevent

accidental

shock

stray

current.

The

potential

danger

that

development

stray

current

may

give

fatal

shock

should

person,

for

example,

place

one

hand

the

welding

machine

and

the

other

the

switch

box,

other

grounded

equipment.

not

ground

pipelines

carrying

gases

flammable

liquids

and

conduits

carrying

electrical

conduc

tors.

sure

conductors

can

safely

carry

the

ground

current.

When

connecting

the

welding

machine,

properly

ground

the

machine

frame

case.

1-11.

CONTAINERS

WHiCH

HELD

COMBUSTIBLES

DONT

weld

containers

which

have

held

combustible

flammable

materials

which,

when

heated,

give

off

ftammabte

toxic

vapors

without

proper

cleaning,

purg

ing,

inerting.

Welding

containers

which

have

held

flammable

combust

ible

materials

may

extremely

dangerous.

prevent

fire

explosion

the

container,

the

recommendations

the

American

Welding

Society

Pamphlet

A6.O

Welding

Cutting

Containers

Which

Have

Held

Combustibles.

DONT

depend

your

eyes

nose

decide

safe

weld

closed container.

Find

Out

what

was

the

container

use

explosimeter.

very

small

amount

residual

flammable

gas

liquid

can

cause

serious

explosion.

NEVER

use

oxygen

ventilate

container.

When

you

know

the

container

held

gas

liquid

which

will

readily

dissolve

water:

Flush

out

with

water

several

times

and

then

fill

with

water

far

work

permits,

positioning

container

permit

introduction

much

water

possible.

Before

welding

sure

there

vent

opening

pro

vide

for

release

air

pressure.

When

you

know

the

container

held

gas

liquid

which

will

not

readily

dissolve

water:

Clean

out

thouroughly

with

steam

cleansing

agent

and

purge

all

air

inert

with

gas

such

carbon

dioxide

nitrogen

before

repairing.

Carbon

dioxide

heavier

than

air

and

will

tend

remain

the

container

the

opening

the

top.

Use

steam

clean

out

light

material,

Use

strong

caustic

soda

solution

clean

out

heavy

oils

grease.

sure

purge

all

air

inert

with

gas,

such

nitro

gen

carbon

dioxide,

matter

how

well

you

have

cleaned.

There

may

still

traces

oil,

grease,

other

readily

oxidizable

material

under

the

seams.

careful

when

cleaning

with

steam

caustic

soda

wear

goggles

and

gloves.

DONT

clean

where

there

poor

ventilation.

Ventilation

necessary

carry

away

harmful

explosive

vapors.

DONT

clean

where

there

are

open

flames.

When

scraping

hammering

remove

heavy

sludge

scale,

use

spark

resistive

tool

and

keep

wet

avoid

sparks.

Keep

your

head

and

arms

far

away

from

your

work

possible,

1-12.

HOLLOW

CASTINGS

DONT

weld

hollow

(cored)

castings

that

have

not

been

properly

vented.

The

casting

may

explode.

(Figure

1-6)

Figure

1-6.

Dont

weld

hollow

(cored)

castings

1-13.

EXPLOSION

HAZARDS

NEVER

weld

near

explosive

atmospheres.

Such

atmos

pheres

can

created

flammable

gas

leaks

vapors

from

flammable

liquids

(gasoline,

alcohol,

etc.)

com

bustible

dusts.

1.14.

VENTILATION

DONT

weld

confined

spaces

without

adequate

ventilation.

When

welding

confined

spaces,

provide

ventilation

accordance

with

United

States

American

Standard

Z49.1,

1967.

Always

provide

adequate

ventilation

blowers,

air

lines,

other

acceptable

means:

Never

use

compressed

ygen.

The

depletion

the

oxygen

supply,

the

heat

weld

ing,

and

the

fumes

given

off

may

cause

severe

discomfort

serious

illness.

When

toxic

fumes from

lead

cadmium

bearing

materials

any

other

substances

are

present

harmful

concentrations,

always

use

air

supplied

respirator.

______---

Page

1-15.

SOLVENTS

not

weld

where

chlorinated

hydrocarbon

vapors

from

greasing,

cleaning,

spraying

may

reach

drawn

into

air

surrounding

the

welding

operation.

The

heat

the

arc

can

decompose

solvent

vapors

form

phosgane,

highly

toxic

gas

and

other

irritating

decomposition

products.

not

weld

where

ultraviolet

light

from

the

electric

arc

can

penetrate

air

containing

even

minute

amounts

vapors

from

~olvents

such

trichloroethylene

perchloroethylene.

traviolet

light

can

decompose

the

vapors

form

phosgene,

highly

toxic

gas

and

other

irritating

products.

1-16.

FIRE

HAZARDS

electrode

the

table

top

contact

with

grounded

metallic

surface.

(Figure

1-7)

When

not

use,

never

place

electrode

holder

contact

with

the

tabletop

other

metallic

surface

contact

with

welding

ground.

Provide

insulated

hook

holder

for

the

electrode

holder.

potential

danger

that

holder

contact

with

the

ground

circuit

provides

dead

short

circuit

the

welding

machine.

the

machine

should

started

up,

this

short

circuit

would

cause

excessive

load

the

chine

and

may

damage

the

insulation.

1-20.

FACE

PROTECTION

DONT

use

cracked

defective

helmets

shields.

DONT

weld

near

flammable

combustible

materials.

Fires

can

caused

the

arc,

contact

with

the

heated

metal,

slag,

sparks.

Keep

combustibles

least

feet

from

the

arc

suitably

protected.

welding

must

done

particular

area,

move

the

combustibles

away.

they

cannot

moved,

cover

them

completely

with

fire

resistive

screens.

Cover

cracks

openings

floors

walls;

sweep

floor

free

combustibles

and

wet

down,

wood,

being

sure

welder

wears

insulation

shoe

coverings.

Avoid

welding

par

tition

walls

contact

with

combustibles.

Heats

metal

the

other

side

partition

wall

being

weded

upon

can

ignite

combustibles

contact

with

the

partition.

Where

other

than

minor

fire

might

develop,

have

fire

watcher

stand-by

with

suitable

fire

extinguishing

equipment

for

least

one-half

hour

after

the

welding

completed.

1-17.

ELECTRICAL

SHOCK-VOLTAGE

OPEN

power

circuits

before

checking

machines.

Before

working

the

wiring,

switches,

controls,

etc.,

open

the

power

line

disconnect

switch.

most

welding

shops

the

power

supply

used

for

arc

welding

machines

230

460

volts,

Open

circuit

voltages

are

usually

less

than

100

volts

and

welding

arc

voltage

drops

are

still

lower.

However,

all

these

voltages

are

capable

developing

harmful

fatal

current

the

body.

DONT

touch

electrically

hot

parts.

NEVER

touch

any

exposed

non-insulated

part

the

cables,

cable

connectors,

clamps,

electrode

holders,

elec

trodes,

the

power

supply

equipment

prevent

harmful

fatal

electric

shock

burns.

1-18.

ELECTRICAL

SHOCK-DAMPNESS

NEVER

work

damp

area

without

suitable

insulation

gainst

shock.

Keep

hands,

feet,

and

clothing

dry

all

times.

To.prevent

harmful

body

shocks,

keep

hands,

feet

and

cloth

ing

dry.

Never

stand

lie

puddles

water,

damp

ground,

against

grounded

metal

when

welding

without

suitable

sulation

against

shock.

Always

find

dry

board

rubber

mat

stand

when

water,

moisture,

perspiration

cannot

avoided.

Dampness

between

the

body

and

energized

grounded

metallic

part

lowers

the

resistance

the

passage

current

the

body

which

may

produce

harmful

fatal

shock.

Salt

perspiration

sea

water

dangerously

lowers

contact

resistances.

Figure

1-7,

Dont

leave

electrode

contact

with

grounded

metallic

surface.

Keep

the

helmet,

hand

shields,

face

shield

good

condi

tion.

cracks

occur

the

fibre

material,

replace

the

shield,

since

the

leakage

arc

rays

may

cause

serious

burns.

1-21.

EVE

PROTECTION

NEVER

under

any

circumstances,

look

electric

arc

without

eye

protection.

Make

sure

that

flash

goggles

are

used

under

the

weld

ing

helmet

all

times,

particularly

while

gas

shielded-

arc

welding.

some

type

arc

welding,

such

gas

shielded-arc

welding,

ultra-violet

and

infra-red

radiation

from

the

arc

particularly

intense

and

requires

constant

attention

avoid

arc

flashes

the

welder

when

striking

arc

and

avoid

exposure

other

welders.

NEVER

strike

arc

without

ascertaining

that

nearby

per

sons

either

have

the

necessary

protective

equipment

are

looking

the

opposite

direction.

For

welding

operations

open

areas,

provide

portable,

non-

ref

Iecting

screens

shield

persons

nearby

from

the

rays

the

arc.

Eye

burns

from

the

arc,

through

not

generally

per

manent

injuries,

are

exceedingly

painful.

Such

burns

fre

quently

referred

flashes,

feel

hot

sand

the

eye.

the

eye

focused

the

arc

without

filter-glass

protec

tion,

infra-red

radiation

can

cause

retinal

scarring

and

paired

vision.

For

eye burns

consult

your

first

aid

station

doctor.

NEVER

use

cracked,

ill-fitting,

defective

plates.

The

filter

glass

plate

provided

the

helmets

and

shields

must

reputable

manufacture

conforming

the

latest

Ameri

can

National

Standards

Institute,

Standard

Z2.1.

Replace

cracked

ill-fitting

filter

plates

promptly.

NEVER

use

filter

plates.without

protecting

cover

glass.

Figure

1-8,

Use

eye

protection

all

times

1-19.

STARTING

UNDER

LOAD

DONT

leave

uninsulated

electrode

holder,

live

OM-313

Page

Keep

clean

cover

glass

front

the

filter

plate

for

the

protection

thereof.

Frequent

renewal

these

cover

glasses

necessary,

since

they

become

covered

with

spatter,

reducing

vision.

1-22.

CLOTHING

NEVER

use

poor,

inadequate,

worn-out

clothing.

Wear

heavy

shoes,

tightly

laced.

Keep

clothing

dry.

Proper

and

dry,

oil-free

clothing

essential

for

the

welders

protection.

Clothing

must

not

only

keep

off

the

spatter

and

molten

particles,

but

must

also

obstruct

the

rays

the

arc

and,

when

necessary,

insulate

the

body

from

harmful

electri

cal

currents.

Wear

leather

asbestos

gloves

all

times

protect

the

hands

and

wrists.

Dark

colored

shirts

are

preferred

light

ones

because

light

ones

reflect

arc

rays

exposed

parts

the

body.

the

case

gas

shielded-arc

welding,

light

colors

are

reflective

and

may

cause

eye

burns

due

the

tense

ultra-violet

rays

given

the

process.

Avoid

cotton

fabrics

when

gas

shielded-arc

welding.

arc

burn

the

skin

resembles

sunburn,

except

that

usually

severe.

Clothing

can

made

flame

resistant

treatment

with

solution

3/4

pound

sodium

stannate

gallon

water,

then

wrun9

out

and

dipped

solution

1/4

pound

ammonium

sulphate

per

gallon

water.

Dont

wash

clothing

prepared

water,

but

dry

clean.

When

welding

operations

are

performed

vertical

and

overhead

positions,

leather

sleevelets.

aprons,

and

some

cases

leggings

and

ear

plugs

should

used

prevent

severe

burns

from

spatter

and

molten

metal.

1-23.

HOT

METAL

BURNS

NEVER

pick

pieces

metal

which

have

just

been

welded

heated,

the

stub

ends

electrodes

which

have been

discarded.

1-24.

GRINDING

AND

CHIPPING

NEVER

any

chipping

grinding

without

protective

goggles.

(Figure

1-10)

Whenever

necessary

grind

chip

metal,

wear

protec.

tive

goggles

specifically

designed

for

this

purpose.

Serious

eye

injuries

may

result

from

failure

wear

protective

goggles.

1-25.

COMPRESSED

GAS

CYLINDERS

NEVER

strike

arc

compressed

gas

cylinder.

Always

observe

the

following

precautions

regards

compressed

cylinders:

Avoid

accidental

contact

the

electrodes,

electrode

holder,

other

electrically

energized

parts

with

compressed

gas

cylinder

any

other

pressure

vessel.

Serious

accidents

fires

may

result.

Use

I.C.C.

DOT.

cylinders.

They

are

manufactured

and

maintained

accordance

with

DOT.

require

ments

and

are

safe

long

they

are

properly

hayidled.

Dont

drop

cylinders.

3. Identify

gas

content

the

name

marked

the

cylin

der.

the

cylinder

unmarked,

not

use

it.

Return

the

supplier.

not

rely

color

code.

Never

use

cylinder

its

contents

for

other

than

intended

purposes.

Keep

oil

and

grease

away

from

oxygen

cylinders

and

cylinder

valves.

Keep

cylinders

away

from

exposure

sparks,

hot

slag,

open

flame

and

all

possible

sources

ignition

excessive

heat.

careful

that

cylinders

are

not

placed

come

part

electrical

circuit.

Avoid

third

rails,

wires

and

electric

welding

circuits.

When

transporting

cylinders

crane,

use

cradle

plat

form

other

suitable

support.

Never

lift

the

cylinders

slings,

the

caps

electric

magnets.

Never

use

cylinders

supports

rollers.

Never

try

mix

any

gases

cylinder.

Never

try

refill

cylinder.

Mark

tag

empty

cylinders

Empty

MT.

Send

Emptys

back

the

supplier

promptly.

15,

15.

Keep

Emptys

and

Fulls

separate.

16.

Never

tamper

with

alter

cylinder

numbers

other

markings.

This

not

only

foolish

but

may

illegal.

not

tamper

with

change

fittings

cylinders.

valves

cannot

opened

hand,

not

use

ham

mer

wrench.

Notify

supplier,

19.

Protect

cylinder

valves

from

bumps,

falls,

falling

jects,

and

from

weather.

Keep

them

covered

with

cylinder

caps

when

moving

cylinders.

Keep

valves

closed

empty

cylinders.

See

that

your

cylinders

are

clear

passageways

and

active

work

areas

and

that

they

are

secured

against

falling,

22.

adapter

required

between

cylinder

and

regulator,

always

use

standard

adapter.

These

may

obtained

from

your

supplier.

Where

right

and

left

hand

threads

are

used

adapter,

use

two

wrenches

insure

leak

proof

connections.

23.

not

store

cylinders

unventilated

areas.

NEVER

pick

hot

objects.

(Figure

1-9)

10.

11.

12.

13.

14.

Figure

1-9.

Never

pick

hot

objects

17,

18.

20,

21.

Figure

1-10.

Never

any

chipping

grinding

without

protective

goggles.

Page

SECTION

2-INTRODUCTION

Model

Welding

Current

Ranges

Amperes

Mao.

Open

Ciruuit

Vollugo

Rated

Wsldieg

Current

Amperes

Input

Ruled

LoS

Output

60Hz.



208)260

Vults

230

Volts

460

Volts

hoe

Ooerull

Oimensions

Inches)

Weight

Net

Ship

Without

Power

Poctor

Correction

With

Power

Pector

Correction

Low

25-125

High

105-325

Low

20-88

High

70-250

250W

Volts,

30%

Outy

Cycle

103

20.7

11.8

26-1/4

Wdth

332



340

342



350

200

Volts,

50%

Ooty

Cycle

16.1

8.2

25051

Volts.

30%

Ouly

Cycle

15.6

11.8

20051

Volts,

50%

Outy

Cycle

11.5

8.2

~NEMA

RATIN~jthe

above

electrical

specifications

Conform

with

Nema

Rating

1-1971,

Nema

Class

11(30)

and

comply

with

ANSI

Standard

C87.1-1971.

Figure

2-1.

Specifications

This

manual

has

been

prepared

especially

for

use

familiar

izing

personnel

with

the

design,

installation,

operation,

main

tenance, and

troubleshooting

this

equipment

All

information

presented

herein

should

given

careful

con

sideration

assure

optimum

performance

this

equipment

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

purch~er

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

M0%Jel

Designation

and/or

Stock

Number

and

Serial

(or

Style)

Number

the

equipment

supplied.

This

unit

single

phase

powered

welding

power

source,

which

produces

both

and

welding

current.

This

welding

power

source

capable

operation

either

200,

230

460

volt

Hertz

primary

electricel

power.

Jumper

links

are

provided

with

the

welding

power

source

for

the

purpose

matching

the

machine

one

the

above

available

input

voltages.

AA-gol

g73-4

Before

the

equipment

put

into

operation,

the

safety

sec

tion

the

front

this

manual

should be

read

completely.

This

will

help

avoid

possible

injury

due

misuse

improper

welding

applications.

The

following

definitions

apply

CAUTION,,

IMPORTANT,

and

NOTE

blocks

found

throughout

this

manual:

Installation,

operating,

and

maintenance

procedures,

practices,

etc.,

which

will

result

personnel

injury

loss

life

not

carefully

followed.



Installation,

operating,

and

maintenance

procedures,

practices,

etc.,

which

will

result

damage

equip-

men

Proper

installation

can

contribute

materially

the

satisfac

tory

and

trouble-free

operation

the

welding

power

source.

suggested

that

each

step

this

section

studied

care

fully

and

followed

detail.



Installation,

operating,

and

maintenance

procedures,



practices.

etc.,

which

essential

emphasize

3-1.

LINE

DISCONNECT

SWITCH

SECTION

INSTALLATION

CAUTION

precautionary

measure

should

toprovide

maximum

protection

against

electrical

shock. Before

electrical

connections

are

made

from

the

switch,

sure

that

the

line

disconnect

switch

has

been

opened

the

primary

input

circuit

fuses

have

been

removed

and

remain

that

way

until

the

installation

has

been



completed.

Proper

installation

can

contribute

materially

the

satisfac

tory

and

trouble.free

operation

the

welding

machine.

suggested

that

each

step

this

section

studied

carefully

and

followed

detail.

3-2.

LOCATION

good

installation

essential

the

welding

power

source

provide

satisfactory

and

dependable

service.

2-1.

GENERAL

Figure

2-2.

Block

Diagram

24.

SAFETY

2-2.

RECEIVING-HANDLING

2-3.

DESCRIPTION

NOTE

OM-313

Page

~ldi

owe

should

loca

ted

that

the

front

and

rear

panels

with

the

air

vents

are

clear

any

obstruction.

Cooling

air

drawn

through

the

front

upper

air

vent

and

expelled

Out

of the

rear

panel

air

vent.

The

location

should

be such

that

minimum

amount

dust

and

dirt

will

drawn

into

the

air

stream.

Preventive

main

tenance

consists

removing

the

wrapper

from

the

welding

power

source

and

blowing

Out

the

dust

accumulation

inside

the

unit.

For

this

reason

desirable

locate the

unit

that

the

wrapper

can

removed

without

any

difficulty.

This

ac/dc

arc

welding

power

source

single

phase

unit

and

must

connected

single

phase

power

line.

Consult

the

local

public

electric

utility

there

any

question

about

the

system

used

locally

the

proper

connections

necessary

connect

single

phase

power

service

the

welding

power

source.

NOTE



recommended

that

the

primary

leads

the

heavy

rubber

covered

type

run

solid

flexible

conduit.

Select

the

proper

size

primary

fuse

and

cable

from

Table

3-1.

Table

3-1.

Primary

Wire

and

Fuse

Size

PRIMARY

SIZE

IAWGI

FUSE

SIZE

AMPERES

MODEL

200V

230V

460V 57Ev 200V 230V

460V

57EV

WIhoot

P,F.C.

No.

No.2

No.6

No.8

150

With

P.F.C.

No.

No.4

No.8

No.

125

100

18) (8) (8) (8)

Numbers

indicate

ground

wire

size.

Insert

the

two

primary

leads

plus

one

ground

lead

through

the

access

hole

provided

the

lower

left

portion

the

rear

panel.

See

Figure

3-2

for

hole

location.

This

1-3/4

inch

dia

meter

hole

will

standard

conduit

fittings.

The

two

primary

leads

are

connected

terminals

and

the

primary

terminal

board

(TEl),

which

located

behind

the

primary

access

door

the

rear

panel.

The

ground

lead

must

connected

the

stud

the

pri

mary

terminal

board

labeled

GAD.

The

remaining

end

the

ground

lead

should

connected

suitable

ground

such

as:

water

pipe,

ground

rod,

etc.

Use

whatever

grounding

means

acceptable

the

local electrical

inspection

authority.

The

stud

labeled

CR0

connected~

welding

power

source

chassis

and

for

grounding

purposes

only.

not

connect

wire

from

the

terminal

labeled

GAD

either

one

the

single

phase

line

terminals

this

will

result

electrically

hot

welding

power



source

chassis.

The

standard

welding

power

source

designed

operate

either

200,

230

460

volts,

Hertz

primary

electrical

power.

This

machine

was

shipped

from

the

factory

with

the

jumper

links

arranged

for

the

highest voltage

the

machine

has

been

designed

operate

on.

setup

the

welding

power

source

for

the

voltage

used,

position

the

jumper

links,

located

the

primary

terminal

board,

shown

Figure

3-3.

200

(208)

VOLTS

230

VOLTS

460

VOLTS

~oo~

o~o

oo~~

GA.

Gfl

A-OlO

586

Figure

3-3.

Primary

Voltage

Jumper

Link

Arrangement

~ver

umper

link

con

nection

nec

essary

obtain

the

proper

input

voltage

connections,

such

460

volts,

connect

both

jumper

links

across

the

same

two

terminals.

This

will

prevent

losing

the

second

jumper

link.

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

operation

any

arc

welding

power

source

great

extent

dependent

the

use

welding

cables

and

connections

that

are

good

condition

and

adequate

size.

insulated

holder

must

used

ensure

the

operators

safety.

gw~h

ac,

the

cables

coiled

they

will

generate

magnetic

field

that

will

seri

ously

affect the

operation

the

welding

power

source.

Always

lay

the

welding

cables

out.

PRIMARY

CABLE

INPUT

HOLE

PRIMARY

VOLTAGE

JUMPER

LINKS

3-3/8

LINE

DISCONNECT

SWITCH

GROUND

CONNECTION

Figure

3-2.

Primary

Connections

AC-901

973.3

Figure

3-1,

Dimensional

Drawing

3-3.

PRIMARY

CONNECTIONS

3-4.

SECONDARY

WELDING

CONNECTIONS

Page

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