Miller ANALOG 300 Owner's manual

Miller
Brand
Miller
Model
ANALOG 300
Category
Welding System
Type
Owner's manual

This manual is also suitable for

October
1973
FORM:
OM-215
Serial
No.
MODEL
ANALOG
300
W/E
LECTROSLOPE
W/PULSE
R
W/ELECTROSLOPE
&
PULSER
STOCK
NO.
901
408
901
410
901
417
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
OWNERS
MANUAL
~er
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
NWSA
CODE
NO.
4579
0.50.
CERTIFICATE
NAME
OF
EQUIPMENT:________________________
MODEL
NO.
SERIAL
NO.__._____________________________
DATE
This
equipment
has
been
type-tested
under
standardized
field
test
conditions
as
recommended
by
the
Joint
Industry
Committee
on
High
Frequency
Stabilized
Arc
Welding
Machines
found
to
rad
iate
less
than
10
microvolts
per
meter
at
a
distance
of
one
mile,
the
maximum
allowable
limit
established
by
the
Federal
Communications
Commission
for
equipment
of
this
type.
Installations
using
this
equipment
on
the
basis
of
these
tests,
may
reasonably
be
expected
to
meet
the
radiation
limitations
established
by
the
Federal
Communications
Commission,
only
when
in
stalled,
operated
and
maintained
as
specified
in
the
instruction
book
provided.
USERS
CERTIFICATION
The
welding
equipment
identified
above
has
been
installed
in
accordance
with
the
specific
in
structions
applicable
to
this
model
as
outlined
in
the
instruction
book
furnished.
It
is
being
used
only
for
the
purpose
for
whkh
it
was
intended
and
is
being
maintained
and
operated
in
accord-
once
with
the
manufacturers
instructions.
Date
lnstalled
SECTION
1-
SAFETY
RULES
FOR
OPERATION
OF
ARC
WELDING
MACHINE
1
-
1.
GENERAL
These
rules
apply
to
ac
and
dc
welding
generators,
ac
trans
former
and
ac/dc
welding
machines,
and
dc
transformer
recti
fier
welding
machines.
In
arc-welding
operations,
where
electrically
energized
parts
are
exposed,
observe
the
following
safety
rules
to
insure
max
imum
personal
safety
and
protect
nearby
persons.
Failure
to
observe
these
safety
precautions
may
expose
not
only
you,
but
fellow
workers
as
well,
to
serious
injuries.
Once
these
rules
are
learned
and
kept
in
mind,
proceed
with
maxi
mum
assurance.
1
-2.
WELDING
CABLES
DONT
overload
cables,
(Figure
1-1)
NEVER
use
welding
cables
at
currents
in
excess
of
their
rated
capacity.
It
will
cause
overheating
and
rapid
deterioration
of
the
insulation.
It is
also
uneconomical.
DONT
use
worn
or
poorly
connected
cables.
(Figure
1-2)
Inspect
the
cables
frequently.
Immediately
repair
all
breaks
in
the
insulation
with
rubber
and
friction
tapes.
Tighten
all
cable
connections
and
adequately
insulate
any
joints
where
a
connector
may
have
an
exposed
conductive
part.
In
addition
to
the
potential
hazard
to
life,
a
hazard
occurs
when
exposed
sections
of
cable
come
in
Contact
with
grounded
metallic
objects,
causing
an
arc.
Unprotected
eyes
may
be
injured
and
fire
may
result
if
combustible
materials
such
as
oil
or
grease
are
in
the
vicinity.
The
efficiency
and
quality
of
welding
will
be
improved
by
elimination
of
these
dangerous
grounds,
and
by
keeping
connections
tight.
1
-
3.
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
in
good
condition
to
provide
close
contact
with
the
electrodes.
Defective
jaws
will
permit
the
electrode
to
wob
ble,
making
control
of
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
of
the
electrode
lead
to
the
holder
tight
at
all
times.
Use
only
fully
insulated
electrode
holders
(and
without
pro
truding
screwheads.)
Never
touch
two
electrode
holders
from
two
separate
welding
machines
at
the
same
time.
1
-4.
CODE
CONFORMANCE
The
machine
and
its
equipment
must
be
installed
and
main
tained
in
accordance
with
the
National
Electrical
Code
and
local
requirements.
1
-5.
PARALLEL
CONNECTIONS
See
diagrams
in
the
instruction
manual
applying
to
the
weld
ing
machine
used.
1
-
6.
POWER
DISCONNECT
SWITCH
If
the
welding
machine
does
not
include
a
power
disconnect
switch,
install
one
at
or
near
the
machine.
1
-7.
POLARITY
SWITCH
DONT
operate
the
polarity
switch
under
load.
The
polarity
switch
(when
supplied)
is
provided
for
changing
the
electrode
lead
from
positive
(reverse
polarity)
to
negative
(straight
polarity).
Never
move
it
while
under
the
load
of
a
welding
current.
Operate
this
switch
Only
while
the
machine
is
idling
and
the
welding
circuit
is
open.
The
potential
dan
gers
of
opening
the
circuit
while
carrying
high
current
are:
1.
An
arc
will
form between
the
Contact
surfaces
of
the
switch
and
severely
burn
them.
2.
The
pers6n
throwing
the
switch
may
receive
a
severe
burn
from
this
arcing.
1-8.
RANGE
SWITCH
DONT
operate
the
range
switch
under
load.
The
range
switch
(when
supplied)
is
provided
for
obtaining
required
current
settings.
It
must
never
be
operated
while
the
machine
is
under
the
load
of
welding
current.
Operate
the
range
switch
only
while
the
machine
is
idling
and
the
welding
circuit
is
open.
The
potential
danger
of
switching
the
circuit
while
carrying
high
current
is
the
formation
of
an
arc
be
tween
the
contact
surface
which
will
severely
burn
them.
Repeated
occurrences
of
this
arcing
will
eventually
prevent
operation
of
the
contacts.
1
-
9.
EXHAUST
GASES
DONT
use
gas
engine
units
in
confined
spaces
without
vent
ing
the
exhaust
gases.
(Figure
1-4)
If
gasoline
or
other
fuel
driven
welding
machines
are
operated
indoors,
provide
means
to
pipe
the
exhaust
gases
to
the
Out
side
air
to
avoid
carbon
monoxide
poisoning.
Figure
1-1.
Dont
overload
cables
Figure
1-2.
Dont
use
worn
or
poorly
connected
cables
OM-215
Page
1
1-15.
SOLVENTS
Do
not
weld
where
chlorinated
hydrocarbon
vapors
from
de
greasing,
cleaning,
or
spraying
may
reach
or
be
drawn
into
air
surrounding
the
welding
operation.
The
heat
of
the
arc
can
decompose
solvent
vapors
to
form
phosgene,
a
highly
toxic
gas
and
other
irritating
decomposition
products.
Do
not
weld
where
ultraviolet
light
from
the
electric
arc
can
penefrate
air
containing
even
minute
amounts
of
vapors
from
solvents
such
as
trichloroethylene
or
perchloroethylene.
Ul
traviolet
light
can
decompose
the
vapors
to
form
phosgene,
a
highly
toxic
gas
and
other
irritating
products.
1-16.
FIRE
HAZARDS
DONT
weld
near
flammable
or
combustible
materials.
Fires
can
be
caused
by
the
arc,
by
Contact
with
the
heated
metal,
by
slag,
or
sparks.
Keep
combustibles
at
least
35
feet
from
the
arc
or
suitably
protected.
If
welding
must
be
done
in
a
particular
area,
move
the
combustibles
away.
If
they
cannot
be
moved,
cover
them
completely
with
fire
resistive
screens.
Cover
cracks
or
openings
in
floors
or
walls;
sweep
floor
free
of
combustibles
and
wet
down,
if
wood,
being
sure
welder
wears
insulation
shoe
coverings.
Avoid
welding
on
par
tition
walls
in
contact
with
combustibles,
Heated
metal
on
the
other
side
of
partition
wall
being
welded
upon
can
ignite
combustibles
in
contact
with
the
partition.
Where
other
than
a
minor
fire
might
develop,
have
a
fire
watcher
stand-by
with
suitable
fire
extinguishing
equipment
for
at
least
one-half
hour
after
the
welding
is
completed.
1-17.
ELECTRICAL
SHOCK-VOLTAGE
OPEN
power
circuits
before
checking
machines.
Before
working
on
the
wiring,
switches,
controls,
etc.,
open
the
power
line
disconnect
switch.
In
most
welding
shops
the
power
supply
used
for
arc
welding
machines
is
230
or
460
volts~
Open
circuit
voltages
are
usually
less
than
100
volts
and
welding
or
arc
voltage
drops
are
still
lower.
However,
all
of
these
voltages
are
capable
of
developing
a
harmful
or
fatal
current
to
the
body.
DONT
touch
electrically
hot
parts.
NEVER
touch
any
exposed
or
non-insulated
part
of
the
cables,
cable
connectors,
clamps,
electrode
holders,
elec
trodes,
or
the
power
supply
equipment
to
prevent
harmful
or
fatal
electric
shock
or
burns.
1-18.
ELECTRICAL
SHOCK-DAMPNESS
NEVER
work
in
a
damp
area
without
suitable
insulation
a
gainst
shock.
Keep
hands,
feet,
and
clothing
dry
at
all
times.
To.prevent
harmful
body
shocks,
keep
hands,
feet
and
cloth
ing
dry.
Never
stand
or
lie
in
puddles
of
water,
damp
ground,
or
against
grounded
metal
when
welding
without
suitable
in
sulation
against
shock.
Always
find
a
dry
board
or
rubber
mat
to
stand
on
when
water,
moisture,
or
perspiration
cannot
be
avoided.
Dampness
between
the
body
and
an
energized
or
grounded
metallic
part
lowers
the
resistance
to
the
passage
of
current
to
the
body
which
may
produce
a
harmful
or
fatal
shock.
Salt
in
perspiration
or
sea
water
dangerously
lowers
contact
resistances.
electrode
on
the
table
top
or
in
contact
with
a
grounded
metallic
surface.
(Figure
1-7)
When
it
is
not
in
use,
never
place
an
electrode
holder
in
contact
with
the
tabletop
or
other
metallic
surface
in
contact
with
welding
ground.
Provide
an
insulated
hook
or
holder
for
the
electrode
holder.
A
potential
danger
is
that
a
holder
in
contact
with
the
ground
circuit
provides
a
dead
short
circuit
on
the
welding
machine.
If
the
machine
should
be
started
up,
this
short
circuit
would
cause
an
excessive
load
on
the
ma
chine
and
may
damage
the
insulation.
1-20.
FACE
PROTECTION
DONT
use
cracked
or
defective
helmets
or
shields.
Keep
the
helmet,
hand
shields,
or
face
shield
in
good
condi
tion.
If
cracks
occur
in
the
fibre
material,
replace
the
shield,
since
the
leakage
of
arc
rays
may
cause
serious
burns.
1-21.
EVE
PROTECTION
NEVER
under
any
circumstances,
look
at
an
electric
arc
without
eye
protection.
I
Figure
1-8.
Use
eye
protection
at
all
times
CAUTION
I
Make
sure
that
flash
goggles
are
used
under
the
weld
ing
helmet
at
all
times,
particularly
while
gas
shielded-
arc
welding.
In
some
type
of
arc
welding,
such
as
gas
shielded-arc
welding,
ultra-violet
and
infra-red
radiation
from
the
arc
is
particularly
intense
and
requires
constant
attention
to
avoid
arc
flashes
to
the
welder
when
striking
an
arc
and
tq
avoid
exposure
to
other
welders.
NEVER
strike
an
arc
without
ascertaining
that
nearby
per.
sons
either
have
the
necessary
protective
equipment
or
are
looking
in
the
opposite
direction.
For
welding
operations
in
open
areas,
provide
portable,
non-
ref
lecting
screens
to
shield
persons
nearby
from
the
rays
of
the
arc.
Eye
burns
from
the
arc,
through
not
generally
per
manent
injuries,
are
exceedingly
painful.
Such
burns
fre
quently
referred
to
as
flashes,
feel
like
hot
sand
in
the
eye.
If
the
eye
is
focused
on
the
arc
without
filter-glass
protec
tion,
infra-red
radiation
can
cause
retinal
scarring
and
im
paired
vision.
For
eye
burns
consult
your
first
aid
station
or
doctor.
NEVER
use
cracked,
ill-fitting,
or
defective
plates.
The
filter
glass
plate
provided
in
the
helmets
and
shields
must
be
of
reputable
manufacture
conforming
to
the
latest
Ameri
can
National
Standards
Institute,
Standard
Z2.1.
Replace
cracked
or
ill-fitting
filter
plates
promptly.
NEVER
use
filter
plates
without
a
protecting
cover
glass.
I
I
Figure
1-7.
Dont
leave
electrode
in
contact
with
grounded
metallic
surface.
1-19.
STARTING
UNDER
LOAD
DONT
leave
an
uninsulated
electrode
holder,
or
a
live
OM-215
Page
3
Whenever
it
is
necessary
to
grind
or
chip
metal,
wear
protec
tive
goggles
specifically
designed
for
this
purpose.
Serious
eye
injuries
may
result
from
failure
to
wear
protective
goggles.
1-25,
COMPRESSED
GAS
CYLINDERS
NEVER
strike
an
arc
on
a
compressed
gas
cylinder.
Always
observe
the
following
precautions
in
regards
to
compressed
gas
cylinders:
1.
Avoid
accidental
contact
of
the
electrodes,
electrode
holder,
or
other
electrically
energized
parts
with
a
compressed
gas
cylinder
or
any
other
pressure
vessel.
Serious
accidents
or
fires
may
result.
2.
Use
I
.C~C.
or
DOT.
cylinders.
They
are
manufactured
and
maintained
in
accordance
with
DOT.
require
ments
and
are
safe
so
long
as
they
are
properly
h~dIed.
Dont
drop
cylinders.
3.
Identify
gas
content
by
the
name
marked
on
the
cylin
der.
If
the
cylinder
is
unmarked,
do
not
use
it.
Return
it
to
the
supplier.
Do
not
rely
ona
color
code.
4.
Never
use
a
cylinder
or
its
contents
for
other
than
intended
purposes.
5.
Keep
oil
and
grease
away
from
oxygen
cylinders
and
cylinder
valves.
6.
Keep
cylinders
away
from
exposure
to
sparks,
hot
slag,
open
flame
and
all
possible
sources
of
ignition
or
excessive
heat.
7.
Be
careful
that
cylinders
are
not
placed
so
as
to
be
come
a
part
of
an
electrical
circuit.
Avoid
third
rails,
wires
and
electric
welding
circuits.
8.
When
transporting
cylinders
by
crane,
use
cradle
plat
form
or
other
suitable
support.
9.
Never
lift
the
cylinders
by
slings,
by
the
caps
or
by
electric
magnets.
Never
use
cylinders
as
supports
or
rollers.
Keep
a
clean
cover
glass
in
front
of
the
filter
plate
for
the
protection
thereof.
Frequent
renewal
of
these
cover
glasses
is
necessary,
since
they
become
covered
with
spatter,
reducing
vision.
1-22.
CLOTHING
NEVER
use
poor,
inadequate,
or
worn-out
clothing.
Wear
heavy
shoes,
tightly
laced.
Keep
clothing
dry.
Proper
and
dry,
oil-free
clothing
is
essential
for
the
welders
protection.
Clothing
must
not
only
keep
,off
the
spatter
and
molten
particles,
but
must
also
obstruct
the
rays
of
the
arc
and,
when
necessary,
insulate
the
body
from
harmful
electri
cal
currents.
Wear
leather
or
asbestos
gloves
at
all
times
to
protect
the
hands
and
w~ists.
Dark
colored
shirts
are
preferred
to
light
ones
because
light
ones
reflect
arc
rays
to
exposed
parts
of
the
body.
In
the
case
of
gas
shielded-arc
welding,
light
colors
are
more
reflective
and
may
cause
eye
burns
due
to
the
in
tense
ultra-violet
rays
given
off
by
the
process.
Avoid
cotton
fabrics
when
gas
shielded-arc
welding.
An
arc
burn
on
the
skin
resembles
a
sunburn,
except
that
it
is
usually
more
severe.
Clothing
can
be
made
flame
resistant
by
treatment
with
a
solution of
3/4
pound
of
sodium
stannate
in
1
gallon
of
water,
then
wrung
out
and
dipped
in
a
solution
of
1/4
pound
ammonium
sulphate
per
gallon
of
water.
Dont
wash
clothing
so
prepared
in
water,
but
dry
clean.
When
welding
operations
are
to
be
performed
in
vertical
and
overhead
positions,
leather
sleevelets,
aprons,
and
in
some
cases
leggings
and
ear
plugs
should
be
used
to
prevent
severe
burns
from
spatter
and
molten
metal.
1-23.
HOT
METAL
BURNS
NEVER
pick
up
hot
objects.
(Figure
1-9)
Figure
1-9.
Never
pick
up
hot
objects
NEVER
pick
up
pieces
of
metal
which
have
just
been
welded
or
heated,
or
the
stub
ends
of
electrodes
which
have
been
discarded.
1-24.
GRINDING
AND
CHIPPING
NEVER
do
any
chipping
or
grinding
without
protective
goggles.
(Figure
1-10)
10.
11.
Never
try
to
mix
any
gases
in
a
cylinder.
12.
Never
try
to
refill
a
cylinder.
13.
Mark
or
tag
empty
cylinders
Empty
or
MT.
14,
Send
Emptys
back
to
the
supplier
promptly.
15.
15.
Keep
Emptys
and
Fulls
separate.
16.
Never
tamper
with
or
alter
cylinder
numbers
or
other
markings.
This
is
not
only
foolish
but
may
be
illegal.
17.
Do
not
tamper
with
or
change
fittings
on
cylinders.
18.
If
valves
cannot
be
opened
by
hand,
do
not
use
ham
mer
or
wrench,
N.~otify
supplier.
19.
Protect
cylinder
valves
from
bumps,
falls,
falling
ob
jects,
and
from
weather,
Keep
them
covered
with
cylinder
caps
when
moving
cylinders.
20.
Keep
valves
closed
on
empty
cylinders.
21.
See
that
your
cylinders
are
clear
of
passageways
and
active
work
areas
and
that
they
are
secured
against
falling.
22.
If
adapter
is
required
between
cylinder
and
regulator,
always
use
a
standard
adapter.
These
may
be
obtained
from
your
supplier.
Where
right
and
left
hand
threads
are
used
on
adapter,
use
two
wrenches
to
insure
leak
proof
connections.
23.
Do
not
store
cylinders
in
unventilated
areas.
Figure
1-10.
Never
do
any
chipping
or
grinding
without
protective
goggles.
Page
4
SECTION
2-
INTRODUCTION
2-1.
GENERAL
This
manual
has
been
prepared
especially
for
use
in
familiarizing
personnel
using
this
equipment,
with
the
Design,
Installation,
Operation
and
Maintenance
of
the
welding
machine.
In
some
cases
the
contents
of
this
manual
are
generalized.
All
information
con-
cerning
this
equipment
should
be
given
careful
con
sideration
to
assure
the
best
performance
of
the
welding
machine.
2-2.
RECEIVING-HANDLING
To
prepare
the
welding
machine
for
installation,
several
items
should
be
checked.
Clean
all
pack
ing
material
from
around
the
unit
and
carefully
in
spect
for
damage
that
may
have
been
caused
by
ship
ping.
Any
claims
for
loss
or
damage
that
may
have
occured
in
transit
must
be
filed
by
the
buyer
with
the
carrier.
Copy
of
bill
of
lading
and
freight
bill
will
be
furnished
on
request
if
occasion
to
file
claim
arises.
Be
sure
to
read
all
the
instructions
before
at
tempting
to
operate
the
welding
machine.
When
requesting
information
concerning
the
weld
ing
machine,
be
sure
to
furnish
serial,
stock,
and
model
numbers.
2-3.
DESCRIPTION
-
This
welding
machine
is
designed
to
serve
as
the
power
source
for
the
Gas
Tungsten
-
Arc
Welding
(GTAW)
process.
This
holds
true
regardless
of
the
control
module
the
welding
machine
is
equipped
with.
The
principle
components
making
up
this
welding
machine
are
a
three
phase
main
weld
transformer,
six
woundcore
control
reactors,
conversion
recti
fiers,
and
various
control
circuits.
In
addition,
a
separate
regulated
power
supply
is
built
into
the
welding
machine
to
furnish
regulated
power
to
the
control
circuits.
The
effects
of
line
voltage
fluctuations
on
the
weld
current
output
are
eliminated
through
the
use
of
an
electronic
closed-loop
feedback
system.
The
design
of
this
welding
machine
ensures
a
true
constantcurrent
welding
power
source.
The
weld
ing
machines
weld
current
output
is
controlled
by
a
multiturn
potentiometer.
This
potentiometer
se
lects
a
value
of
reference
voltage
and
feeds
it
into
the
control
amplifiers
which
drive
the
magnetic
amplifiers.
The
magnetic
amplifiers
in
turn
control
the
weld
current
appearing
at
the
electrode.
The
fan
motor
operates
at
a
low
or
high
speec.
When
the
welding
machine
is
Idling
or
being
used
for
light
work,
the
fan
motor
will
operate
at
low
speed.
When
internal
components
of
the
welding
machine
heat
up
to
a
certain
temperature,
the
fan
motor
runs
at
high
speed
for
better
cooling.
After
the
components
have
cooled,
the
fan
motor
auto
matically
returns
to
low
speed.
The
Pulse
Control
is
designed
to
furnish
a
signal
to
the
welding
machine
control
circuit
which
creates
a
pulsing
type
weld
current.
Various
controls,
lo
cated
on
the
control
panel,
are
provided
to
control
-
the
background
current,
peak
current
(pulse
am
plitude),
pulse
frequency
and
pulse
duty
ratio
(on
time).
All
inter-connecting
circuitry
between
the
pulse
control
and
the
welding
machine
is
factory
wired.
A
switch,
located
on
the
control
panel,
is
provided
to
turn
the
pulse
control
module
on
or
off.
Electroslope
provides
a
means
of
controlling
the
Weld
Current
at
the
Start
and
Finish
of
the
weld.
These
controls
are
adjustable,
which
means
the
operator
can
choose
a
setting
that
is
best
suited
for
the
particular
welding
condition.
2-4.
SAFETY
Before
attempting
to
make
primary
or
second
ary
connections,
change
parts
or
make
repairs,
be
sure
the
welding
machine
is
completely
dis
connected
from
the
main
power
line.
If
it
should
become
necessary
to
perform
live
voltage
troubleshooting
on
the
control
unit
or
weld
ing
machine,
take
all
necessary
precautions
to
avoid
chances
of
electrical
shock.
It
is
a
very
good
idea
when
doing
live
circuit
troubleshooting
to
have
a
second
person
present
In
case
the
person
doing
the
troubleshooting
should
require
aid.
When
checking
capacitors
and
their
associated
circuitry,
inake
sure
they
are
fully
discharged
be
fore
coming
into
contact
with
bare
leads
or
con
nections.
Always
keep
all
panels
and
the
cover
In
place
when
the
welding
machine
is
being
used.
If
they
are
not
in
place,
a
component
cooling
problem
exists,
besides
being
a
safety
hazard.
The
following
definitions
apply
to
Cautions,
Im
portants
and
Notes
found
throughout
this
manual.
Installation,
operating,
and
maintenance
proc
ed
ures,
practices,
etc.,
which
will
result
in
person
nel
injury
or
loss
of
life
If
not
carefully
followed.
I
I
ITANT
-F
rri
Installation,
operating,
and
maintenance
proc
ed
ures,
practices,
etc.,
which
it
Is
essential
to
em
phasize.
I
WELDING
RATED
MAX.
OPEN
POWER
INPUT
AT
RATED
LOAD
CURRENT
WELDING
CURRENT
CIRCUIT
THREE
PHASE
60
Hz
RANGE
@
15
VOLTS
VOLTAGE
AMPERES
DIMENSIONS
WEIGHT
MODEL
AMPERES
100%
DUTY
CYCLE
dc
208
V
230
V
460
V
kw
kva
HEIGHT
WIDTH
DEPTH
NET
SHIPPING
300
AMP
3
To
300
300
85
121
115
57
11.5
45.9
38-1/2
23-1/2
42
lOl4Ibs.
1114
:bs:
Figure
2-1.
Specifications
I
Installation,
operation,
and
maintenance
proced
ures,
practices,
etc.,
which
will
result
In
damage
to
equipment,
I
I
I
I
OM-215
Page
5
SECTION
3
-
INSTALLATION
3-1.
LOCATION
A
good
installation
is
essential
if
thewelding
ma
chine
is
to
provide
satisfactory
and
dependable
ser
vice,
Proper
component
operating
temperatures
are
maintained
by
the
air
stream
produced
by
the
weld
ing
machine
fan.
Therefore,
the
welding
machine
should
be
located
so
that
the
air
passage
into
the
welding
machine
is
not
restricted
and
the
back
of
the
welding
machine
is
away
from
the
wall
(18
inches
minimum
distance)
so
that
the
air
passage
from
the
fan
will
not
be
blocked.
The
location
should
be
such
that
a
minimum
a-
mount
of
dirt
or
dust
will
be
drawn
into
the
air
stream.
Preventive
maintenance
will
consist
of
re
moving
the
cover
and
blowing
out
the
dust
accumu
lation
Inside
the
welding
machine.
For
this
reason
it
is
desirable
to
locate
the
unit
so
that
the
cover
can
be
removed.
Figure
3-1.
Dimensional
Drawing
3-2.
HIGH
FREQUENCY
RADIATION
The
Federal
Communications
Commission
has
established
certain
radiation
limits
that
must
be
High
frequency
has
certain
undesirable
character
istics
which
should
be
eliminated
or
at
least
mini
mized.
Any
electrical
equipment
utilizinghighfre
quency
energy
in
any
way
is
capable
of
radiating
in
terference
if
not
properly
installed.
Since
the
Arc
Starter
Unit
is
a
basic
type
of
radio
transmitter,
It
may
cause
interference
with
reception
of
nearby
radio
units.
It
is
recommended,
therefore,
that
a
maximum
of
protection
be
provided
to
arrest,
as
much
as
possible,
leakage
of
radiation.
maintained
in
order
to
comply
with
legal
operating
requirements.
The
manufacturer
of
the
equipment
covered
in
this
manual
has
conducted
approved
field
tests
on
this
model
and
certified
at
the
front
of
this
manual,
that
radiation
can
be
expected
to
be
within
the
legal
li
mits
if
correct
installation
procedures
are
followed
as
outlined
in
the
HIGH
FREQUENCY
CERTIFICA
TION
section
in
the
back
of
this
manual.
The
importance
of
a
correct
installation
cannot
be
overemphasized
since
case
histories
of
inter
ference
due
to
high
frequency
stabilized
arc
welding
machines
have
shown
invariable
that
inadequate
in
stallation
was
at
fault.
3-3.
PRIMARY
POWER
CONNECTIONS
(Figure
3-2
&
3-3)
This
dc
arc
welding
machine
is
a
three
phase
unit
and
must
be
connected
to
a
three
phase
power
line.
The
standard
primary
voltage
requirements
of
the
welding
machine
are
208,230,
or
460
volts,
60
hertz.
The
welding
machine
should
be
operated
from
a
separately
fused
or
circuit
breaker
protected
cir
cuit.
Lift
the
lower
rear
panel
to
make
primary
power
connections.
The
primary
input
voltage
con
nection
board
is
directly
behind
this
panel.
Con
sult
Table
3-1
for
recommended
primary
power
and
ground
cable
sizes
for
the
primary
voltage
which
will
be
used.
Table
3-1
also
indicates
the
fuse
size
to
use
in
the
line
Disconnect
Box
for
the
line
voltage
that will
be
used.
Enclose
the
primary
power
leads
between
the
Line
Disconnect
Box
and
the
welding
machine
In
a
solid
or
flexible
metallic
con
duit.
This
is
necessary
to
help
eliminate
high
fre
quency
radiation.
Figure
3-2.
Primary
Power
Connections
TABLE
3-1.
Recommended
Primary
Wire
And
Fuse
Sizes
PRIMARY
WIRE
SIZE-
AWG
FUSE
SIZE
IN
AMPS
208
V.
230
V.
460
V-
208
V.
230
V.
460
V.
No.
1
(No.6)
No.2
(No.6)
No.6
(No.8)
200
175
90
Numbers
in
(
I
are
ground
wire
sizes.
Connect
the
primary
cables
to
terminals
Li,
L2
and
L3.
A
fourth
lead,
ground
connection,
should
be
fastened
to
the
stud
on
the
base
of
the
welding
ma-
23.1/2
AA-901
0941
WeLDING
MACHINE
Ir
AA-990
505-2
I
I-
Page
6
chine
located
directly
below
the
primary
terminal
board.
It
is
recommended
that
the
ground
lead
al
ways
be
connected
first.
The
stud
labeled
GRD
is
connected
to
the
welding
machine
chassis
and
is
forgroundingpurposes
only.
Do
not
connect
a
wire
from
the
terminal
labeled
GRD
or
GB
to
one
of
the
three
phase
line
terminals
as
this
may
result
in
an
electrically
hot
welding
machine
chassis.
00
00
OO~
0
0
OO(~j~
00
460
Volts
&
'Lt
~L2
'L~fl~jfl
Figure
3-3.
Primary
Voltage
Jumper
Link
Arrangement
The
copper
jumper
links
on
the
primary
board
must
be
in
the
position
to
match
the
line
voltage
being
used.
Figure
3-3
shows
jumper
link
posi
tions
for
the
three
standard
primary
voltages.
Welding
machines
are
shipped
from
the
factory
with
the
copper
jumper
links
in
the
position
for
the
high
est
line
voltage
the
unit
is
designed
for.
In this
case
it
would
be
the
460
volt
position.
Thus,
if
the
line
voltage
that will
be
used
to
power
this
weld
ing
machine
is
either
208
or
230
volts,all
the
jump
er
links
on
the
primary
board
must
be
placed
in
the
position
indicated
for
208
or
230
volts
operation.
3-4.
SECONDARY
WELDING
CONNECTIONS
It
is
recommended
that
the
welding
cables
be
kept
as
short
as
possible,
placed
close
together-
TABLE
3-2.
Recommended
Secondary
Cable
Size
WELDING
AMPERES
TOTAL LENGTH
OF
CABLE
COPPE~
IN
WELD
CIRCUIT
50
100
150
200 250 300 350
400
100
150
200
250
300
350
4
2
1
1/0
2/0
3/0
4
2
1
1/0
2/0
3/0
2
2
2
1
1
1/0
1/0
2/0
2/0 3/0
2/0
4/0
2
1/0
2/0
3/0
4/0
4/0
1
2/0
3/0
4/0
4/0
2-2/0
1(0
3/0
4/0
4/0
2-2/0
2-3/0
1/0
3/0
4/0
2-2/0
2-3/0
2-3/0
and
be
of
adequate
current
carrying
capacity.
The
resistance
of
the
welding
cables
and
connection
cause
a
voltage
drop
which
is
added
to
the
voltage
of
the
arc.
Excessive
cable
resistance
may
result
in
overloading
as
well
as
reducing
the
maximum
current
output
of
which
the
welding
machine
is
ca
pable.
The
proper
operation
of
any
arc
welding
machine
is
to
a
great
extent
dependent
on
the
use
of
welding
cables
and
connections
that
are
in
good
condition
and
of
adequate
size.
An
insulated
holder
must
be
used
to
ensure
welders
safety.
3-5.
GAS
AND
WATER
CONNECTIONS
(Figure
3-4)
The
gas
and
water
valves,
located
behind
the
lower
front
panel
door,
provide
on-off
control
of
gas
and
water
to
the
torch.
The
gas
valve
fittings
have
right
hand
threads,while
the
water
fittings
have
left
hand
threads.
If
a
recirculating
type
of
water
cooling
system
is
used,
do
not
connect
the
system
through
the
water
valve
as
damage
may
occur
to
the
motor
of
the
cool
ant
system
because
the
water
valve
will
shut
off,
thus
blocking
the
water
flow.
3-6.
REMOTE
CURRENT CONTROL
RECEPTACLE
AND
SELECTOR
SWITCH
(Figure
3-4)
The
remote
current
control
receptacle
and
STAN
DARD-REMOTE
switch,
located
behind
the
lower
front
access
door,
above
the
hinge,
provides
a
con
nection
point
to
connect
and
use
a
remote
current
control
such
as
the
optional
RFCE-31
foot
control
(1000
ohm).
The
STANDARD-REMOTE
switch
is
labeled
ac
cordingly
with
the
REMOTE
position
being
used
when
an
external
current
control
is
connected
to
the
re
ceptacle.
The
STANDARD
position
must
be
used
when
all
current
control
is
controlled
at
the
weld
ing
machine.
When
a
remote
current
control
is
being
used,
It
will
operate
as
a
fine
current
control
function
of
all
the
welding
machines
current
control
settings.
3-7.
START
(CONTACTOR)
CONTROL
RECEPTACLE
(Fig
ure
3-4
&
3-5)
The
Start
(contactor)
Control
Receptacle,
a
two
prong
twistlock,
Is
located
next
to
the
amperage
control
receptacle
under
the
lowerfrontpaneldoOr.
A
normally
open
(N.O,)
switch
is
usually
connected
to
this
receptacle
in
order
to
control
the
onoff
weld
power
via
the
primary
contactor.
When
the
GTAW
MANUAL
mode
Is
being
used
and
the
contactor
control
switch
Is
connected
to
this
re
ceptacle,
closing
the
switch
will
start
the
manual
weld
sequence
with
on-off
control
of
weld
current
being
controlled
by
this
switch.
This
receptacle
Is
recommended
for
contactor
control
only
when
the
GTAW
MANUAL
mode
is
being
used.
When
the
GTAW
AUTO
models
being
used,
the
Re
mote
Program
start
and
stop
control
should
be
con
nected
to
the
Remote
Control
Terminal
Block
2T,
which
is
explained
in
paragraph
3-9.
3-8.
115
VOLT
AC
RECEPTACLE
(Figure
3-4)
115
volts
ac,
60hertz,isavailableatthis
3
prong,
duplex
receptacle
located
under
the
lower
frontac
cess
door
panel.
The
circuit
is
protected
by
a
5
ampere
circuit
breaker.
I
I
~O0~
~oo(~
208
Volts
~
o~1
'L2
OL3~fl
0~0
0~0.o~0
230
Volts
G~.
~Li_~L2
____
AA-901094-6
NOTE:
A.
B.
.C.
50
FEET
OR
LESS
AA-901
18110
CABLE
SIZE
IS
BASED
ON
DIRECT
CURRENT
(OCI.I00%
DUTY
CYCLE
AND
EITHER
A
4
VOLTS
OR
LESS
DROP OR
A
CURRENT
DENSITY
OF
NOT
OVER
-300
CIRCULAR
MILS
PER
AMP.
WELD
CABLE
INSULATION
WITH
A
VOLTAGE
RATING
TO
WITH
STAND
THE
OPEN
CIRCUIT
VOLTAGE
(O.C.V.)
OF THE
WELD
ING
MACHINE
MUST
BE
USED.
WHILE
MOST
WELDING
MA
CHINES
HAVE
AN
OPEN
CIRCUIT
VOLTAGE
OF
LESS
THAN
100
VOLTS.
SOME
WELDING
MACHINES
OF
SPECIAL
DESIGN
MAY
HAVE
HIGHER
OPEN
CIRCUIT
VOLTAGE.
OM-215
Page
7
3-9.
REMOTE
CONTROL
TERMINAL
BLOCK
2T
(Figure
3-4
&
3-5)
This
terminal
block,
located
behind
the
lower
front
panel
door,
provides
remote
control
connec
tion
points
for
control
of
the
various
welding
machine
functions.
The
types
of
connections
are
as
follows:
1.
B
emote
Start
(Contactor)
Control
B
emote
Start
control
using
a
normally
open
(N.O.)
switch
is
obtained
by
connecting
the
switch
between
terminals
No.
1
and
No.
113
of
the
terminal
block.
2.
B
emote
Emergency
Stop
Control
(Not
available
in
Pulser
only
model)
En
order
to
extinguish
the
arc
when
in
the
GTAW
AUTO
mode
of
operation
a
normally
closed
momen
tary
contact
switch
must
be
connected
between
ter
minals
122
&
1
of
terminal
strip
2T.
Once
the
arc
has
been
established
in
the
GTAW
AUTO
mode
it
cannot
be
extinguished
until
this
contact
is
opened.
The
factory
installed
jumper
link
between
terminals
No.
1
and
122
must
be
removed
when
Bemote
Stop
Control
is
being
used.
3.
Bemote
Upslope
&
Downslope
Control
(Electro
slope
Models
Only)
A
momentary
contact,
single
pole,
double
throw,
center
off
switch
connected
to
terminal
strip
2T
will
provide
remote
upslope
and
downslope
control.
The
center
pole
from
the
switch
connects
to
terminal
120,
the
upslope
terminal
from
the
switch
to
terminal
72,
and
the
downslope
terminal
from
the
switch
to
ter
minal
107.
TERMINAL
STRIP
2T
SPECIAL
1000
OHM
CURRENT
CONTROL
CONTACTOR
CONTROL
AA-901
094-2
Single
pole
(normally
open)
Micro
Switches
or
re
mote
pushbuttons
can
also
be
used.
To
trigger
into
upslope,
connect
a
normally
opensetofcontactsbe
tween
120
and
72.
To
trigger
into
downslope,
close
between
120
and
107.
If
it
is
desired
to
go
directly
from
arc
start
into
upslope
with
no
hold
at
the
initial
current
level
(no
preheat),
connect
a
jumper
permanently
from
120
to
72.
Auxiliary
(extra
cost)
controls,
such
as
the
FDT
15
fixture
delay
timers
and
the
PB
C-i
pendant
con
trol
also
connect
to
the
2T
terminal
strip.
See
in
structions
supplied
with
these
controls
for
their
particular
connection
and
operation.
713
719
7
722125120
7210736123
219
~~-*.X
r1
16,6
I
ii
IUPIDN,
i
I
$REMOTE
SLOPE
/
L_....4..J
L_
REMOTE
REMOTE
START
EMERG.
STOP
-
(REMOVE
LINK
~.BETWEEN
18122
Figure
3-5.
Terminal
Strip
2T
Connections
SECTION
4-.
OPERATION
m
4-1.
POWER
ON-OFF
SWITCH
AND
PILOT
LIGHT
(Figure
4-1,
4-2
&
4-3)
The
power
switch
controls
line
power
to
the
fan
motor
and
control
circuitry
of
the
welding
machine.
Turning
the
power
switch
ON
will
start
the
fan
motor
and
energize
control
circuits
placing
the
STANDARD-REMOTE
CURRENT
CONTROL
SWITCH
GAS
ELECTRODE
VALVE
WORK
Figure
3-4.
Lower
Front
Panel
Component
Location
I
Paragraphs
4-i
thru
4-6
apply
to
all
models
cover
ed
in
this
manual.
Page
8
welding
machine
in
a
ready
status.
The
pilot
light,
next
to
the
power
switch,
indicates
whenthecontrol
circuits
are
energized.
4-2.
BACKGROUND
(WELD)
CURRENT
CONTROL
(Fig
ure
4-1,
4-2
&
4-3)
The
term
Background
Current
Control
is
used
when
the
welding
machines
control
panel
is
equipped
with
Pulser
Controls.
On
welding
machines
without
the
Pulser
Controls
it
is
called
the
weld
Current
Control.
Regardless
of
the
type
of
welding
machine
panel,
it
controls
the
weld
current
level
in
all
modes
of
operation
with
a
range
extending
from
the
minimum
to
maximum
output
of
the
welding
machine.
In
welding
machines
equipped
with
Pulser
Con
trols,
this
control
is
usually
used
to
set
the
lower
or
background
level
in
the
pulsing
output
sequence.
It
reads
directly
in
amperes,
3
to
300.
If
a
remote
amperage
control
station
is
used,
the
Background
(Weld)
Current
Control
will
deter
mine
the
maximum
output
of
the
welding
machine
with
the
remote
control
operating
between
the
mini
mum
output
of
the
welding
machine
and
the
setting
of
the
Background
(Weld)
Current
Control.
4-3.
STARTING
CURRENT
SELECTOR
SWITCH
(Figure
4-1,
4-2
&
4-3)
In
addition
to
the
high
frequency
ON-OFF
switch
located
under
the
front
access
door,
there
is
an
in
dependent
Start
Current
Selector
Switch
on
the
front
panel.
It
is
a
three
position
toggle
switch
which
should be
set
according
to
conditions
at
the
torch.
The
OFF
and
1
positions
are
generally
used
with
small
diameter
electrodes,
and
the
2
position
with
large
diameter
electrodes.
The
functions
of
the
three
positions
are
as
fol
lows:
1.
OFF
-
Recommended
for
argon
gas
and
all
size
electrodes.
In
this
position
the
high
frequency
(if
turned
on)
Ignites
the
arc
at
the
initial
cur
rent
setting.
No
additional
starting
pulse
is
pro
vided.
2.
No.
1
-
Recommended
for
argon
or
helium
and
.010
inch
through
.040
inchdiameterelectrodes.
Provides
a
25
ampere
pulse
of
start
currentfor
1/6
second
(10
cycles).
3.
No,
2
-
Recommended
for
helium
and
1/16
inch
diameter
and
larger
electrodes.
Provides
a
50
ampere
pulse
of
start
current
for
1/6
second
(10
cycles).
In
this
position
the
normal
3
am
pere
minimum
current
of
the
machine
is
raised
to
25
amperes
so
as
to
adequately
sustain
the
arc
with
larger
electrodes.
4-4.
HIGH
FREQUENCY
OFF-START
SWITCH
(Figure
3-4)
High
frequency
appears
at
the
electrode
1/4
sec
ond
after
the
welding
machines
primary
contactor
is
closed
if
the
High
Frequency
Switch
is
in
the
START
position,
The
high
frequency
remains
on
tintil
the
arc
is
established
at
which
time
it
auto
matically
turns
off.
The
OFF
position
prevents
high
frequency
opera
tion.
The
High
Frequency
OFF-START
switch
is
lo
cated
behind
the
lower
front
access
door
and
is
la
beled
accordingly.
4-5.
METERS(Figure4-1,4-2&4-3)
The
welding
machine
is
equipped
with
a
dc
am
meter
and
a
dc
voltmeter,
These
meters
are
in
ternally
connected
to
the
welding
machine
output
welding
terminals.
The
voltmeter
will
indicate
the
dc
voltage
at
the
terminals,butdoes
not
necessarily
indicate
the
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
machine
ter
minals
may
be
considerable,
For
best
results
al
ways
keep
the
welding
cables
short
and
of
ample
size
to
carry
the
welding
current,
All
connections
in
the
welding
circuit
should
be
clean
and
tight
and
under
no
circumstances
should
the
welding
current
be
conducted
through
a
bearing
of
any
type.
The
panel
ammeter
included
with
this
machine
is
a
(–)
2
per
cent
(frill
scale)
instrument,
This
is
the
meter
manufacturers
guarantee.
When
new,
they
are
generally
more
accurate,
However,
if
welding
(or
setting
up)
at
the
low
current
end,
at
10
amperes
for
instance,
the
meter
reading
could
be
as
much
as
6
amps
off,
either
way.
(2
per
cent
of
300
amps)
The
digital
dial
on
the
other
hand
is
considerably
more
accurate
especially
at
the
low
end.
The
weld
ing
machines
current
should
be
within
lper
cent
or
1
ampere
(whichever
is
greater)
of
the
dial
setting.
Thus
if
the
digital
dial
is
set
to
10
amperes
the
weld
current
output
will
be
within
(–)
1
ampere.
It
becomes
obvious
that
the
digital
dials
should
always
be
trusted
as
more
accurate
than
the
panel
ammeter,
a
simple
rule
of
thumb
is
this:
Up
to
100
amps,
accuracy
is
(–)
1
amp.
Above
100
amps,
accuracy
Is
(–)
1
per
cent,
In
practice,
it
is
found
that
dial
accuracy
Is
even
more
accurate
than
the
specified
1
per
cent,
Production
tests
include
factory
calibration
using
1/2
per
cent
laboratory
quality
instruments,
A.
Recorder
Jacks
Near
each
meter
is
a
set
of
red and
black
test
jacks.
These
can
be
used
to
supply
signals
repre
senting
arc
current
and
terminal
voltage
to
remote
chart
recording
instruments.
See
schematic
dia
gram.
Although
these
outputs
are
equipped
with
R
,F,
chokes,
care
should be
taken
when
connecting
to
the
inputs
of
sensitive
instruments,
Notethatthenega
tive
(black)
post
of
the
current
signal
Is
electrically
common
with
the
positive
(red)
post
of
the
voltage
signal,
This
signal
should
be
investigated
when
using
a
common
-
chassis
Input
multi-channel
re
corder,
The
current
signal
output
Is
Oto
50
millIvolts
d.c.
and
the
voltage
signal
output
is
0
to
85
VDC,
P50
and
P51
represent
the
R,F,
filters,
The
use
of
a
low
input
Impedence
recorder
or,a
second
(remote)
ammeter
connected
to
the
ampere
recorder
jack
will
throw
the
panel
ammeter
out
of
calibration
while
in
the
SET-UP
Mode,
4-6.
POST-FLOW
TIMER
(Figure
3-4)
The
post-flow
timer
determines
how
long
gas
and
water
will
flow
after
the
weld
is
completed.
The
purpose
of
having
a
post
(after)
flow
of
gas
after
the
weld
Is
completed,
is
to
allow
the
tungsten
elec
trode
to
cool
in
an
inert
atmosphere
which
will
pre
vent
contamination
of
the
electrode.
It
Is
recom
mended
that
about
10
seconds
of
postflow
time
be
used
for
every
100
amperes
of
weld
current,
OM-215
Page
9
Figure
4-2.
Control
Panel
View
For
Models
With
Electroslope
Controls
Only
AA-901
410-1
AA-901
417-2
AA.901
417-2
Figure
4-3.
Control
Panel
View
For
Models
With
Electroslope
&
Pulser
Controls
Figure
4-1.
Control
Panel
View
For
Model
With
Pulser
Controls
Only
Page
10
4-7.
OPERATION
OF
WELDING
MACHINE
WITH
PULSE
CONTROL
In
GTAW
(Tig)
welding,
pulsing
refers
to
the
alternate
raising
and
lowering
of
the
main
weld
cur
rent
at
a
periodic
rate.
The
raised
portions
of
the
weld
current
are
controlled
in
width
and
height,
and
frequency,
forming
pulses
of
weld
current.
These
pulses
and
the
lower
current
level
between
them
(called
the
background
current)
alternately
heat
and
chill
the
moltenweldpuddle.
The
combined
effect
gives
the
operator
better
control
of
penetra
tion,
bead
width,
crowning,
and
undercutting,
and
puddle
slag
in
out
of
position
welding,
specifically
vertical
up.
The
pulsing
feature
can
be
utilized
either
alone
or
in
conjunction
with
electroslope
if
the
machine
is
so
equpped.
A.
Pulse
Width
(Percent
ON
Time)
Control
(Figure
4-1
&
4-3)
The
Pulse
Width
Control
regulates
how
long
the
pulse
current
will
be
on
during
one
pulse
cycle.
The
control
dial
is
calibrated
from
zero
0
to
1000.
Table
4-1
shows
the
Pulse
Width
Control
dial
ca
librations
and
percent
on
time
ofthepulsefor
vari
ous
dial
settings.
weld
puddle
to
cause
the
puddle
to
groW
in
depth
and
width.
The
peak
current
(pulse
amplitude)
control
op
erates
independently
of
the
background
current
con
trol.
To
adjust
the
level
of
the
peak
current,
the
panel
ammeter
can
be
used
in
conjunction
with
the
set-up
position
or
it
can
be
adjusted
by
referring
to
Table
42
which
translates
dial
readings
(0
to
1000)
Into
peak
current
(0
to
300)
amps.
TABLE
4-2.
AMPERES
VS
DIAL
CALIBRATION
0-1000
DIALS
(PULSE
PEAK,
INITIAL
AND
FINAL
CURRENT
DIALS)
DIAL
SETTING
0
50
100
200
300
400
500
600
700
800
900
1000
yr
%ON
TIME
OF
PEAK
CURRENT
10%
23%
35%
50%
60%
66%
72%
75%
80%
83%
86%
90%
FOR
WELD
CURRENT
AMPS
SET
DIAL
TO
FOR
WELD
CURRENT
AMPS
SET
DIAL
TO
FOR
WELD
CURRENT
AMPS
SET
DIAL
TO
3
010
34
113
80
267
4
013
35
117
82
274
5
017
36
120
84
280
6
020
37
123
86
287
7
023
38
127
88
294
8
027
39
130
90
300
9
030
40
133
92
307
10
033
41
137
94
314
11
037
42
140
96
320
12
040
43
142
98
326
13
043
44
147
100
333
14
047
45
150
105
350
15
050
46
153
110
366
16
053
47
157
115
383
17
057
48
160 120
400
18
060
49
163
125
427
19
063
50
167
130
433
20
066
52
173
135
450
21
070
54
180
140
466
22
073
56
187
145
483
23 077
58
193
150
500
24
080
60
200
160
534
25
083
62
207
170
566
26
087
64
214
180
600
27
090
66
220
190
633
28
093
68
227
200
667
29
097
70
234 220
733
30
100
72
240
240
800
31
103 74
247
260
866
32
107
76
254 280
933
33
111
78
260
300
1000
TABLE
4-1.
Pulse
Width
Dial
Settings
VS
Percent
On
Time
The
minimum
on
time
available
during
one
pul
se
cycle
is
10
percent
of
the
cycle.
The
maximum
on
time
of
the
pulse
cycle
is
approxImately
90
per
cent.
Figure
4-4
gives
an
idea
of
the
on
time
ad
justment.
50%
ON
TIME
CURRENT
--F--
PEAK
CURRENT
80%ON
TIME
20%
ON
TIME
Figure
4-4.
Pulse
ON
Time
AA901
410-2
B.
Peak
Current
Control
(Figure
4-1
&
4-3)
The
peak,
current
control
on
the
front
panel
al
lows
the
adjustment
of
the
pulse
current
level
(am
plttude),
This
control
allows
the
operator
a
means
of
injecting
enough
current
momentarily
into
the
A
selector
relay,
located
on
the
pulser
circuit
board,
alternately
selects
either
the
background
current
signal
or
the
peak
current
signal.
Thus,
If
the
peak
current
control
Is
sethighºr
than
the
back
ground
current
control,
the
control
signal
will
In
crease
when
the
relay
contacts
selecting
the
peak
current
control
setting
is
In
use,
This
results
dn
a
boosting
or
pulsing
of
the
weld
current
to
the
am
plitude
preset
on
the
peak
current
control
dial,
This
is
considered
standard
pulsed
OTAW
procedure.
If
the
pulse
peak
current
is
set
equal
to
the
back
ground
control,
no
current
pulses
will
be
evident
in
the
output.
If
the
peak
current
control
Is
set
below
the
background
current
control
the
pulses
will
be
downward
In
direction,
not
the
usual
method
of
operation.
C.
Pulse
Frequency
Control
(Figure
4-1
&
4.3)
The
number
of
pulses
per
second
is
determined
by
the
pulse
frequency
control
dial,
measured
and
calibrated
in
pulses
per
second,
The
frequency
range
available
is
from
1
10,
this
Is
the
number
of
pulses
injected
into
the
weld
current
per
sec
ond,
Due
to
the
fact
that
the
pulse
frequency
dial
is
not
linear
it
will
be
necessary
to
refer
to
Figure
OM-215
Page
11
a
second.
Setting
the
upsiope
dial
for
3
seconds
for
instance,
will
result
in
the
currentchanging
linearly
from
the
value
set
on
the
initial
current
dial
to
the
value
set
on
the
weld
or
background
current
dial
over
a
period
of
3
seconds.
The
same
is
true
of
the
downslope,
if
it
is
set
for
5
seconds
for
instance,
the
weld
current
will
di
minish
to
the
setting
of
the
final
current
dial
linear
ly
over
a
period
of
5
seconds.
These
slopes
can
be
can
be
initiated
(triggered)
by
the
push
buttons
on
the
front
panel
of
the
welding
machine
or
by
remote
push
buttons,
limit
switches,
etc.,
connected
to
the
2T
terminal
strip.
The
initial
slope
need
not
be
upwards
in
direction,
it
can
beadjustedforadrop
off
in
cur
rent
if
desired
by
settingthe
initial
current
dial
to
a
higher
level
than
the
weld
or
background
current
dial.
Conversely
the
final
slope
need
not
be
down
ward
in
direction
but
can
be
set
for
an
Increase
of
current
at
the
end
of
the
weld
should
that
be
re
quired.
Since
both
the
upslope
and
downslope
dials
are
calibrated
in
time,
the
current
change
during
slo
ping
can
be
from
any
value
within
the
range
of
the
welding
machine
to
any
other
value
and
no
inter
action
with
the
time
control
will
occur.
C.
Final
Current
Control
(Figure
4-2
&
4-3)
The
final
current
level
Is
controlled
by
Llie
linal
Current
Control
which
has
anadjustable
range
from
the
minimum
to
the
maximum
output
of
the
welding
machine.
Whatever
final
current
level
is
selected
will
be
held
until
the
program
is
stopped
by
opening
the
contactor,
if
in
the
MANUAL
mode.
In
AUTO
mode
the
emergency
stop
button
provision
at
2T
must
be
used.
If
this
control
is
set
at
a
higher
level
than
the
Background
(weld)
Current
level,
an
upward
slope
will
take
place
when
the
downslope
portion
of
the
weld
is
initiated.
However
in
most
applications,
final
current
level
Is
generally
set
at
a
lower
level
than
the
Background
(weld)
Current
level
in
order
to
provide
a
cratering-out
end
to
the
weld.
D.
FUNCTION
SWITCH
(Figure
4-2
&
4-3)
1.
Set-Up
The
SET-UP
mode
is
particularly
useful
in
pre
scheduling
initial
and
final
slopes
and
in
setting
the
current
level
desired
for
the
initial
current
and
final
current.
Turn
the
function
switch
to
SET-UP
and
the
initial
current
can
be
read
direct
ly
and
adjusted
by
reading
the
panel
meter.
De
pressing
the
upslope
push
button
will
then
display
the
upslope
time
and
the
weld
or
background
cur
rent
value
(which
should
agree
with
the
setting
of
the
digital
current
dial).
Next,
the
dow~slope
push
button
can
be
depressed
which
will
display
the
downslope
time
and
hold
at
the
final
current
value.
This
can
then
be
adjusted
by
means
of
the
final
cur
rent
dial.
To
reset
from
the
SET-
UP
mode
it
is
necessary
to
momentarily
turn
off
the
main
power
switch.
2,
GTAW
Manual
The
GTAW
MANUAL
or
Weld
in
Pulser
only
model,
hand
or
manual
torch
operation
is
beingem
ployed.
The
start
switch
must
be
held
closed
to
weld
in
this
mode
of
operation.
When
welding
In
the
GTAW
MANUAL
or
Weld
mode
(ie
with
foot
control),
It
is
recommended
that
a
jumper
be
Installed
between
terminals
72
and
120
on
the
terminal
strip
2T.
This
wllltake
the
operator
directly
through
upsiope
to
the
direct
reading
Cur
rent
Control
as
soon
as
the
arc
is
initiated.
Set
the
upslope
time
to
zero.
To
obtain
better
starts
when
this
operation
is
performed
the
Initial
Cur
rent
Control
should
be
set
somewhat
above
zero.
If
a
jumper
is
not
installed
the
current
will
be
held
at
the
setting
of
the
Initial
Current
Control
and
the
foot
control
becomes
a
vernier
of
It.
The
operator
will
have
a
choice
at
the
end
of
the
man
ual
weld
to
either
crater-out
with
his
foot
control
or
by
closing
a
momentary
contact
switch
(Con
nected
between
terminals
120
&
107
on
terminal
strip
2T),
use
the
downslope
portion
of
the
elec
troslope.
3.
GTAW
Auto
(Not
available
on
Pulser
only
model)
The
GTAW
AUTO
mode
places
the
welding
ma
chine
in
an
automatic
mode
of
operation
controlled
by
the
start
control,
upslope,
downslope,
and
stop
switches.
In
order
to
start
the
weld
program
sequence
(go
into
initial
current)
the
Start
switch
must
be
mo
mentarily
depressed.
The
Start
Switch
may
be
either
connected
to
the
Remote
Start
(contactor)
Receptacle
or
to
terminals
1
and
113
on
terminal
strip
2T,
both
of
which
are
located
behind
the
lo
wer
front
access
door
(See
Figure
34).
By
momentarily
depressing
the
Ups
lope
Start
But
ton
on
the
front
panel
or
the
Remote
Upslope
Switch
(See
paragraph
3-9
for
Remote
Upsiope
Switch
Con
nections),
the
welding
machine
will
go
fromthelnl
tial
current
setting
into
upslope.
Once
upslope
Is
completed
the
welding
machine
will
automatically
level
off
at
the
background
(weld)
current
setting.
In
order
to
go
from
the
background
(weld)
Current
setting
into
downslope,
the
Downslope
Start
But
ton
on
the
front
panel
or
Remote
Downslope
Switch
(See
paragraph
3-9
for
Remote
Downslope
Switch
connections)
must
be
momentarily
depressed.
This
will
take
the
operator
through
downslope
and
auto
matically
level
off
at
the
final
current
level.
The
welding
machine
will
remain
at
the
final
current
level
until
the
Remote
Momentary
Stop
Switch
Is
depressed
(See
paragraph
3-9
for
Connections).
SECTION
5
QUI~i1CE
OF
OPERATION
5-1.
OPERATION
SAFETY
CAUTION
Never,
under
any
circumstances,
operate
these
I
power
units
with
cover
removed
or
the
side
panels
removed.
In
addition
to
the
safety
hazard,
impro
per
cooling
may
result
in
damage
to
the
power
transformer
and
power
unit
components.
War
ranty
is
void
if
the
machine
is
operated
with
the
~cover
removed
or
the
side
panels
removed
5-2.
VOLT-AMPERE
CURVES
(Figure
5-1)
The
volt-ampere
curves
show
the
output
current
available
at
any
given
output
voltage
within
the
li
mits
Of
the
minimum
and
maximum
of
the
weld
cur
rent
control.
A
curve
has
been
plotted
for
every
50
amperes
of
welding
current
to
aid
In
selection
of
proper
operating
voltage.
Due
to
the
fact
that
this
welding
machine
Is
of
the
constant
current
type
It
will
be
noted
on
the
volt
ampere
curve
that
a
considerable
amount
of
voltage
change
is
permitted
without
variation
In
the
current.
OM-215
Page
13
5-3.
MANUAL
GAS
TUNGSTEN-ARC
WELDING
WITH
FOOT
CONTROL
When
performing
manual
GTAW
welding
with
a
remote
foot
amperage
and
contactor
control,
re
member
that
if
the
foot
control
is
advanced
only
a
slight
amount
(cracked)
the
weld
current
will
be
at
absolute
minimum,
three
amps
or
less.
This
makes
arc
starting
difficult.
Accordingly,
it
Is
recom
mended
that
the
Starting
Current
Selector
Switch
be
set
to
No.
1
or
No.
2
posItion
whenever
a
remote
foot
control
is
in
use,
with
helium
or
argon.
Re
member
that
the
machine
mm.
is
25
amps
when
in
No.
2
position.
As
a
further
help
in
manual
GTAW
welding,
it
is
best
to
have
the
torch
in
position;
ready
to
strike
the
arc
before
the
foot
pedal
is
depressed.
This
will
ensure
that
the
first
starting
pulse
will
not
be
wasted.
If
the
foot
pedal
is
depressed
while
the
torch
is still
a
considerable
distance
from
the
work
piece,
the
H.F.
will
strike too
soon
and
the
initial
starting
pulse
will
be
wasted
trying
to
establish
an
impracticafly
long
arc.
The
relays
will
then
reset,
chatter,
etc.
This
is
normal
operation
and
should
be
expected
if
the
H.F.
is
energized
before
the
torch
is
in
welding
position.
To
summarize:
For
best
starts,
always
have
the
electrode
tip
within
1/8
inch
of
the
workpiece
be
fore
depressing
the
foot
control.
5-4.
MANUAL
GAS
TUNGSTEN-ARC
WELDING
(Figure
5-2)
1.
Make
primary
power
connections
as
outlined
in
paragraph
3-3.
2.
Connect
a
proper
size
welding
cable
from
the
WORK
terminal.on
the
welding
totheworkpiece.
Connect
another
welding
cable
of
proper
size
from
the
ELECTRODE
terminal
of
the
welding
machine
to
the
electrode
holder.
See
Table
32
for
proper
secondary
cable
size.
3.
Select
the
proper
size
tungsten
electrode
from
Table
51
and
Insert
It
into
the
electrode
hold
er.
.010
Up
to
25
Up
to
30
.020
15to40
20to50
.040
25to80
3OtolOO
1/16
50to145
60to160
3/32
135
to
235
150
to
260
1/8
225
to
300
250
to
300
111
~
I
The
above
connections
are
for
dc
straight
polarity.
If
dc
reverse
polarity
is
desired,
reverse
the
sec
ondary
connections.
4.
Make
gas
and
water
connections
as
outlined
in
paragraph
3-5
and
set
post-flow
timer
to
de
sired
setting.
5.
If
a
remote
current
control
is
being
used,
place
the
Remote
Current
STANDARD-REMOTE
Switch
in
the
REMOTE
position.
If
one
is
not
used,
ensure
that
the
switch
is
in
the
STAND
ARD
position.
6.
Connect
a
start
(contactor)
control
switch
as
out
lined
in
paragraph
3-7
or
3-9.
7.
If
used,
connect
upsiope
and
downslope
switch
as
outlined
in
paragraph
39.
8.
Set
the
Background
(weld)
CurrentControltode
sired
setting.
9.
Set
all
pulser
controls
to
desired
setting.
10.
Set
Electroslope
Controls
to
desired
setting.
11.
Place
the
Starting
Current
Selector
in
the
de
sired
position.
12.
Place
the
OFF-START
High
Frequency
Switch
in
desired
position.
13.
Place
the
Function
Switch
in
the
GTAW MANUAL
or
WELD
position.
14.
Place
the
Power
Switch
in
the
ON
position.
15.
Close
the
start
(contactor)
control
switch.
1~
On
model
with
Pulser
module
only,
steps
16
&
17
are
not
required.
16.
Depress
the
upslope
button
or
switch
to
transfer
out
of
initial
current
and
into
upslope
and
weld.
17.
Depress
the
downslope
button
or
switch
to
go
into
downslope
and
final
current.
18.
To
stop
the
weld
sequence,
release
the start
(contactor)
control
switch.
19.
Thrn
gas
and
water
supply
off.
20.
Place
the
Power
Switch
in
the
OFF
position.
5-5.
AUTOMATIC
GAS
TUNGSTEN-ARC
WELDING
1.
Make
primary
power
connections
as
outlined
in
paragraph
3-3.
2.
Connect
a
proper
size
welding
cable
from
the
WORK
terminal
on
the
welding
totheworkpiece.
Connect
another
welding
cable
of
proper
size
from
the
ELECTRODE
terminal
of
the
welding
machine
to
the
electrode
holder.
See
Table
3-2
for
proper
secondary
cable
size.
3.
Select
the
proper
size
tungsten
electrode
from
Table
5-1
and
insert
it
into
the
electrode
hold
er.
I
The
above
connections
are
for
dc
straight
polarity.
If
dc
reverse
polarity
is
desired,
reverse
the
sec
ondary
connections.
4.
Make
gas
and
water
connections
as
outlined
in
paragraph
3-5
and
set
post-flow
timer
to
de
sired
setting.
80
70
60
0
>
50
40
30
20
10
03
MIN.
100
150
200
D
C
AMPERES
Figure
5-1.
Volt-Ampere
Curves
CA-SQl
401-1
I
I
TABLE
5-1.
Recommended
Tungsten
Electrode
Sizes
2%
THORIATED
TUNGSTEN
I
Page
14
5.
If
a
remote
current
control
is
being
used,
place
the
Remote
Current
STANDARD-REMOTE
Switch
In
the
REMOTE
position.
If
one
is
not
used,
ensure
that
the
switch
is
in
the
STANDARD
position.
6.
Connect
a
start
(contactor)
control
switch
as
out
lined
in
paragraph
3-7
or
3-9.
7.
Connect
Upslope,
Downslope,
andRemote
Emer
gency
Stop
Switches
as
outlined
in
paragraph
3-9,
8.
Set
the
Background
(weld)
Current
Control
to
the
desired
setting.
9.
Set
all
pulser
controls
to
desired
setting.
10.
Set
all
Electroslope
controls
to
desired
setting.
11.
Place
the
Starting
Current
Selector
in
the
de
sired
position.
12.
Place
the
OFF-START
High
Frequency
Switch
In
the
desired
position.
13.
Place
the
Function Switch
In
the
GTAW
AUTO
position.
14.
Place
the
Power
Switch
in
the
ON
position.
15.
Momentarily
depress
the
start
control
switch
to
initiate
the
weld.
16.
Momentarily
depress
the
upslope
button
or
switch
to
transfer
out
of
Initial
current
and
Into
up
slope
and
weld.
17,
Depress
the
downslope
button
or
switch
moment
arily
to
go
into
downslope
and
final
current.
18.
To
stop
the
weld
sequence,
depress
the
Remote
Stop
Switch
momentarily.
19.
Turn
gas
and
water
supply
off.
20.
Place
the
Power
Switch
in
the
OFF
position.
SECTIOWk3
6=
MMNTENANCE
Be
sure
the
branch
circuit,
main
disconnect
switch
or
circuit
fuses
are
removed
before
attempting
any
Inspection
or
work
on
the
inside
of
the
welding
ma
chine.
Placing
the
On-Off
power
switch
on
the
weld
ing
machine
in
the
Off
position,
does
not
remove
voltage
from
the
power
terminal
inside
of
the
ma
chine.
6-2.
RECTIFIERS
The
rectifiers
should
be
cleaned
with
a
source
of
dry
compressed
air
when
the
plates
become
dusty
or
dirty.
This
is
best
done
by
removing
the
side
panels
and
blowing
the
dirt
etc.,
out
of
the
welding
machine.
6-3.
MAIN
TRANSFORMER
AND
OTHER
COMPONENTS
Use
dry
compressed
air
to
clean
the
components
inside
of
the
welding
machine.
Keep
all
the
panels
open
to
make
sure
the
dust
and
dirt
blows
out
of
the
welding
machine.
LEGEND
ELECTRODE
L__J
WORK
E:E1
WATER
IN

WATER
OUT
(MACHINE)
WATER
OUT
(TORCH)
GAS
IN
IdeS
GAS
OUT
START
(CONTACTOR)
CONTROL
IflJ
REMOTE
AMPERAGE
CONTROL
DRAIN
Figure
5-2.
Gas
Tungsten-Arc
Welding
Connection
Diagram
AC901
417-4
6-1.
MAINTENANCE
SAFETY
U
OM-215
Page
15
6-4.
FAN
MOTOR
The
welding
machine
is
equipped
with
an
exhaust
fan
and
relies
on
forced
draft for
adequate
cooling
for
high
duty
cycles
and
overload.
The
fan
motor
is
manufactured
with
lifetime
lubricated
sealed
ball
bearing.
6-5.
CIRCUIT
PROTECTION
Fl
-
6
amp,
cartridge
fuse
located
inprimary
side
of
control
transformer.
Located
in
back
of
the
center
air
baffle
inside
of
welding
ma
chine.
CB1
3
amp,
circuit
breaker,
protects
115
vac
control
circuit.
CB2
10
amp,
circuit
breaker,
protects
115
vac
duplex
receptacle
circuits.
CB3
-
3
amp,
circuit
breaker,
protects
30
volt
con
trol
circuit.
CB4
-
5
amp,
circuit
breaker,
protects
mag-amp
115
vac
control
circuit,
~rcult
breakers
are
incated
behind
the
lower
front
access
door,
6-6.
SPARK
GAP
ADJUSTMENT
(High
Frequency
Unit)
The
spark
gaps
are
normally
set
at
.008
apart
at
the
factory.
It
will
be
necessary
to
periodical
ly
readjust
these
after
extended
operation.
Us
ually
inspection
and
adjustment
every
three
or
four
AC-901
411-5
months
will
suffice,
Re-adjustment
is
also
Indicat
ed
when
intermittent
operation
of
the
gaps
Is
noted,
Usually
this
occurs
when
the
setting
has
increased
Figure
6-2.
Printed
Circuit
Board
Location
to
.013
or
greater.
-
This
welding
machine
utilizes
several
printed
cir
cuit
boards
in
its
control
circuitry,
One
board
serves
as
the
regulated
power
supply
furnishing
proper
voltages
to
the
other
boards,
I
I7T~7l
- -
~
The
plug
in
amplifiers
on
the
printed
circuit
boards
are
of
the
plug
in
type
as
shown
in
Figure
6-3.
Do
not
attempt
to
un-solder
the
terminals
for
the
am
plifiers.
from
the
printed
Circuit
Board,
AA-020
623
Figure
6-1.
Spark
Gap
Adjustment
To
Adjust
Spark
Gaps:
1.
Loosen
screw
A,
Adjustonesparkgapat
a
time,
2,
Place
feeler
gauge
of
proper
thickness
between
gaps
C,
-
3,
Apply
slight
pressure
against
spark
gap
holder
B,
Feeler
gauge
is
held
firmly
in
gap.
4.
Tighten
screw
A,
5,
Adjust
the
remaining
spark
gap.
6-7.
THEORY
OF
OPERATION:
CLOSED
LOOP
FEED
BACK
SYSTEM
-
AA-9O1
4116
_________________________________________________________
Figure
6-3.
Plug-In
Amplifiers
1.
Electroslope
Board
2.
Pulser
Board
3.
Integrator
Board
4.
Power
Supply
Board
C
I
For
easy
access
to
printed-circuit
boards,
remove
U
the
four
Phillipshead
screws
at
the
corners
of
the
front
nameplate.
Page
16
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Miller ANALOG 300 Owner's manual

Miller
Brand
Miller
Model
ANALOG 300
Category
Welding System
Type
Owner's manual
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