Miller JC600199 Owner's manual

Miller
Brand
Miller
Model
JC600199
Category
Welding System
Type
Owner's manual

This manual is also suitable for

July
1982
FORM:
OM-254B
OWN
ERS
MANUAL
TI1UHER
~
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON,
WI
54912
USA
ADDITIONAL
COPY
PRICE
65
CENTS
NWSA
CODE
NO.
4579
PRINTED
IN
U.S.A.
Effective
With
Serial
No.
JC600199
MODEL
CP-750
E
LIMITED
WARRANTY
EFFECTIVE:
JUNE
1.
1979
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY-Subject
to
the
terms
and
conditions
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
submitted
by
the
original
user
within
the
foregoing
periods.
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
(
furnished
by
Miller
is
free
from
defect
in
workmanship
and
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
material
as
of
the
time
and
place
of
delivery
by
Miller.
No
war-
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
ranty
is
made
by
Miller
with
respect
to
engines,
trade
ac-
therefore
shall
be,
at
Millers
option
(11
repair
or
(21
replacement
cessories
or
other
items
manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(31
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of
their
respective
manufacturers,
if
any
.
All
Miller
service
station
or
(41
payment
of
or
credit
for
the
purchase
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
date
of
original
purchase.
return
of
the
goods
at
Customers
risk
and
expense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
clai-
~
Except
as
specified
below,
Millers
warranty
does
not
apply
mant
on
the
warranty
claim
procedures
to
be
followed.
to
components
having
normal
useful
life
of
less
than
one
I
1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
MILLERMATIC
parts
that
come
in
contact
with
the
welding
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA-
?
wire
including
nozzles
and
nozzle
insulators
where
failure
does
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
not
result
from
defect
in
workmanship
or
material.
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
Miller
shall
be
required
to
honor
warranty
claims
on
war-
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
within
the
following
periods
from
the
date
of
delivery
of
Equip-
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
i
ment
to
the
original
user:
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EX
CLUDED
AND
DISCLAIMED
BY
MILLER.
1.
Arc
welders,
power
sources
and
components
.
.
1
year
2.
Original
main
power
rectifiers
3
years
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
(labor
-
1
year
onlyl
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
3.
All
wefding
guns
and
feeder/guns
90
days
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
4.
All
other
Millermatic
Feeders
1
year
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
5.
Replacement
or
repair
parts,
exclusive
of
labor
.
60
days
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
6.
Batteries
6months
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER
WARRANTIES
DO
NOT
EXTEND
provided
that
Miller
is
notified
in
writing
within
thirty
130)
days
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
of
the
date
of
such
failure.
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
~,
~.
~r,
~
~t,
j~
~
..~
a~
~t.
J~
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
SAFETY
RULES
FOR
OPERATION
OF
ARC
WELDING
POWER
SOURCE
1
-
1
Introduction
1
1
-
2.
General
Precautions
1
1
3.
Arc
Weldinq
3
1
-4.
Standards
Booklet
Index
4
SECTION
2
INTRODUCTION
2-1.
General
7
2
-
2.
Receiving-Handling
7
2
-
3.
Description
7
2-4.
Safety
7
SECTION
3
INSTALLATION
3-1.
Location
8
3
-
2.
Electrical
Input
Connections
8
3
-
3.
Secondary
Connections
9
3
.
4.
115
Volts
AC
Receptacles
9
3
-
5.
Contactor
Control
Connections
9
3
-
6.
Remote
Voltage
Control
Connections
10
3-
7.
Slope
Reactor
Connections
10
SECTION
4
FUNCTION
OF
CONTROLS
4-1.
PowerSwitch
11
4
-
2.
Voltage
Control
11
4
-
3.
Remote
Voltage
Control
Receptacle
&
Switch
11
4
-
4.
Contactor
Control
Receptacle
&
Switch
11
4
-
5.
Circuit
Breaker
Overload
Protection
11
4-6.
Meters
11
4-7.
Duty
Cycle
11
4
-
8.
Volt-Ampere
Graph
12
SECTION
5
SEQUENCE
OF
OPERATION
5-1.
Gas
Metal-Arc
Welding
12
5
-
2.
Shutting
Down
12
SECTION
6
MAINTENANCE
6-1.
FanMotor
12
6
-
2.
Transformer
12
6-
3.
Rectifier
13
6
-
4.
Control
Circuit
Protection
13
SECTION
7
TROUBLESHOOTING
PARTS
LIST
SECTION
1
-
SAFETY
RULES
FOR
OPERATION
OF
ARC
WELDING
POWER
SOURCE.
1.-i.
INTRODUCTION
-
We
learn
by
exper!ence.
Learning
safety
through
personal
exp~riance,
liLe
a
child
touching
a
hot
stove
is
harmful,
wasteful,
arid
un
wise.
Let
the
experience
of
others
teach
you.
Safe
practices
developed
from
experience
in
the
use
of
welding
and
cutting
are
described
in
this
manual.
Research,
development,
and
field
experience
have
evolved
reliable
equipment
and
safe
installation,
opera
tion,
and
servicing
practices.
Accidents
occur
when
equipment
is
improperly
used
or
maintained.
The
reason
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
at
tempting
to
install,
operate,
or
service
the
equipment.
Comply
with
these
procedures
as
applicable
to
the
par
ticular
equipment
used
and
their
instruction
manuals,
for
personal
safety
and
for
the
safety
of
others.
Failure
to
observe
these
safe
practices
may
cause
serious
injury
or
death.
When
safety
becomes
a
habit,
the
equipment
can
be
used
with
confidence.
These
safe
practices
are
divided
into
two
Sections:
1
-
General
Precautions,
common
to
arc
welding
and
cutting;
and
2
-
Arc
Welding
(and
Cutting)
(only).
Reference
standards:
Published
Standards
on
safety
are
also
available
for
additional
and
more
complete
pro
cedures
than
those
given
in
this
manual.
They
are
listed
in
the
Standards
Index
in
this
manual.
ANSI
Z49.1
is
the
most
complete.
The
National
Electrical
Code,
Occupational
Safety
and
Health
Administration,
local
industrial
codes,
and
local
inspection
requirements
also
provide
a
basis
for
equip
ment
installation,
use,
and
service.
1-2.
GENERAL
PRECAUTIONS
A.
Burn
Prevention
Wear
protective
clothing
-
leather
(or
asbestos)
gauntlet
gloves,
hat,
and
high
safety-toe
shoes.
Button
shirt
collar
and
pocket
flaps,
and
wear
cuff
less
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.2.
Avoid
oily
or
greasy
clothing.
A
spark
may
ignite
them.
Hot
metal
such
as
electrode
stubs
and
workpieces
should
never
be
handled
with~iut
gloves.
Medical
first
aid
and
eye
treatment.
First
aid
facilities
and
a
qualified
fir~t
aid
person
should
be
available
for
each
shift
unless
medical
facilities
are
close
by
for
im
mediate
treatment
of
flash
burns
of
the
eyes
and
skin
burns.
Ear
plugs
should
be
worn
when
working
on
overhead
or
in
a
confined
space.
A
hard
hat
should
be
worn
when
others
work
overhead.
Flammable
hair
preparations
should
not
be
used
by
per
sons
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
pi~duce.
Prevent
them
with
adequate
ventilation
as
described
in
ANSI
Standard
Z49.1
listed
1
in
Standards
index.
NEVER
ventilate
with
oxygen.
Lead
-,
cadmium
-.
zinc
-,
mercury
-,
and
beryllium
-
bearing
and
similar
materials,
when
welded
(or
cut)
may
produce
harmful
concentrations
of
toxic
fumes.
Ade
quate
local
exhaust
ventilation
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
us
ed.
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
ven
tilated,
or
the
operator
wears
an
air-supplied
respirator.
Work
in
a
confined
space
only
while
it
is
being
ven
tilated
and,
if
necessary,
while
wearing
an
air-supplied
respirator.
Gas
leaks
in
a
confined
space
should
be
avoided.
Leaked
gas
in
large
quantities
can
change
oxygen
con
centration
dangerously.
Do
not
bring
gas
cylinders
into
a
confined
space.
Leaving
confined
space,
shut
OFF
gas
supply
at
source
to
prevent
possible
accumulation
of
gases
in
the
space
if
downstream
valves
have
been
accidently
opened
or
left
open.
Check
to
be
sure
that
the
space
is
safe
before
re-entering
it.
Vapors
from
chlorinated
solvents
can
be
decomposed
by
the
heat
of
the
arc
(or
flame)
to
form
PHOSGENE,
a
highly
toxic
gas,
and
other
lung
and
eye
irritating
pro
ducts.
The
ultraviolet
(radiant)
energy
of
the
arc
can
also
decompose
trichloroethylene
and
per
chloroethylene
vapors
to
form
phosgene.
DO
NOT
WELD
or
cut
where
solvent
vapors
can
be
drawn
into
the
welding
or
cutting
atmosphere
or
where
the
radiant
energy
can
penetrate
to
atmospheres
containing
even
minute
amounts
of
trichioroethylene
or
per
chloroethylene.
OM-254
Page
1
Empties:
Keep
valves
closed,
replace
caps
securely;
mark
MT;
keep
them
separate
from
FULLS
and
return
promptly.
Prohibited
use.
Never
use
a
cylinder
or
its
contents
for
other
than
its
intended
use,
NEVER
as
a
support
or
roller.
Locate
or
secure
cylinders
so
they
cannot
be
knocked
over.
Passageways
and
work
areas.
Keep
cylinders
clear
of
areas
where
they
may
be
struck.
Transporting
cylinders.
With
a
crane,
use
a
secure
sup
port
such
as
a
platform
or
cradle.
Do
NOT
lift
cylinders
off
the
ground
by
their
valves
or
caps,
or
by
chains,
slings,
or
magnets.
Do
NOT
expose
cylinders
to
excessive
heat,
sparks,
slag,
and
flame,
etc.
that
may
cause
rupture.
Do
not
allow
contents
to
exceed
130F.
Cool
with
water
spray
where
such
exposure
exists.
Protect
cylinders
particularly
valves
from
bumps,
falls,
falling
objects,
and
weather.
Replace
caps
securely
when
moving
cylinders.
Stuck
valve.
Do
NOT
use
a
hammer
or
wrench
to
open
a
cylinder
valve
that
can
not
be
opened
by
hand.
Notify
your
supplier.
Mixing
gases.
Never
try
to
mix
any
gases
in
a
cylinder.
Never
refill
any
cylinder.
Cylinder
fittings
should
never
be
modified
or
exchang
ed.
3.
Hose
Prohibited
use.
Never
use
hose
other
than
that
designed
for
the
specified
gas.
A
general
hose
identification
rule
is:
red
for
fuel
gas,
green
for
oxygen,
and
black
for
inert
gases.
Use
ferrules
or
clamps
designed
for
the
hose
(not
or
dinary
wire
or
other
substitute)
as
a
binding
to
connect
hoses
to
fittings.
No
copper
tubing
splices.
Use
only
standard
brass
fit
tings
to
splice
hose.
Avoid
long
runs
to
prevent
kinks
and
abuse.
Suspend
hose
off
ground
to
keep
it
from
being
run
over,
stepped
on,
or
otherwise
damaged.
Coil
excess
hose
to
prevent
kinks
and
tangles.
Protect
hose
from
damage
by
sharp
edges,
and
by
sparks,
slag,
and
open
flame.
Examine
hose
regularly
for
leaks,
wear
and
loose
con
nections.
Immerse
pressured
hose
in
water;
bubbes
in
dicate
leaks.
Repair
leaky
or
worn
hose
by
cutting
area
out
and
splic
ing
(1-2D3).
Do
NOT
use
tape.
4.
Proper
Connections
Clean
cylinder
valve
outlet
of
impurities
that
may
clog
orifices
and
damage
seats
before
connecting
regulator.
Except
for
hydrogen,
crack
valve
momentarily,
pointing
outlet
away
from
people
and
sources
of
ignition.
Wipe
with
a
clean
lintless
cloth.
Match
regulator
to
cylinder.
Before
connecting,
check
that
the
regulator
label
and
cylinder
marking
agree,
and
that
the
regulator
inlet
and
cylinder
outlet
match.
NEVER
CONNECT
a
regulator
designed
for
a
particular
gas
or
gases
to
a
cylinder
containing
any
other
gas.
Tighten
connections.
When
assembling
threaded
con
nections,
clean
and
smooth
seats
where
necessary.
Tighten.
If
connection
leaks,
disassemble,
clean,
and
retighten
using
properly
fitting
wrench.
Adapters.
Use
a
CGA
adapter
(available
from
your
sup
plier)
between
cylinder
and
regulator,
if
one
is
required.
Use
two
wrenches
to
tighten
adapter
marked
RIGHT
and
LEFT
HAND
threads.
Regulator
outlet
(or
hose)
connections
may
be
iden
tified
by
right
hand
threads
for
oxygen
and
left
hand
threads
(with
grooved
hex
on
nut
or
shank)
for
fuel
gas.
5.
Pressurizing
Steps:
Drain
regulator
of
residual
gas
through
suitable
vent
before
opening
cylinder
(or
manifold
valve)
by
turning
adjusting
screw
in
(clockwise).
Draining
prevents
ex
cessive
compression
heat
at
high
pressure
seat
by
allowing
seat
to
open
on
pressurization.
Leave
adjusting
screw
engaged
slightly
on
single-stage
regulators.
Stand
to
side
of
regulator
while
opening
cylinder
valve.
Open
cylinder
valve
slowly
so
that
regulator
pressure
in
creases
slowly.
When
gauge
is
pressurized
(gauge
reaches
regulator
maximum)
leave
cylinder
valve
in
following
position:
For
oxygen,
and
inert
gases,
open
fully
to
seal
stem
against
possible
leak.
For
fuel
gas,
open
to
less
than
one
turn
to
permit
quick
emergency
shutoff.
Use
pressure
charts
(available
from
your
supplier)
for
safe
and
efficient,
recommended
pressure
settings
on
regulators.
Check
for
leaks
on
first
pressurization
and
regularly
there-after.
Brush
with
soap
solution
(capful
of
Ivory
Liquid*
or
equivalent
per
gallon
of
water).
Bubbles
in
dicate
leak.
Clean
off
soapy
water
after
test;
dried
soap
is
combustible.
E.
User
Responsibilities
Remove
leaky
or
defective
equipment
from
service
im
mediately
for
repair.
See
User
Responsibility
statement
in
equipment
manual.
*Trademark
of
Proctor
&
Gamble.
OM-254
Poge
3
F.
Leaving
Equipment
Unattended
(dose
ga;
supply
at
source
and
drain
gas.
G.
~pe
Staging-Support
Rope
staging~suppoi-t
should
not
be
used
for
welding
or
c~tting
operation;
rope
may
burn.
1
-3.
ARC
WELDING
-
Comply
with
precautions
in
-1,
1
-2,
and
this
section.
Arc
Welding,
properly
done,
k
a
safe
process,
but
a
careless
operator
invites
trouble.
The
equipment
carries
high
currents
at
significant
oltages.
The
arc
is
very
bright
and
hot.
Sparks
fly,
fumes
rise,
ultraviolet
and
infrared
energy
radiates,
weldments
are
hot,
and
compressed
gases
may
be
us
eJ.
The
wise
operator
avoids
unnecessary
risks
and
pro
tects
himself
and
others
from
accidents.
Precautions
ar~~
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
radia
i~ori
can
damage
eyes,
penetrate
lightweight
clothing,
reflect
from
light-colored
surfaces,
and
burn
the
skin
ard
eyes.
Skin
burns
resemble
acute
sunburn,
those
from
gas-shielded
arcs
are
more
severe
and
painful.
DONT
GET
BURNED;
COMPLY
WITH
PRECAU
TIONS.
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
prevent
entry
of
sparks.
2.
Eye
and
Head
Protection
Protect
eyes
from
exposure
to
arc.
NEVER
look
at
an
electric
arc
without
protection.
Welding
helmet
or
shield
containing
a
filter
plate
shade
no.
12
or
denser
must
be
used
when
welding.
Place
over
face
before
striking
arc.
Protect
filter
plate
with
a
clear
cover
plate.
Cracked
or
broken
helmet
or
shield
should
NOT
be
worn;
radiation
can
pass
through
to
cause
burns.
Cracked,
broken,
or
loose
filter
plates
must
be
replaced
IMMEDIATELY.
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
circula
tion,
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
1-2B.
Generator
engine
exhaust
must
bevented
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
surface
when
welding,
without
suitable
protection.
Page
4
To
protect
against
shock:
5.
Terminals
And
Other
Exposed
Parts
Keep
body
and
clothing
dry.
Never
work
in
damp
area
without
adequate
insulation
against
elecirical
shock.
Stay
on
a
dry
duckboard,
or
rubbe
rriat
when
damp
ness
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
circulator
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
li
quid
such
as
oil
or
fuel.
Three-phase
connection.
Check
phase
requirements
of
equipment
before
installing.
If
only
3-phase
power
is
available,
connect
single-phase
equipment
to
only
two
wires
of
the
3-phase
line.
Do
NOT
connect
the
equip
ment
ground
lead
to
the
third
(live)
wire,
or
the
equip
ment
will
become
electrically
HOT
-
a
dangerous
condi
tion
that
can
shock,
possibly
fatally.
Before
welding,
check
ground
for
continuity.
Be
sure
conductors
are
touching
bare
metal
of
equipment
Frames
at
connections.
If
a
line
cord
with
a
ground
lead
is
provided
with
the
equipment
for
connection
to
a
switchbox,
connect
the
ground
lead
to
the
grounded
switchbox.
If
a
three-
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
recep
tacle.
Never
remove
the
ground
prong
from
a
plug,
or
use
a
plug
with
a
broken
off
ground
prong.
2.
Electrode
Holders
Fully
insulated
electrode
holders
should
be
used.
Do
NOT
use
holders
with
protruding
screws.
3.
Connectors
Fully
insulated
lock-type
connectors
should
be
used
to
join
welding
cable
lengths.
4.
Cables
Frequently
inspect
cables
for
wear,
cracks
and
damage.
IMMEDIATELY
REPLACE
those
with
excessively
worn
or
damaged
insulation
to
avoid
possibly
-
lethal
shock
from
bared
cable.
Cables
with
damaged
areas
may
be
taped
to
give
resistance
equivalent
to
original
cable.
Keep
cable
dry,
free
of
oil
and
grease,
and
protected
from
hot
metal
and
sparks.
Terminals
and
other
exposed
parts
of
electrical
units
should
have
insulating
covers
secured
before
operation.
6.
Electrode
Wire
Electrode
wire
becomes
electrically
HOT
when
the
power
switch
of
gas
metal-arc
welding
equipment
is
ON
arid
welding
gun
trigger
is
pressed.
Keep
hands
and
body
clear
of
wire
and
other
HOT
parts.
7.
Safety
Devices
Safety
devices
such
as
interlocks
and
circuit
breakers
should
not
be
disconnected
or
shunted
out.
Before
installation,
inspection,
or
service,
of
equip
ment,
shut
OFF
all
power
and
remove
line
fuses
(or
lock
or
red-tag
switches)
to
prevent
accidental
turning
ON
of
power.
Disconnect
all
cables
from
welding
power
source,
and
pull
all
115
volts
line-cord
plugs.
Do
not
open
power
circuit
or
change
polarity
while
welding.
If,
in
an
emergency,
it
must
be
disconnected,
guard
against
shock
burns,
or
flash
from
switch
arcing.
Leaving
equipment
unattended.
Always
shut
OFF
and
disconnect
all
power
to
equipment.
Power
disconnect
switch
must
be
available
near
the
welding
power
source.
1-4.
STANDARDS
BOOKLET
INDEX
For
more
information,
refer
to
the
following
standards
or
their
latest
revisions
and
comply
as
applicable:
1.
ANSI
Standard
Z49.1,
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from
the
American
Welding
Society,
550
Le
Jeune
Rd,
P.O.
Box
351040,
Miami,
FL
33135.
2.
NIOSH,
SAFETY
AND
HEALTH
IN
ARC
WELDING
AND
GAS
WELDING
AND
CUTTING
obtainable
from
the
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
3.
OSHA,
SAFETY
AND
HEALTH
STANDARDS,
29CFR
1910,
obtainable
from
the
U.S.
Govern
ment
Printing
Office,
Washington,
D.C.
20402.
4.
ANSI
Standard
Z87.1,
SAFE
PRACTICES
FOR
OCCUPATION
AND
EDUCATIONAL
EYE
AND
FACE
PROTECTION
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
5.
ANSI
Standard
Z41.1,
STANDARD
FOR
MENS
SAFETY-TOE
FOOTWEAR
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
OM-254
Page
5
6.
ANSI
Standard
Z49.2,
FIRE
PREVENTION
IN
THE
USE
OF
CUTTING
AND
WELDING
PRO
CESSES
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018
7.
AWS
Standard
A60,
WELDING
AND
CUT
TING
CONTAINERS
WHICH
HAVE
HELD
COM
BUSTIBLES
obtainable
from
the
American
Welding
Society,
550
Le
Jeune
Rd.,
P.O.
Box
351040,
Miami,
FL
33135.
8.
NFPA
Standard
51,
OXYGEN
-
FUEL
GAS
SYSTEMS
FOR
WELDING
AND
CUTTING
ob
tainable
from
the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
9.
NFPA
Standard
70-1978,
NATIONAL
ELEC
TRICAL
CODE
obtainable
from
the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
10
NFPA
Standard
SiB,
CUTTING
AND
WELDING
PROCESSES
obtainable
from
the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
11.
CGA
Pamphlet
P-i,
SAFE
HANDLING
OF
COM
PRESSED
GASES
IN
CYLINDERS
obtainable
from
the
Compressed
Gas
Association,
500
Fifth
Avenue,
New
York,
NY
10036.
12.
CSA
Standard
Wi
17.2,
CODE
FOR
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from
the
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
13.
NWSA
booklet,
WELDING
SAFETY
BIBLIOGRAPHY
obtainable
from
the
National
Welding
Supply
Association,
1900
Arch
Street,
Philadelphia,
PA
19103.
14.
American
Welding
Society
Standard
AWSF4.1
Recommended
Safe
Practices
for
the
Prepara
tion
for
Welding
and
Cutting
of
Containers
and
Piping
That
Have
Held
Hazardous
Substances,
obtainable
from
the
American
Welding
Society,
550
Le
Jeune
Rd.,
P.O.
Box
351040,
Miami,
FL
33135.
15.
ANSI
Standard
Z88.2
Practice
for
Respiratory
Protection
obtainable
from
the
American
Na
tional
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
P~iqe
6
SECTION
2-
INTRODUCTION
Rnted
Welding
Current
Amperes
Load
Voltage
Ranges
Maximum
Open-
Circuit
Voltage
Amperes
Input
At
Rated
Load
Output
60
Hz.
Three-Phase
kw
Dimensions
(Inches)
Weight
(Poundsl
Net
I
Ship
230
Volts
460
Volts
kva
150
75
59.8
~
750@
50
Volts
100%
Duty
Cycle
25-56
74
46.4
Height
-
57-1/4
Width
-
27-1/2
Depth-49
I
~
1726
I
1826
I
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.
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
manufacturer
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.
This
unit
is
a
three-phase
welding
power
source
which
pro
duces
dc
welding
current.
This
welding
power
source
is
de
signed
specifically
for
use
with
the
Gas
Metal-Arc
(GMAWI
Welding
process.
2-4.
SAFETY
Before
the
eqwpment
is
put
nto
operation,
the
safety
sec
tion
at
the
front
of
this
manual
should
be
read
completely.
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
Figure
2-).
Specifications
2-1.
GENERAL
Figure
2-2.
Block
Diagram
2-2.
RECEIVING-HANDLING
TB-901
181-lB
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:
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
hazard
to
person
nel.
2-3.
DESCRIPTION
1
I
I
rTA~1
I
I
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.
~NOTE
~
U
I
U
U
OM-254
Page
7
SECTION
3
-
INSTALLATION
2.1.
LOCATION
(Figure
3-1)
A
p
oper
installation
site
should
be
selected
for
the
welding
po..:r
roirce
it
the
unit
is
to
provide
dependable
service,
and
emain
relatively
maintenance
free.
A
proper
installation
site
permits
freedom
of
air
movement
mm
md
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
power
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
ove
r
the
in
ta
ke
air
passages
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
ranty
is
void
if
any
type
of
filtering
device
is
used
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.
I
CAUTION
Before
making
electrical
input
connections
to
the
welding
power
source,
machinery
lockout
proce
duret
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.
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.
IMPORT
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.
Figure
3-1.
Dimensional
Drawing
and
Base
Mounting
Hole
Layout
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
U
Do
not
connect
the
input
conductors
to
the
three-
phase
power
supply
until
all
input
electrical
connec
tions
have
been
made
to
the
welding
power
source.
I
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
-
AWG
Fuse
Size
In
Amperes
230V
380V
460V
575V
230V
380V
460V
575V
1/0
3
4
6
225
150
125
90
16)
(61 (8)
(8)
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
It
is
recommended
that
a
terminal
lug
of
adequate
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
terminal
hardware
used
on
the
primary
i
contactor.
U
I
Page
13
Open
the
right
rear
side
door
to
obtain
access
to
the
primary
contactor.
Connect
the
three
input
conductors
directly
to
the
line
terminals
of
the
primary
contactor
and
connect
the
ground
conductor
to
the
terminal
labeled
GROUND.
See
Fig
ure
3-2
for
input
conductor
connections.
The
remaining
end
of
the
ground
conductor
should
be
connected
to
a
proper
grnund.
Use
whatever
grounding
method
that
is
acceptable
to
the
local
electrical
inspection
authority.
The
terminal
labeled
GROUND
is
connected
to
the
welding
power
source
chassis
and
is
for
grounding
purposes
only.
Do
not
connect
a
conductor
from
the
terminal
labeled
GROUND
to
any
one
of
the
line
terminals
on
the
primary
contactor
as
this
will
result
in
an
electrically
hot
welding
power
source
chassis.
C.
Matching
The
Welding
Power
Source
To
The
Avail
able
Input
Voltage
The
input
voltage
jumper
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
unit
may
be
operated
are
stated
on
the
nameplate
and
on
the
input
voltage
label.
See
Figure
3-2
for
location
of
this
label.
The
input
voltage
jumper
links
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
designed,
the
jumper
links
will
have
to
be
moved
to
the
proper
positions
before
operating
the
unit.
Figure
3-3
shows
the
various
positions
of
the
jumper
links
on
the
standard
welding
power
source.
If
the
input
voltages
on
the
name
plate
differ
from
those
shown
in
Figure
3-3,
the
input
voltage
jumper
links
must
be
positioned
as
shown
on
the
input
voltage
label.
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.
3-3.
SECONDARY
CONNECTIONS
(Figure
4-1)
The
POSITIVE
and
NEGATIVE
secondary
terminals
are
located
behind
the
lower
front
access
panel.
The
access
panel
which
covers
the
secondary
terminals
is
secured
by
two
fas
teners.
To
open
the
access
panel,
rotate
the
fasteners
counler
clockwise
one
full
turn.
Likewise,
so
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
welding
cables
and
connections
that
are
in
good
condition
and
of
adequate
size.
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.
WE
LOIN
C
*TDTA
LLEN
C
TI-I
OF
CABLE
ICOPPE
RI
IN
WELD
CIA
CIJIT
AMPERES
SO
too
150
200
250
300
350
400
100
4
4
2
2
2
1
1/0 1/0
150
2 2
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
A-002
623
NOTE:
A.
50
FEET
OR
LESS.
B
CABLE
SIZE
IS
BASED
ON
DIRECT
CURRENT
IDCI.
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
RECEPTACLE
(Figure
4-1)
Two
receptacles,
both
labeled
115
VAC,
are
provided
on
the
front
panel.
The
duplex
115
VAC
receptacle
fRC4)
is
in
tended
to
be
used
for
operating
accessory
equipment.
The
three-pole
twistlock.
115
VAC
receptacle
(RC2)
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
the
plug
as
far
as
it
will
turn
in
a
clockwise
direction.
3-5.
CONTACTOR
CONTROL
CONNECTIONS
(Figure
4-1)
The
CONTACTOR
CONTROL
Receptacle
IRC3)
provides
a
junction
point
for
connecting
a
Remote
Contactor
Control
device
to
the
contactor
control
circuitry
in
the
welding
power
source.
To
connect
the
Remote
Contactor
Control
to
the
CONTAC
TOR
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
Line
Table
3-2.
Secondary
Cable
Sizes
Figure
3-2.
Input
Conductor
Connections
Te-gol
181-2
I
I
I
I
230
VOLTS
460
VOLTS
Figure
3-3.
Input
Voltage
Jumper
Link
Arrangement
OM-254
Page
9
turn
in
a
clockwise
direction
The
plug
will
now
be
locked
in
the
receptacle
and
will
not
pull
out
under
stress.
i
p.El
1~EP9RT~~~)
r
--.
lnih
11
t~
VA.
Receptacles
and
CONTACTOR
CON
TROL
Circuitry
are
protected
by
a
15
ampere
fuse
1F21
orhich
is
located
behind
the
right
front
side
panel.
II
it
chould
become
necessary
to
replace
the
fuse,
rincuri
that
a
fuse
of
the
same
rating
is
used
for
a
replacement.
A
fuse
of
a
larger
raring
will
permit
over
loadinq
o~
the
115
volts
circuitry
and
thereby
cause
_~,rnage
to
the
welding
power
source.
3-6.
REMOTE
VOLTAGE
CONTROL
CONNECTIONS
(Figure
4-1)
The
VOLTAGE
CONTROL
Receptacle
(RC1),
located
on
the
hunt
panel,
is
a
three-pole,
twistlock
receptacle.
The
VOLTAGE
CONTROL
Receptacle
provides
a
connection
point
between
the
Remote
Voltage
Control
and
the
welding
power
sourci
voltage
adjustment
circuitry.
When
utilizing
a
Remole
Voltage
Control
insert
the
plug
from
a
Remote
Volt
agi
Control
fully
into
the
VOLTAGE
CONTROL
Receptacle
and
thnn
rotate
the
plug
as
far
as
it
will
turn
io
a
clockwise
direction
This
rotating
action
will
secure
the
plug
in
the
receptacle
and
prevent
it
from
coming
out
if
tension
should
he
applied
to
the
Remote
Voltage
Control
cord.
37.
SLOPE
REACTOR
CONNECTIONS
Be
sure
the
branch
circuit
or
main
disconnect
switch
is
open
or
electrical
input
circuit
fuses
are
removed
befote
attempting
any
inspection
or
work
on
the
in
side
of
the
welding
power
source.
Placing
the
POWER
Switch
on
the
welding
power
source
in
the
OFF
posi
tion
does
not
remove
voltage
from
the
power
ter
miritalt
inside
of
the
welding
power
source.
The
slope
reactor
)Z),
located
behind
the
left
rear
tide
panel,
has
three
sets
of
five
slope
reactor
coil
taps.
An
increase
or
decrease
in
slope
may
be
deemed
necessary
with
a
particular
43
Gas
Metal-Arc
Welding
process.
An
increase
in
slope
results
in
lets
available
short
circuit
welding
current
and
slower
welding
response.
The
slope
connections
are
positioned
for
0
turns
(OT)
slope
(no
slope),
upon
shipment.
To
change
the
slope
connections,
proceed
as
follows:
(See
Figure
3-4
for
slope
reactor
coil
tap
connections.)
1.
Open
the
left
rear
side
panel
to
obtain
access
to
the
slope
reactor
coils.
2.
Disconnect
leads
43,
44,
and
45
from
the
slope
reactor
coil
taps.
3.
Reconnect
leads
43,
44,
and
45
to
the
desired
slope
re
actor
coil
taps.
IMPORTANT
Ensure
that
leads
43,
44,
and
45
are
connected
to
the
same
value
reactor
coil
tap.
Ensure
also
that
leads
43,
44.
and
45
are
reconnected
to
the
same
reactor
coil
from
which
these
leads
were
disconnected.
SECTION
4-FUNCTION
OF
CONTROLS
I
I
I
I
4.
Close
the
left
front
side
panel.
I
I
21c~
45r
TA-gol
181-5
Figure
3-4.
Slope
Reactor
Coil
Tap
Connections
44
ST
ST
Primary
Overload
Voltage
Power
Circuit
Breaker
Control
Switch
DC
Voltmeter
115
VAC
Duplex
Receptacle
Positive
Weld
Output
Terminal
Voltage
Control
Switch
DC
Ammeter
Contactor
Control
Switch
Circuit
Breaker
115
VAC
Twistlock
Receptacle
Contactor
Control
Receptacle
Negative
Weld
Output
Terminal
Figure
4-1.
Front
Panel
View
TB-gol
181-4A
Page
10
4-1.
POWER
SWITCH
(Figure
4-1)
Placing
the
POWER
Switch
in
the
ON
position
will
energize
thr
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
ion
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
and
primary
contactor.
To
completely
cut-off
all
electrical
input
power
to
the
welding
power
source,
it
will
be
necessary
to
place
the
line
disconnect
switch
in
the
OFF
position
or
remove
the
line
fuses.
4-2.
VOLTAGE
CONTROL
(Figure
4-1)
The
VOLTAGE
CONTROL,
located
on
the
front
panel,
pro
vides
a
means
of
selecting
the
voltage
desired
within
the
load
voltage
slope
connection
range
being
used.
Rotating
the
con
trol
in
a
clockwise
direction
will
increase
the
load
voltage.
Whenever
a
Remote
Contactor
Control
is
to
be
used,
make
connections
to
she
CONTACTOR
CONTROL
Receptacle
)RC3)
on
the
welding
power
source
as
instructed
in
item
3~5.
In
order
for
a
Remote
Contactor
Control
Station
to
operate
the
contactor
in
the
welding
power
source,
the
Remote
Con
tactor
Control
must
be
able
to
supply
115
volts
ac
60
Hz
power
to
the
CONTACTOR
CONTROL
Receptacle
whenever,
weld
output
is
desired.
Also,
whenever
suspension
of
weld
output
is
desired,
the
Remote
Station
must
be
able
to
cut-off
the
115
volts
ac
supply
to
the
receptacle
(RC3).
Another
prerequisite
for
remote
control
of
the
contactor
is
to
have
the
CONTACTOR
CONTROL
Switch
on
the
welding
power
source
in
the
REMOTE
position.
If
this
switch
it
left
in
he
STANDARD
position,
the
contactor
will
energize
as
soon
as
the
POWER
Switch
is
positioned
to
ON.
The
CONTACTOR
CONTROL
Circuitry
(and
115
VAC
Re.
ceptaclea)
it
protected
by
a
15
ampere
fuse
)F2)
which
is
located
behind
the
right
front
side
panel.
If
this
fuse
should
open,
the
contactor
coil
would
de-energize
(if
the
CON
TACTOR
CONTROL
Switch
were
in
the
STANDARD
posi
don)
and
all
weld
output
would
be
suspended.
Alto,
if
this
fuse
should
open,
it
will
be
noted
that
115
volts
ac
would
not
be
available
at
the
115
VAC
Receptacles.
IMPORT
When
replacing
fuse
F2,
ensure
that
the
fuse
being
used
as
a
replacement
is
one
of
proper
size
and
rating.
A
fuse
of
larger
rating
will
permit
overloading
of
the
115
volts
circuitry
and
thereby
cause
damage
to
the
welding
power
source.
The
scale
surrounding
the
VOLTAGE
CONTROL
is
cali
brated
in
percentage
and
should
not
be
misconstrued
as
an
amperage
or
voltage
reading.
It
is
recommended
that
the
meters
be
read
whenever
it
is
necessary
to
know
the
amper
age
and
voltage
output.
4-3.
REMOTE
VOLTAGE
CONTROL
RECEPTACLE
&
SWITCH
(Figure
4-1)
If
a
Remote
Voltage
Control
is
to
be
used,
make
Connections
from
rhe
Remote
Voltage
Control
to
the
VOLTAGE
CON
TROL
Receptacle
as
instructed
in
item
3-6.
When
remote
control
of
the
voltage
is
desired,
it
is
essential
that
the
VOLTAGE
CONTROL
Switch
be
placed
in
the
RE
MOTE
position.
Likewise,
if
a
Remote
Voltage
Control
it
not
to
be
utilized,
the
switch
must
be
in
the
STANDARD
position.
When
in
the
STANDARD
position
only
the
VOLT
AGE
CONTROL
on
the
front
panel
will
control
the
voltage.
The
30
volts
control
circuitry
in
the
welding
power
source
is
protected
by
a
circuit
breaker
(CR2)
which
is
located
on
the
right
side
of
the
front
panel.
If
this
circuit
breaker
opens,
the
weld
output
goes
to
minimum
output
and
remains
there,
regardless
of
the
position
of
any
of
the
welding
power
source
controls.
When
this
occurs,
neither
the
VOLTAGE
CONTROL,
or
Remote
Voltage
Control
will
have
any
effect
on
~ne
weld
output.
Manually
reset
the
circuit
breaker
before
attempting
to
resume
operation.
This
welding
power
source
is
equipped
with
an
overload
Circuit
Breaker
(CR1)
which
will
suspend
all
weld
output
in
the
event
an
excessive
overload
is
placed
on
the
welding
power
source.
The
Circuit
Breaker
circuitry
consists
of
two
current
trans
formers
)CT1
&
CT2(
which
are
located
on
the
primary
side
of
the
main
transformer
(Ti)
and
two
sets
of
contacts
which
are
wired
in
series
with
the
contactor
coil.
Should
an
over
load
occur,
the
current
sensing
transformers
would
detect
the
overload
and
cause
the
Circuit
Breaker
to
trip.
When
the
breaker
trips,
the
two
sets
of
contacts
in
series
with
the
Con.
tactor
coil
will
open
and
thereby
cause
the
Contactor
to
de-energize
and
suspend
all
weld
output.
To
place
the
weld
ing
power
source
in
a
ready-to-weld
status
again,
it
will
be
necessary
to
manually
place
the
Circuit
Breaker
atms
on
the
front
panel
in
the
ON
position.
46.
METERS
(Figure
4-1)
This
welding
power
source
is
equipped
with
a
dc
ammeter
and
a
dc
voltmeter.
These
meters
are
internally
connected
to
the
welding
power
source
weld
output
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.
The
ammeter
will
indicate
the
weld
current
output
of
the
welding
power
source.
4-7.
DUTY
CYCLE
(Figure
4-2)
.
c~
-
.
-
~
I
I
U
NOTE
I
I
The
contacts
of
the
VOLTAGE
CONTROLareof
the
continuous
type,
thereby
making
it
possible
to
ad(ust
this
control
while
welding.
4-5.
CIRCUIT
BREAKER
OVERLOAD
PROTECTION
(Figure
4-1)
4-4.
CONTACTOR
CONTROL
RECEPTACLE
&
SWITCH
(Figure
4-1)
~IIuflhIlL.]jU
I
I
Whenever
the
CONTACTOR
CONTROL
Switch
is
in
the
STANDARD
position,
open.circuit
voltage
will
be
present
at
the
secondary
terminals
as
long
as
the
POWER
Switch
is
positioned
to
ON.
1000
~a
900
E
ow
ja.
800
700
U
I
30
40
50
60
708090100
%DUTY
CYCLE
DA.901
181-1
Figure
4-2.
Duty
Cycle
Chart
OM-254
Page
11
Thu
dirty
cycle
of
a
welding
power
sOtrice
is
the
percentage
I
a
ten
minute
period
that
a
welding
power
tout
ce
con
safely
be
operated
ni
a
given
output
ciii
ciii
-rIlirIq.
This
welding
ir~.jrr
snur
cr-i
in,
nun
Rt
7~ir
nhltpernv,
iflO
nirceit
duty
cyci~.
Tins
merits
the
wriidilirl
power
suurr:rn-:vIi
be
safrnly
operated
at
750
anlprrres
welrlirer
c.rrrvor
coicticununciy.
If
the
welding
current
is
increased
SilO
duty
cynic
viii
decrease
Figure
1-2
untihies
the
oporatol
to
Irnici
nrc
the
sole
ouSuirt
hi
,~rrldi
ng
powet
source
ar
var
ir
15
ui
y
noises
~Pr~RTA~T
L
~
-~
Exceeding
the
ndieriterl
duly
C/lie
will
cause
the
t~iriirq
pointer
sourss
Na
ov-rheaS
and
thereby
cause
damage
to
the
welding
power
source
components.
Tie
volt-ampere
curve
shows
the
output
voltage
available
at
an-c
given
output
current
within
the
limits
of
the
minimum
and
maximum
values
of
the
VOLTAGE
CONTROL
setting.
Load
voltage
is
predetermined
to
a
large
degree
by
arc
char
acteristics.
With
the
use
of
the
volt-ampere
curve,
it
is
pos
sible
to
determine
the
amperage
required
for
a
specific
load
voltage.
With
reference
to
the
volt-ampere
curve
(Figure
4-3),
the
curve
shows
only
the
maximum
and
minimum
settings
of
the
VOLTAGE
CONTROL
for
each
of
the
five
slope
reactor
tap
connection
ranges.
Curves
of
other
VOLTAGE
CON
TROL
settings
will
fall
between
the
maximum
and
minimum
curves
shown.
SECTION
5
-
SEQUENCE
OF
OPERATION
I-
.
.1
Never,
under
any
Circumstances,
operate
the
welding
power
source
with
the
outer
enclosure
removed.
In
addition
to
a
safety
hazard,
improper
cooling
may
re
sult
in
damage
to
the
welding
transformer
and
the
welding
power
source
components.
Warranty
is
void
if
the
welding
power
source
is
operated
with
the
Outer
enclosure
open
or
removed.
I
~Lu1l.]~IJ
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/or
permanent
bodily
damage.
8.
Turn
on
the
shielding
gas
supply.
5-1.
GAS
METAL-ARC
(GMAW)
WELDING
1
.
Make
Electrical
input
connections
as
outlined
in
item
3-2
-
2
Make
Secondary
connections
as
outlined
in
item
3-3.
3.
If
a
Remote
Contactor
Control
device
is
used,
make
Contactor
Control
connections
as
instructed
in
item
3-5
and
place
the
CONTACTOR
CONTROL
Switch
in
the
REMOTE
position.
4.
II
a
Remote
Voltage
Control
is
to
be
used,
make
con
nections
to
the
VOLTAGE
CONTROL
Receptacle
as
instruction
in
item
3-6
and
place
tIle
VOLTAGE
CON
TROL
Switch
in
the
REMOTE
position.
5.
If
115
volts
ac
is
required
to
operate
a
control/feeder,
make
connections
to
the
three-prong,
twistlock,
115
VOLTS
AC
Receptacle
as
instructed
in
item
3-4.
6.
Rotate
the
VOLTAGE
CONTROL
to
the
approximate
desired
setting.
7
Ensure
that
the
Circuit
Breaker
and
external
Line
Dis
connect
Device
are
in
the
ON
position.
9.
Place
the
POWER
Switch
to
the
ON
position
and
commence
welding.
10.
The
VOLTAGE
CONTROL
may
be
rotated
while
welding.
5-2.
SHUTTING
DOWN
1.
Breakthearc.
2.
Allow
the
welding
power
source
to
idle
for
3
minutes
with
no
load
applied.
3.
Place
the
POWER
Switch
in
the
OFF
position.
4.
Turn
off
the
shielding
gas
at
the
shielding
gas
source.
CAUTION
I
.
-I
If
welding
is
performed
in
a
confined
area,
failure
to
turn
off
the
shielding
gas
supply
could
result
in
a
build
up
of
gas
fumes,
thereby
endangering
personnel
re
entering
the
welding
area.
SECTION
6-
MAINTENANCE
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
in
side
of
the
welding
power
source.
Placing
the
POWER
Switch
on
the
welding
power
source
in
the
OFF
posi
tion
does
not
remove
voltage
from
the
power
ter
minals
inside
of
the
welding
power
source.
U
6-1.
FAN
MOTOR
All
models
are
equipped
with
an
exhaust
fan
and
rely
on
forced
draft
for
adequate
cooling.
The
fan
motor
is
manufac
tured
with
lifetime
lubricated
sealed
ball
bearings
and
no
attention
should be
required.
6-2.
TRANSFORMER
Occasional
blowing
out
of
the
dust
and
dirt
from
around
the
transformer
is
recommended.
This
should
be
done
periodi
cally
depending
upon
the
location
of
the
unit
and
the
I
4-8.
VOLT-AMPERE
CURVE
(Figure
4-3)
I
200
300
400
500
600
700
800
900
EB-901
181-1
Figure
4-3.
Volt-Ampere
Curve
I
I
I
I
I
CAUTI9N__~
I
Page
12
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
re
move
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
(Fl).
This
fuse
is
located
behind
the
right
rear
side
door.
Should
this
fuse
open
the
welding
power
source
would
com
pletely
shut
down.
The
15
volts
control
circuit
is
protected
by
fuse
F3
located
on
the
center
baffle.
If
the
fuse
opens
control
of
Output
is
avail
able
but
complete
minimum
cannot
be
obtained.
I
I
IMPORTANT
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.
I
I
SECTION
7
-
TROUBLESHOOTING
Hazardous
voltages
are
present
on
the
internal
cir
cuitry
of
the
welding
power
source
as
long
as
power
is
connected
to
the
unit.
Disconnect
power
before
attempting
any
inspection
or
work
on
the
inside
Qf
the
unit.
Troubleshooting
of
internal
circuitry
should
be
performed
by
qualified
personnel
only.
The
following
chart
is
designed
to
diagnose
and
provide
remedies
for
some
of
the
troubles
that
may
develop
in
this
welding
power
source.
It
is
assumed
that
proper
installation
has
been
made,
according
to
Section
3
of
this
manual,
and
that
the
welding
power
source
has
been
functioning
properly
until
this
trouble
developed.
Use
this
chart
in
conjunction
with
the
circuit
diagram
while
performing
troubleshooting
procedures.
If
the
trouble
is
not
remedied
after
performing
these
procedures,
the
nearest
Factory
Authorized
Service
Station
should
be
contacted.
In
all
cases
of
equipment
malfunction,
the
manufacturers
recommendations
should
be
strictly
followed.
TROUBLE
PROBABLE
CAUSE
REMEDY
Limited
output
and
low
open-cir-
cuit
voltage,
Operation
on
single-phase.
Open
line
fuse
on one
phase.
Check
incoming
three-phase
power
for
correct
voltage
Re.
place
fuse
if
open.
Input
voltage
jumper
links
con-
nected
to
wrong
terminals,
Connect
jumper
links
for
input
voltage
being
used.
See
the
input
voltage
label
on
the
primary
connection
board.
Fan
runs
slow.
Input
voltage
jumper
links
on
pri-
mary
Connection
board
connected
for
incorrect
voltage.
Connect
jumper
links
for
input
voltage
being
used.
See
Fig-
ure
3-3
and
the
input
voltage
label
on
the
primary
con-
nection
board.
Fan
does
not
run.
Weld
output
available,
Fan
motor
defective.
Check
fan
motor
leads
for
possible
short.
Re-insulate
fan
motor
leads,
if
shorted.
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
(Fl?,
,f
open.
Line
fuses
open.
Replace
line
fuses,
if
defective,
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.
Fan
runs
but
no
weld
output
or
115
VAC
output.
Fuse
(F2)
open.
Replace
fuse
(F2),
if
open.
Fan
runs,
115
VAC
available,
but
no
weld
output.
Circuit
breaker
(CB
1)
tripped.
Reset
circuit
breaker
(CB
1).
if
tripped.
Centrifugal
switch
(FMS)
open.
Replace
centrifugal
(FMS)
switch.
Fan
runs,
115
VAC
available,
but
low
weld
output.
Circuit
breaker
(CB2)
open.
Manually
reset
circuit
breaker
(CB2).
1f
it
becomes
necessary
to
replace
any
fuse
in
the
welding
power
source,
ensure
that
a
fuse
of
the
proper
size
is
used,
OM.254
Page
13
REMOrE
CONTROL
CPT~ONA1
~EXTRA)
Figure
7-1.
Circuit
Diagram
Circuit
Diagram
No.
B-087
120
Paqe
14
July
1982
FORM:
OM-254B
PARTS
LIST
Effective
With
Serial
No.
JC600199
Item
Dia.
Part
No.
Mkgs.
No.
Description
Quantity
Figure
A
Main
Assembly
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-254
Page
1
1
1
1
1
2
2
1
1
3
1
1
1
1
003
107
COVER,
top
2
3
4
SRi
037 354
Figure
D
053
445
RECTIFIER,
silicon
diode
(Fig
B
Pg
2)
BAFFLE,
center
-
w/components
(Pg
3)
BASE
5
6
T2
026
627
036 646
GASKET,
lifting
eye
cover
TRANSFORMER,
kva
2
7
8
9
Z
~
036
697
008519
003
110
REACTOR,
slope
PANEL,side-top
PANEL,
side
10
11
12
Ti
Figure
E
Figure
G
101
811
PANEL,
rear-w/components
(Pg
4)
TRANSFORMER,
power
(Pg
7)
BUS
BAR,
accontrol
13
14
15
MA1,3
MA2
036
270
036
230
Figure
F
AMPLIFIER,
magnetic
(FigCPg2)
AMPLIFIER,
magnetic
(Fig
C
Pg
2)
PANEL,
front
-
w/components
(Pg
6)
Fig
F
Figure
A
-
Main
Assembly
I
TD-901
181-B
Fig
C
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Miller JC600199 Owner's manual

Miller
Brand
Miller
Model
JC600199
Category
Welding System
Type
Owner's manual
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