Read and understand the entire contents of this manual, with special emphesis on the safety material througheut the manual, before inetaiting, opereting, or maintaining thie equip- ment. This unit and these instructions are for use ‘only by parsons trained and experienced in the safe operation of welding equipment. Do not allow un- trained persons to install, operate, or maintain this unit, Contact your distributor if you do not fully understand these instructions. July 1887 FORM: OM.-284F Effective With Seriat No. JH164331 MODEL PLAZCUT OWNER’S MANUAL MILLER ELECTRIC MFG. CO. ‘718 8. SOUNDS ST, P.O. Box 1079 APPLETON, WI 54912 USA NWSA CODE NO. 4579HEAR SaDE Dee Sat Fee IDE IE Aah oe Sea, eat LIMITED WARRANTY EFFECTIVE: OCTOBER 1, 1986 a 4 x 4 A £ x a “This warranty supersedes ail previous MILLER warranties and ls excislve with no other guarantees or warranties expressed or imped LIMITED WARRANTY - Subject to the tems and condi. tions hereot, Miler Becwic Mig. Co., Appleton, Wisconsin ‘warrants to ite Okewbutor Dealee that all new snd unusod Equipment furnished by Miler is fre from detect in workman hp ane mataral as ofthe time an place of delivery by Nil. No waranty is mde by Miler with respect to engines, rade ‘ecestories of Other ams manufactured by ormers. Such ‘engines, rade accesvoris and other items are sold subject 2 the warrantes of thelr respective manufacturers, any «Al ‘snes are warranted by their manctacturer for one year rom Gate of original purchave, excent Tecumseh engines which have a two year warranty. Except as specified below, Mier's warranty does aot apply tw components having norral useful Ife of lass than one (1) year, uch as epot welder tips, relay and contactor points, MILLzRMATIC parts that coms in contact with the welding wire including nol and rozte insulators where falure does hot result fom defect in workmanship o materia Miler shall be vocuired to honor warranty claims on War ‘anced Equipment in the event of falure ruling froma defect \althin de flowing petiods from the cee of detvery of Equlp> ‘ent to the ongnat User 1. Are welder, power soutss, bots, and components. 1 year 2. Load barks Ayer 23. Original main power rections ‘yews labor - 1 year ony) 4. Alling guns, feecer/gun and plasma torches... 90 days 5. Allether Nibermatic Feeders year 6. Roplacoment or repr pats, exclusive of labor. 60 days 7. Baterion ‘Gmonte provided that Miler eaten wet within tit (30) days Of the dete of 800% Fale As a matter of general poly only, Mier ray honor eens bite by the orginal use within the foregoing periods, In the case of miler’ brosch of waranty Or any ater duty with resect te the quay of any goods, the exckavetemadis ‘arafore shall be, at Mile’sopton (1 repair oF 2) replacement where authorized in wing by Miler appropriate cases, (3), the reasonable cost of repar oF replacement at an authored Miler saree station or (4) payment of or credit forthe purchase De fess reasonable cepracation based upen actual use) upon return of the goods at Customers rst and expence. MILLER ‘opti of ropa or tplacamant wil be FOB, Foctoy, a ‘Appleton, Weconsin, of F.0.8, et @ MILLER authored verdce faa, therefore no corpensiion for vansporaton costs of ‘ny Kind wil be alowed. Upon recast of note of apsaront ‘Selector flue, Miler sal instruct the carat on the waranty ‘lem procedure to be followed. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPUED WARRANTY, GUARANTY OR REPRESENTA TOV AS TO PERFORMANCE, AND ANY REMEDY. FOR BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OF COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUPMENT FURNISHED BY MILLER iS (CLUDED AND DISCLAIMED BY MILLER, EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN. WRITING, [MILLER “PRODUCTS “ARE INTENDED FOR ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL. USERS AND FOR OPERATION BY PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE .OF WELDING EQUIPMENT AND NOT G03 CONSUMERS OR (CONSUMER USE. MILLER'S WARRANTIES DO NOT EXTEND TO, AND NO RESELLER IS AUTHORIZED TO EXTEND IMILLER'S WARRANTIES TO, ANY CONSUMER, RE EE ERE GS AO Ba ORECERTIFICATE NAME OF EQUIPMENT_________ Mops. No. G7 fsatasesnseeteeecasasissnsseaseneasaiasiaan#(7 einsdsamstaiqassasaniotanngsnsisasassdsiaiaisig This equipment hos been type-tested under standordized field test conditions es recommended by the Joint Industry Committee on High Frequency Stabilized Are Welding Machinee found to rad- fate less thon 10 microvolts per meter ot 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 10 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 ine structions epplicable to this model as outlined in the instruction book furnished. It is being used only for the purpose for which it was intended and is being meintoined and operated in accord- once with the manufocturer’s instructions, Det inalndecececsceeteaeseeseceecee/s122e20:208¢ QigaghseseeeeseseeeeseeceascaecsesreteHEeEECAYa TABLE OF CONTENTS ee Section No. Page No. SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE Introduction. 1 2. General Precautions . 3. Arc Welding. 1 1 1 1 4. Standards 8 iin SECTION 2 - INTRODUCTION 2-1. Volt-Ampere Curves... : 2-2. Recommended Plasma vAre Cina rameters. 2-3. DutyCyole..... 2-4. General Information And Satety . 2-8. 2-6. IN Receiving Handling weseesee - Description ..... 3 3 3 - INSTALLATION = 1. Installation Of Handle And Running Gear . ae ree 2. Location pee 9 3. Installation Of Fiter/Regulator And Bracket 9 4. Torch Assembly ......... E 9 5. Work Cable Assembly 7 7 10 6. Installation Of Torch And Work Cable. eee 10 7. Electrical Input Connections ca IN 4 - OPERATOR CONTROLS 4-1. Power Switch 4-2) Power Lignt.. B 4-3. Ready Switch eee potetee B 4-4 Ready Light ...-- aoreneen ee : 3 13 4-5. Range Switch .-- : B SECTION 5 - SEQUENCE OF OPERATION 5-1. Start-Up... : : : B 5-2, ShutDown 12...) 14 SECTION 6 - MAINTENANCE & TROUBLESHOOTING 6-1. Fan Motor 18 6-2. Internal Cleaning 15 6-3. Cables.. 15 8-4. Spark Gaps Se aera aeee eae 6-5. Electrode Inspection And Replacement... eG eet 16 6-7. Fuses .. Celts ere ene aug) 6-8. Troubleshooting - 16 SECTION 7 - CERTIFICATION FOR HIGH FREQUENCY ARC WELDING EQUIPMENT 7-1. General... oe een eee eeeeeeeea: 7-2. General information ... Re ein earn 7-3. Power Service ‘| 7 7-4, Welding Machine 18 7-5., Welding Leads... 18 7-8. Wing in The Vicinity Of The Welding Area 18 7-7. Grounds ...-.... DI 19 7-8, Metal Building... a 19 7-9. Individual installation Certification «22.02.21. 19 7-10. Check List... 2... 19™=SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE® 1-1. INTRODUCTION - We learn by experience, Learning safety through personal experience, like 2 child touching a hot stove is harmful, wasteful, and 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 2 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 249.1 is the most complete ‘The National Electrical Code, Occupational Safety and Health Administration, focal industrial codes, and local inspection requirements also provide a basis for equip- ment installation, use, and service. 1-2. GENERAL PRECAUTIONS. Differont arc wolding processes, electrode alloys, and fluxes can produce different fumes, gases, and radiation fovals. In addition to the information in this manual, be sure to consult flux and olec- trode manufacturers for specific technical data and precautionary measures concerning their matorial. A. Burn Prevention Wear protective clothing - gauntlet gloves designed for use in welding, hat, and high safety-toe shoas. Button shirt collar and pocket flaps, and wear cuffless trousers to avoid entry of sparks and slag Wear helmet with safety goggles or glasses with side shields underneath, appropriate filter ienses 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 without gloves. Medical first aid and eye treatment. First aid facilities and a qualified first 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 intendirg to weld or cut. B. Toxic Fume Prevention Severe disccmfort, illness or death can result from fumes, vapors, heat, or oxygen enrichment or depletion that welding (or cutting) may produce. Prevent them with adequate ventilation as described in ANSI Stan- dard 249.1 listed 1 in Standards index. NEVER ventilate with oxygen Lead -, cadmium -, zine -, mercury , and beryllium = bearing and similar materials, when welded (or cut) may produce harmful concentrations of toxic fumes. Ade- quate loca! echaust ventilation must be used, or each person in the area as well as the operator must wear an i-supplied respirator. For beryllium, both must be us- ed. Metals coated with or containing materials that emi 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: tiiated and, if necessary, while wearing an alr-supplied respirator. Gas leaks in a confined space should be avoided, Leaked gas ir 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, @ (0M.288 Page 1ighly 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. 00 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 trichloroethylene or per- chlorcethyiene ©. Fire and Explosion Prevention Causes of fire and explosion are: combustibles reached by the arc, flame, flying sparks, hot siag or heated material; misuse of compressed gases and cylinders; and short circuits. BE AWARE THAT fiying sparks or falling slag can pass. through cracks, along pipes, through windows or doors, and through wall or floor openings, out of sight of the goggied operator. Sparks and slag can fly 35 feet. To prevent fires and explosion: Keep equipment clean and operable, free of cil, grease, and {in electrical parts) of metallic particles that can cause short circuits. I combustibles are in area, do NOT weld or cut. Move the work if practicable, to an area free of combustibles. Avoid paint spray rooms, dip tanks, storage areas, ven- tilators. If the work cannot be moved, move com- bustibles at least 35 feet away out of reach of sparks and heat: of protect against ignition with suitable and snug-fitting, fire-resistant covers or shields. Walls touching combustibles on opposite sides should not be welded on (or cut). Walls, ceilings, and floor near work should be protected by heat-resistant covers or shields. Fire watcher must be standing by with suitable fire ex- tinguishing equipment during and for some time after welding or cutting if 2. appreciable combustibles {including building construction) are within 35 feet b. appreciable combustibles are further than 35 feet but can be ignited by sparks ©. openings (concealed or visible) in floors or walls within 35 feet may expose com. bustibies to sparks d. combustibles adjacent to walls, ceilings, roofs, or metal partitions can be ignited by radiant or conducted heat. Hot work permit should be obtained before operation to ‘ensure supervisor's approval that adequate precautions ‘nave been taken. After work is done, check that area is free of sparks, glowing embers, and flames. ‘An empty container that held combustibles, or that can produce flammable or toxic vapors when heated, must M284 Poge2 never be welded on or cut, unless container has first been cleaned as described in AWS Standard A6.0, listed 7 in Standards index This includes: a thorough steam or caustic cleaning (or a solvent or water washing, depending on the com- bustible's soluoility) followed by purging and inerting with nitrogen or carbon dioxide, and using protective equipment as recommended in A6.0. Waterfiling just below working level may substitute for inerting. ‘A container wth unknown contents should be cleaned (see paragraph above). Do NOT denend on sense of ‘smell or sight to determine if itis safe to weld or cut. Hollow castings or containers must be vented before welding or cutting. They can explode. Explosive atmospheres. Never weld or cut where the air ‘may contain flammable dust, gas, or liquid vapors (such as gasoline). D. Compressed Gas Equipment Standard precautions. Comply with precautions in this ‘manual, and trose detailed in CGA Standard P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, listed 11 in Standards index. 1. Pressure Regulators Regulator relief vaive is designed to protect only the regulator from overpressure; it is not intended to protect any downstream equipment. Provide such protection with one or more relief devices. Never connect @ regulator to a cylinder containing gas other than that for which the regulator was designed Remove faulty regulator from service immediately for repair (first close cylinder valve), The following symptoms indicate a faulty regulator: Leaks - if gas leaks externally. Excessive Creep - if delivery pressure continues to ‘ise with downstream valve closed. Faulty Gauge - if gauge pointer does not move off stop pin when pressurized, nor returns to stop pin after pressure release. Repair. Do NOT attempt repair. Send faulty regulators for repair to manufacturer's designated ‘epair center, where special techniques and tools are used by tained personnel 2. Cylinders. Cylinders must be handled carefully to prevent leaks and damage to their walls, valves, or safety devices: Avoid electrical citeuit contact with cylinders. in- cluding third rails, electrical wires, or welding cir- cuits. They can produce short circuit arcs that may lead to a serious accident, (See 1-3C.)ICC or DOT marking must be on each cylinder. tt is an assurance of safety when the cylinder is properly handled, Identifying gas content. Use only cylinders with name of gas marked on them; do not rely on color to identify gas content. Notify supplier if unmarked, NEVER DEFACE or alter name, number, or other markings on 2 eylinder. It is illegal and hazardous. Empties: Keep valves closed, repiace caps securely: mark MT: keep them separate from FULLS and return promatiy. Prohibited use. Never use a cylinder or its contents for Locate or secure cylinders so they cannot be knacked 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, ete. thet 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 maving cylinders ‘Stuck valve. Do NOT use a hammer or wrench to open 2 oylinder valve that can not be opened by hand. Notify vyour supplier. Mixing gases. Never try to mix any geses in a cylinder. Never refil any cylinder. Cylinder fittings should never be modified or exchang- ed. 3. Hose Prohibited use. Never use hose other than that designed ‘or the specified gas. A general hose identification rule ‘st red for fuel gas, green for oxygen, and black for inert gases. Use ferrules or clamps designed for the hose (not or- inary wite 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 (08, or otherwise damaged. Coil excess hose to prevent kinks and tangies. Protect hose from damage by sherp edges, and by sparks, slag, and open fame. Exemine hose regularly for leaks, wear, and loose con- nections. immrerse pressured hose in water; bubbles in- dicate leaks. Repair leaky 0: worn hose by cutting area out and splic- Ing (1-203). Co NOT use tape. 4. Proper Connections Clean cylinder valve outlet of impurities thet may clog otifices and demage seats before connecting regulator. Except for hydrogen, crack valve momentary, 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 928 oF 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 for your sup- plier} between cylinder and regulator, if one is required. Use two wrenches to tighten adapter marked RIGHT and LEFT HAND threads, Regulator outist [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. Preseui 19 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 engages slightly on single-stage regulators. ‘Stand to side of regulator while opening eylinder valve, Open cylinder vaive slowly so thet regulator pressure in- creases siowly, When gauge is pressurized (gauge reaches reguleter 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 fess 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. Srush with soap solution (capful of lvory 0M-264 Pages:Liquid or equivalent per gallon of water!. Bubbles in dicate leak. Clean off soapy water after test; dried soap is combustibie E. User Responsibilities Remove leaky or defective equipment from service im- mediately for repair. See User Responsibility statement in equipment manual. F. Leaving Equipment Unattended Close gas supply at source and drain gas. G. Rope Staging-Support Rope staging-support should not be used for welding or cutting operation; rope may burn. 1-3. ARC WELDING - Comply with precautions in 1-1, 1-2, and this section, Arc Welding, properly done, is a safe process, but a careless operator invites trouble. The equipment’ carries high currents at significant voltages. The arc is very bright and hot. Sparks fiy, fumes tise, ultraviolet and infrared energy radiates, weldments are hot, and compressed gases may be us. fed. The wise operator avoids unnecessary risks and pro- tects himself and others from accidents. Precautions are described here and in standards referenced in index. A. Burn Protection Comply with precautions in 1-2, ‘The welding arc Is intense and visibly bright. Its radia- tion can damage eyes, penetrate lightweight clothing, reflect from light-colored surfaces, and burn the skin land eyes. Skin burns resemble acute sunburn, those from gas-shielded ares are more severe and paintul. DON'T GET BURNED; COMPLY WITH PRECAU. TIONS. 1. Protective Clothing Wear fong-sleeve clothing (particularly for ges-shilded arc) in addition to gloves, hat, and shoes (1-2A). As necessery, use additional protective clothing such as leather jacket oF sleeves, flame-proof apton, and Fie. 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. Bye and Head Protection Protect eves from exposure to arc. NEVER look at an electric arc without protection, Welding heimet or shield containing a filter plate shade no. 12 oF denser must be used when welding. Place over face before striking arc. “Trademark of Proctor & Gamble on-284 Page Protect fiter plate with a clear rover plate. Cracked or troken helmet or shield should NOT be worn; radiation can pass through to cause burne, 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 e: 2s should the heimet no: be lowered over the face before an arc is struck, Lookirg at an are momentarily with unprotected eyes (particularly a high intensity gas-shielded arc) can ‘cause a retinel burn thet may leave @ 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-rellective, non. combustible sereens or panels. Allow for free air circula- ‘ion, particulally 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. Bofore starting to weld, make sure that screen flaps or bay doors are closed. B. Toxic Fume Prevention Comply with precautions in 1-28. Generator engine exhaust must be vented to the outside air. Carbon monoxide can kil ©. Fire and Explosion Prevention ‘Comply with precautions in 1-2¢. Equipment’s ‘ated 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 en arc on a cylinder or other pressure vessel. It creates a britie area thet can cause a violent rupture or iead to such a rupture later under rough handling, D. Compressed Gas Equipment Comply with precautions in 1-20.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. Keep body and clothing dry. Never work in damp area without adequate insulation against electrical shock. Stay on a dry duckboard, or rubber mat when damp- ness or sweat can not be avoided. Sweat, sea water, or moisture between body and an electtically HOT part - or grounded metal ~ reduces the body surface electrical resistance, enabling dangerous and possibly lethal currents 10 flow through the body. 1. Grounding the Equipment ‘When arc weiding equipment is grounded according to the National Electrical Code, and the work is grounded according to ANSI 249.1 “Safety in Welding And Cut ting,” a voltage may exist between the electrode and any conducting object. Examples of conducting objects include, but are not limited to, buildings, electrical tools, work benches, welding power source cases, workpieces, etc. Never touch the electrode and any metal object unless the welding power source is off. ‘When insialing, connset 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 2 pipe carrying ANY gas or a flammable li- quid such as of or fuel ‘Thiee-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 equi 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 weiding, check ground for continuity. Be sure conductors are touching bare metal of equipment frames at connections, If 2 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 @ grounded ‘mating receptacle, the ground lead must be connected to the ground prang only. If the line cord comes with @ three-prong piug, connect to a grounded mating recep- tacle. Never remove the ground prong from @ plug, or use a plug with a broken off ground prong, 2. Electrode Holders Fully insulatec 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 lenaths. 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 meta and sparks. 8. Terminels And Other Exposed Parts Terminals and other exposed parts of electrical units should have insulating covers secured before operation. 6. Electroce ‘2. Equipment with output on/off control (con- tactor) ‘Welding power sources for use with the gas metal arc welding (GMAW). yas tungsten ere welding (GTAW) and similar processes normally are equipped with devices that per- mit on-off control of the welding power out- put. When so equipped the electrode wire becomes electrically HOT when the power source switch is ON and the welding gun switch is closed. Never touch the electrode wire or any conducting object in contact with the electrode circuit unless the welding power source is off b. Equipment without output on/off control (0 contactor) Welding power sources used with shielded metal arc welding (SMAW) and similar pro- cesses may not be equipped with welding power output on-off contro! devices. With such equipment the electrode is electrically HOT when the power switch is turned ON. Never touch the electrode unless the welding power source is off. 7. Safety Cevices Safety devices such as interlocks and circuit breakers: should not be disconnected or shunted out. Before installation, inspection, or service, of equi ‘ment, shut OFF all power and remove line fuses (or lock (OM-284 Page 5or red-tag switches) to prevent accidental turning ON of power. Disconnect all cables from welding power Source, and pull at 118 volts line-cord plugs. Do not opsn power circuit or change polarity while welding. If, in an emergency, it must be disconnected, ‘guard against shock burns, oF 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. F. Protection For Wearers Of Electronic Life ‘Support Devices (Pacemakers) Magnetic fields from high currents can affect pacemaker operation. Persons wearing electronic life support equipment (pacemaker) should consult with their doctor before going near arc welding, gouging, or spot welding operations, 1-4. STANDARDS BOOKLET INDEX For more information, refer to the following standards or their latest revisions end comply as applicable: 1. ANSI Standard 249.1, SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society, 50 Le Jeune Rd, P.O. Box 351040, Miami, FL 33136. 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, 2SCFR 1910, obtainable from the U.S. Govern: ment Printing Office, Washington, D.C. 20402. 4. ANSI Standard 787.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND. FACE PROTECTION obtainable from the American Nationel 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 0M.264 Pages 10, Ww. 12. 13. 4. 15 ANSI Standard 249.2, FIRE PREVENTION IN ‘THE LSE OF CUTTING AND WELDING PRO- CESSES obtainable from the American National Standards institute, 1430 Broadway, New York, NY 10918, AWS Standard 6.0, WELDING AND CUT. TING CONTAINERS WHICH HAVE HELD COM. BUSTIBLES obtainable from the American Welding Society, 550 Le Joune Rd P.O. Box 351040, Miam: FL 33136. NFPA Standard 61, OXYGEN - FUEL GAS SYSTEMS FOR WELDING AND CUTTING ob- tainabla from the National Fire Protection Association, 470 Atiantic Avenue, Boston, MA 02210, NEPA Standard 70-1978, NATIONAL ELEC- TRICAL CODE obtainable from the National Fire Protection Association, 470 Atlantic Avenue, Bostor, MA 02210. NFPA Standard 51B, CUTTING AND WELDING PROCESSES obtainable from the Netional Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210. CGA Pamphlet P-1, SAFE HANDLING OF COM- PRESSED GASES IN CYLINDERS obtainable from tre Compressed Gas Association, 500 Fifth ‘Avenue, New York, NY 10036. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING obtainable fron the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdele, Ontario, Canade MSW 1F3. NWSA booklet, WELDING SAFETY BIBLICGRAPHY obtainable from the National ‘Welding Supply Association, 1900 Arch Steet, Philadelphia, PA 19103. ‘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 Ra. P.O. Box 351040, Misi, FL33135, ANS! Standard 288.2 “Practice for Respiratory Protection’ obtainable from the American Na- tal Standards Institute, 1430 Broadway, New York, NY 10018(eee SECTION 2 - INTRODUCTION mmc mancs| Sete | Geb [eT ew [on [awle om tealw | See | me i | Bes afala]ofsl «|» | sla | eee, | » [efofole[@ la fale lee lesa | re ae, | Figure 2 - 1. Spocifications ent of the power source available in either the HI or m= LOW range. With the use o* the Volt-Ampere curves, itis possible to determine what the current will be at 2 particular voltage, The Volt-Ampere curves show the minimum 00 and maximum curves of each current range, 2-2. PLASMA ARC CUTTING (PAC) ‘8 PARAMETERS (Figure 2-3) - The Plasma Arc Cut- ting (PAC) Parameters chart shows the travel speed, range selection, and torch standoff for metals of various ” thicknesses. pevours 2-3, DUTY CYCLE - This power source is rated at 40 percent duty cycle when operated in the HIGH range. The duty cycle is the percentage of a ten minute period that the unit can be operated at a given output ‘without causing overheating and damage to the unit. Since this urit is rated at 40% duty cycle when ‘operated in the HIGH range, it can be operated at rated ° Cr rr a) load for four minutes out of ten. During the remaining DC AMPERES sere ix minutes, the unit should idle to permit proper cool- jing. When’ operated in the LOW range, this power source is rated at 100 percent duty cycle. This means that the power source can be operated at rated load Figure 2 - 2. Volt-Ampere Curve Thickness _| “$sed pan stan] contnucusty. 2a ga-16 ga] 175 Contact Tiga ans | 65 via 35 v6 a8 20 22 ga Contact 36 90 10 ga - 3/16 77 38 ‘040 Contact es 16 | ‘ 100 | ine WA | 3 a 7 orl <8) mais Figure 2 - 3. Plesma Are Cutting (PAG) ~~ 1658 mm Parameters < roe ite 2-1. VOLT-AMPERE CURVES (Figure 2-2) - The "Add 9in, 228 mmi for hanalos Volt-Ampere curves shaw the output voltage and cur- Figure 2 - 4. Overall Dimensions oM.284 Page?2-4, GENERAL INFORMATION AND SAFETY A. General Information presented in this manual and on various labels, tags, and plates provided on this unit pertains to ‘equipment design, installation, operation, maintenance, and troubleshooting which should be read, understood, ‘and followed for the safe and effective use of this equip: ment. B. Safety The installation, operation, maintenance, and troubleshooting of this equipment requires practices and procedures which ensure personal safety and the safety of others. Therefore, this equipment is to be in- stalled, operated, and maintained only by qualified per- sons in accordance with this manual and all applicable ‘codes such as, but not limited to, those listed at the end of Section 1'- Safety Rules For Operation Of Arc Welding Power Source. Safety instructions specifically pertaining to this unit ap- pear throughout this manual highlighted by the signal words and which identify different levels of hazard. EEG statements include installation, operation, ‘and maintenance procedures or practices which if not carefully followed could result in serious personal injury ‘loss of life laters include installation, uperation, ‘and maintenance procedures or practices which if not carefully followed could result in minor personal injury (or damage to this equipment, A third signal word, IRIGERERES, highlights inetruc- tions which n2ed special emphasis to obtain the most cfficient operetion of this equipment. 2-8. RECEIVING-HANDLING - Bofore installing this equipmert, clean all packing material from around the unit and carefully inspect for any damage that may have occurrec during shipment. Any claims for loss or damage that nay have occurred in transit must be filed by the purchaser with the carrier. A copy of the bill of lading will 2 fumished by the manufacturer on re- quest if occasion to file claim arises. When requesting information concerning this equip- ment, it is essential that Model Description and Serial Number of the equipment be supplied. 2-6. DESCRIPTION - This unit is # direct current, stiaight polarity (electrode negative) power source designed for use with clean, dry compressed air as a cutting agent. It will cut metals up to 3/8 in. (9.5 mm) thickness using the Plasma Arc Cutting (PAC) process, Plasma is air which has been heated to en extremely high temperature and ionized so that the air becomes electrically conductive. The tip of the electrode is located within the nozzle of the torch. The torch nozzle has a small opening (orifice) which constricts the arc, The compressed air flows through the arc where it is heated to the plasma temperature range. Since the sir cannot expand due to the constriction of the nozzle, itis forced through the orifice and emerges in the form of 2 highly compressed air stream. The heat formed by the are and the plasma melts the meal, ang the alr stream force s the moten metal from the cut NN SECTION 3 — INSTALLATION seen Hance Sip—$>a_ Z a Handle————> ale Flat Wacherd Figure 3-1 (oM.284 Pages, Flat Washer $ sn Pin InstallationWEEE ead entire Section 7 regarding high: frequency equipment location and installation re. quirements. 3-1. INSTALLATION OF UTILITY TRAY (Figure 3-1) AWEGUUDIGE FALLING EQUIPMENT can cause serious personal injury or equipment damage. © Use equipment of adequate capacity to ift unit © [Fusing lift forks to handle this unit, be sure the lift forks are long enough to extend out of the op- posite side of the base. © Do not place any part of the body under the unit while itis suspended. 1. Remove uillty tray from bottom of unit. 2. Remove torch, parts kit, and work cable from utility tray, 3. Remove screws from top of wrapper. 4. Install utility tray onto top cover, and secure with screws removed in Step 3. 3-2. INSTALLATION OF HANDLE AND RUNN- ING GEAR KQEQQINIEE FALLING EQUIPMENT can cause Serious personal inury and equipment damage Use equipment of adequate capacity to lift the unit © (Fusing if forks to handle this unit, be sure the lift forks are long enough to extend out of the op- posite side of the base. © D0 not place any part of the body under the unit while its suspended. Place blocks under frame of unit before attaching runn- ing gear 1. Block unit securely in middle to ease installation of front wheels and rear support bracket, 2. Install rear support bracket using 1 /4-20 screws, fiat washers and nuts provided. 3. Slide axle through holes provided in front sides of base, 4. Ingtall two 1/2 in, (12.7 mm) flat washers to each end of axie, 8. Install wheels and 1/2 in. (12.7 mm) flat washers: for outside whee! hub onto axle and secure in place with cotter pins. install cotter pins by ben- ‘ding both legs around axle in one direction or by bending one leg clockwise and the other leg counterclockwise. Legs of cotter pins should conform to contour of axle 2s tightly as possible. 6. Install handles to power source using 1/4-20 seif-tapping screws provided. 3-3. LOCATION (Figure 3-2) Figure 3 - 2. Location A proper installation site should be selected for the ower sourceif the unit is to provide dependable service ‘and remain relatively maintenance free. A proper instalation site permits freedom of air move- ‘ment into anc out of the power source, and also least subjects the units to dust, dirt, moisture, and corrosive vapors. A minimum of 18 inches (257 mm) of unrestricted space must be maintained between the Power source front and rear panels and the nearest ‘obstruction. Also, the underside of the power source must be kept completely free of obstructions. The in- stallation site should also permit easy removal of the power source outer enclosure for maintenance fune- tons. UGE FALLING EQUIPMENT can cause Serious personal injury and equipment damage. © Use equipment of adequate capacity to lift the unit @ fusing fft forks to handle this unit, be sure the lift Forks are tong enough to extend out of the op: posite side of the base. Using lift fores too short will expose internal com- Ponents to damage should the tips of the lift forks penetrate the bottom of the unit. -4. INSTALLATION OF FILTER/REGULATOR AND BRACKET (Figure 3-3) 1. Install cir Filter/ Regulator support bracket using supplied hex-head sheet metal screws into holes provided in rear panel directly above input con- ductor access hole. 2. Remove retaining ring from Filter/Regulator and insert top of Filter/ Regulator through bottom of ‘support bracket, 3. Secure Filter/Regulator to support bracket by reinstaling retaining ring and tightening, (0M.286 Pages4. Connect nipple end of supplied air hose to OUT port of Filter/ Regulator. e— Ring Fiter/ Regulator Figure 3 - 3. Installation Of Filter/Regulator & Bracket 5. Connect other end of air hose to air fitting in lower left comer of reer panel and tighten securely. 6. Connect incoming Filter/Regulator, Be sure that this unit is supplied by 8 clean, dry ait source (see Specifications, Figure 2-1). ir line hose to IN port of 3-5. TORCH ASSEMBLY (Figure 3-4) KELGUINGE ELECTRIC SHOCK can kill. ‘Do not toueh five electrical parts. © Shut down unit and disconnect input power employing “lockout/tagging procedures” before inspecting, installing, oF servicing. Lockout/taaging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device. HOT SURFACES can cause severe burns. ® Allow cooling period before servicing. Troubleshooting of internal parts to be performed only by qualified persons. Install plunger tube into lower torch body and tighten with supplied 6 mm wrench. 2. Install electrode, and tighten with supplied 10 mm wrench, 3. Install and hand tighten nozzle. 4. Install guide pad so that loop end faces the direc- tion of travel. Position guide pad in upper groove Of drill-plate skirt for cutting in LOW range or in lower groove for cutting in Hl range. 5. Place the pad/drill-plate assembly on the torch, oM-284 Page 10 S—~cuide Pad Pa een eee fe £4.71 \teroh Sunda age Figure 3 - 4. Exploded View Of Torch 6. Grasp the notched, hinged section of the drill plate ketween thumb and forefinger 7. Shap notched, hinged section of dril plate over torch studs. Be sure that hinged section pivots correctly on torch studs. 3-6, WORK CLAMP INSTALLION (Figure 3-5) ~ A 10 foot (3 m} work cable with a lug on one end is included with this unit. ‘Steps 185 Figure 3 - 5. Work Clamp Installation Install the work clamp onto the work cable as follows: 1, Insert the end of the work clamp with the ter. minal lug on it through one of the two supplied insulating sleeves.2. Lay the work cable inside the half of the work clamp which has the flatest inner surface. 3. Align the smaller hole in the work clamp with the hole in the work cable terminal lug. Secure the terminal lug to the work clamp with the supplied rut and bolt 4, Bend the tabs on the end of the work clamp around the work cable. 5. Slide the insulating sleeve on the work cable over, the work clamp handle 6. Slide the remaining insulating sleeve over the ‘other work clamp handle. 3-7. INSTALLATION OF TORCH AND WORK CABLE (Figure 3-6) KQED ELECTRIC SHOCK can kill. © Do not touch live electrical parts © Shut down unit and disconnect input power employing “lockout/tagging procedures” before inspecting, installing, or servicing. Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circ breaker or other disconnecting device. Plug Pit Are Gas/Biectrode Ring Firing Terminal Figure 3 - 6. Torch And Work Cable Terminal 1. Remove wrapper. 2. Install strain relief clamp onto torch cables. 3. Insert torch cables through upper hole on front panel 4. Connect Gas/Electrade fitting to upper gas fit ting labeled TORCH on terminal connection board. 5. Connect black Pilot Arc cable to center terminal labeled PILOT ARC on terminal connection board. 6. Insert Work cable through bottom hole on front panel end connect to bottom terminal labeled WORK on terminal connection board. 7. Connect torch trigger amphenol plug to torch ‘vigger amphenol receptacle. 8, Remove lower left screw from lower front panel. ‘Secure strain reliet clamp to lower front panel by reinstaling screw. 9, Replace and secure wrapper. 3-8. ELECTRICAL INPUT CONNECTIONS 9 Read and comply with entire Section 7 regarding high-frequency equipment location and in- stallation requirements before making electrical input connections. This power source is designed to be operated from single-phase, 50 or 60 Hertz, ac input power which has a voltage rating that matches with one of the electrical input voltages shown on the nameplate. Consult the local electric utility if there is any question about the type of electtical system available at the installation site oF how proper conections tothe power source are to bbe made. B. Matching The Welding Power Source To The Available input Voltage (Figure 3-7) AQEGIUNIGE ELECTRIC SHOCK can kill. '® Lo not touch live electrical parts © Shut down unit and disconnect input power ‘employing “lockout/tagging procedures” before ‘internally inspecting, instaling or servicing. Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit reaker or other disconnecting device. INCORRECT INPUT VOLTAGE JUMPER LINK PLACEMENT can damage unit. ® Position jumper links as shown on the input voltage label located on input terminal beard. © Store unused jumper links across linked terminals. This unit is equipped with input voltage jumper links on the input voltage changeover board which allow opera- tion from different line voltages. This unit is shipped with the jumper links positioned for the highest voltage stated on the nameplate. If the unit is to be operated ftom a lower input voltage, remove the wrapper and. locate the input terminal board on right side of power source. Reposition the jumper links to match the available line voltage {see input voltage label on terminal board) 0-284 Page 11€. Input Conductor Connections (Figure 3-8) (IZGIDISE ELECTRIC SHOCK can kill. © Install a fusible line disconnect switch in the input circuit to the power source. This provides a safe and convenient means to complete- ly remove all electrical power from the power source whenever it is necessary to inspect or service the unit. © Employ "lockout/tagging procedures” on input line before making input connections to the power Lockout/tagging procedures consist of padiocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device. Input at rated load output for this unit can be in excess of 50 amperes. Thorefore this unit is shipped with a six ‘gauge, three-conductor power cable equipped with 1/4 in, (6.3 mm) lug terminals. The black and white conduc- tors must be connected to the line terminals and the ‘green conductor to a proper ground, Use a groundi method that is acceptable to the local electrical inspec- tion authority. Table 3-1 provides guidelines for selecting the proper size input conductors and line fuses. The input conduc- tors should be covered with an insulating material that complies with national, state, and local electrical codes. (QUEUE ELECTRIC SHOCK can kill. '® Do not connect an input (white or black) conduc- tor to the ground terminal, © Donor connect the grounal (green) conductor 10 an input line terminal. Incorrect input connections can result in an electrically energized power source chassis. The ground terminalis connected to the power source chassis and is for groun- ding purposes only. Jnput Voltage Label ie Input Voltage jo G00” Changeover Boord Fight Side of Unit with ‘Wrapper Removed fe Figure 3 - 7. Location Of Input Voltage Changeover Board, (0M-284 Page 12 Table 3 - 1. Input Conductor And Fuse Sizes Ingut Conductor Size - AWG" 200v|220v| 230v | agov | 415v | s6ov | s75v (8) | gig) | acs) |10¢10)] 10/10) [42112) [121421 Fuse Size In Amperes 200v|220v|230v | seov | aisv | asov | s75v i00A] 80a | 80a | 70a | 60a | 40a | 354 “Input conductor sizes are based on National Electrical Code Specifications for allowable ampacities of in- sulated copper conductors, having a temperature rating of 75°C, with not more than three conductors in 4 raceway or cable. Numbers in { } are equipment ‘ground conductor sizes. round (teen Ground conor Diconnect \ ey Black Figure 3 - 8, Input Conductor Connections—— SECTION 4 - OPERATOR CONTROLS semen Ready. Range Switeh Ready. Switch Torch Trigger Receptacte ‘Toreh Cable Hole ° |___— Power Light i ° = ase 128 Figure 4 - 1. Front Panel View 4-1. POWER SWITCH (Figure 4-1) - Place the POWER switch in the ON position to energize power source. Place POWER switch in OFF position to shut power source down. 4-2, POWER LIGHT (Figure 4-1) - The POWER light indicates that the power source is energized. The POWER light will be on whenever the POWER switch is in the ON position. 4-3, READY SWITCH (Figure 4-1) - The READY switch is a spring-loaded toggle switch which, when held in the ON position, will energize the control cir- cuitry and place the torch in a ready to cut status. READY switch returns to the normally open position when released, 4-4 READY LIGHT (Figure 4-1) - When the READY light 's on all of the safety devices within the control circuity have been energized and the torch a ready to cut status. If the READY light does not light, atter the READY switch is placed in the ON position, ‘check the safety devices to ensure proper working order (see Section €-8 Troubleshooting}. 4-5. RANGE SWITCH (Figure 4-1) - The RANGE SWITCH provides the means of selecting between the ‘wo amperage ranges. Select the LOW range when cut- ting thin gauge material where the torch comes into direct contact with the work surface. Select the HI ange when cutting thicker material where the standoff distance must be 1/16 in, (1.6 mm) or more. ns SECTION 5 - SEQUENCE OF OPERATION emcee FEXEMIMILISE ELECTRIC SHOCK can kill; MOVING PARTS can cause serious injury: IMPROPER AIR FLOW AND EXPOSURE TO ENVIRONMENT can damage internal parts. © Do not use cables or torch with demaged insula- tion, © Shut down power source and disconnect input power before cleaning slag from nozele and/or guide post. © Maintain at fesst 18 inches (467 mm) of unrestricted space on all sides of unit and keep underside free of obstructions. © Do notplace any fitering device over the intake air passages of this power source. © Keep at covers and panels in place while operating. ‘Warranty is void if any type of filtering device is used or if the power source is operated with eny portion of the outer enclosure removed, (0M 284 Page 13ARC RAYS, SPARKS, AND HOT METAL can burn eyes and skin. © Wear correct eye and body protection. © Wear welding lens No. 4 when operating this unit in the low range; wear welding lens No. 8 when operating in high range. © Allow equipment and work to cool before handl- ing. FUMES AND GASES can seriously harm your health. © Cutting aluminum plate on a water table may cause hydrogen detonation beneath the workpiece. Contact equipment manufacturer for recommended practices for cutting aluminum. © Ventiiate to keep from breathing fumes and gases. © if ventilation is inadequate use approved breathing ‘apparatus. © When possible cut over @ water reservoir or pro- ‘erly ventilated work table designed to minimize fumes, gases, and sparks. HOT METAL AND SPARKS can cause fire or burns. © Do not cut over combustible material, and watch for fire, © Hove fire extinguisher nearby, and know how to use it © Remove all flammable materials from the im- mediate area. CUTTING CONTAINERS can result in explosions, re, or poisonous fumes. © "Cut containers only after proper cleaning. CUTTING WORKPIECE ON CONCRETE FLOOR can cause concrete to explode. © Do not place workpiece on conurete fluor PARTIALLY VAPORIZED METAL PARTICLES will mark glass and scorch @ Remove cover, or protect any glass or trim within approximately 24 in, (610 mm) of the cutting source. See Section 1 - Safety Rules For Operation OF Arc Welding Power Source for basic welding safety infor- mation. CUTTING CURRENT can damage automotive electronic parts. © Disconnect both battery cables before cutting on an automobile. PILOT ARC can cause burns, © Keep torch tip clear of personnel when switch is depressed. © Turn off power source and disconnect input power before removing or replacing torch parts. 5-1. START-UP 1. Determine material type and thickness and cut- ting parameters using Plasma Arc Cutting Parameters (Figure 2-3). ‘oW-284 Page 14 2. Place torch guide pad in upper groove of dill plate skirt for cutting in LOW range or in lower ‘groove for cutting in HI range. 3. Connect WORK cable to work. 4, Turn on air supply. 5. Turn line disconnect and the power source POWER switch to ON position. POWER ON light will illuminate. 6. Hold READY switch in ON position. Illumination ‘of READY light indicates that the torch is ready for operation, 7. Begin cutting. UGE Correct cutting sequence includes 1 t0 7.5 seconds of preflow air and 3 seconds of high fre- quency pilot arc during are initiation. There is 20 to 26 seconds of post flow air after tarch trigger is released to allow for proper cooling of torch after arc is extinguish- ed. 5-2. SHUTTING DOWN 1. Stop cutting, 2. Shut off air supply. 3. Place POWER switch in the OFF position. Helmet aad Glasses Breathing ‘Apparatus eee Aas 186 Figure - 1. Safety Equipmentome SECTION 6 - MAINTENANCE & TROUBLESHOOTING =m Every six months inspect the labels on the unt for legibility. All precautionary labels must be ‘maintained ina clearly readable state and replaced when necessary. See Parts List for part number of precautionary labels. 6-1. FAN MOTOR - This unit is equipped with an exhaust fan and relies on forced draft for adequate cool- ing. The fan motor is manufactured with lifetime sealed bearings and requires no maintenance. 6-2. INTERNAL CLEANING [EGRIMIEE ELECTRIC SHOCK can '® Do not touch live electrical parts © Shut down unit and disconnect input, power employing “lockout/tagging procedures” before inspecting, maintaining, or servicing. Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device. HOT SURFACES can cause severe burns. © Allow cooling period before servicing. Troubleshooting of internal parts to be performed only by qualified persons, Blow out or vacuum the dust and dirt from around the internal components. Do this at least once 2 year depending on the location of the unit and the amount of dust and dirt in the atmosphere. The power source outer enclosure should be removed and a clean, ory airstream or vacuum suction should be used for this cleaning operation. 6-3. CABLES (QGSGRUNISE ELECTRIC SHOCK can kill. ‘@ Do not touch live electrical parts, © Shut down unit and disconnect input power ‘employing “lockout/tagging procedures” before inspecting, maintaining, or servicing. Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device. HOT SURFACES can cause severe burns, ® Allow cooling period before servicing. Troubleshooting of internal parts to be performed only by qualified persons. Every three months inspect cables and torch for breaks in insulation and be sure that all connections are clean and tight, Repair or replace cables as necessary. Clean and tighten connections at each inspection, 6-4, SPARK GAPS (Figure 6-1) AQEGMIMGE ELECTRIC SHOCK can Kill Do not touch live electrical parts. © Shut down unit and disconnect input power employing “lockout! tagging procedures” before inspecting, maintaining, or servicing. Lockout/tagging procedures consist of padiocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device. HOT SURFACES can cause severe burns. © Allow cooling period before servicing. Troubleshooting of internal parts to be performed only by qualified persons. Readiust the spark gaps every three to four months or when intermittent operation occurs. Normal spark gap setting is 0.028 in, (0.635 mm). Do not clean or dress points since the ‘material at the tps is tungsten and impossible to file The entire point should be replaced when the tungsten section has completely disappeared. This unit is provided with a spark gap assembly located ‘behind the front panel. To adjust spark gaps, proceed. 2s follows: 1. Remove wrapper. 2. Loosen screw A. 3. Place feeler gauge of proper thickness between point C. 4. Apply sight pressure against point 8 so feeler gauge is held firmly in gap. 5. Tighten screw A. 6. Reinstall wrapper. Figure 6 - 1. Spark Gap Adjustment 6 - 5. ELECTRODE INSPECTION AND REPLACE. MENT (Figure 6-2) QEGRINIGE ELECTRIC SHOCK can kill © Do not touch lve electrical parts. © Shut down unit and disconnect input power ‘employing “Tockout/tagging procedures” before inspecting, maintaining, or servicing. Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device. HOT SURFACES can cause severe burns. © Allow cooing period before servicing. Troubleshooting of internal parts to be performed only by qualified persons. (OM-284 Page 15INCORRECT AIR PRESSURE can cause excessive electrode wear. © Set Plasma/ Secondary Gas or Air 10 3.6 CFM (98.5 L/min.) at 76 PSI {603 kPa) maximum (see Figure 2-1 Specifications). EXCESSIVE ELECTRODE WEAR can damage torch. © Inspect electrode weekly and replace when zir onium wire is worn down 1/16 to 8/64 in. (1.5 10 2.0 mm) from end of electrode. Inspect the electrode weekly and anytime the nozzle is, replaced (see Section 3-4). Check wear of zirconium wire in electrode according to Figure 6-2 and replace electrode if necessary. Electrode 1/16 10 5/66 in (15 102.0 mmi — Figure 6 -,2. Electrode Length 6-6. CLEANING NOZZLE AND GUIDE PAD (Figure 3-3) KDEGDIIGR ELECTRIC SHOCK can Kill @ Do not touch lve electrical parts. © Shut down unit and disconnect input power ‘employing “lockout! tagging procedures” before inspecting, maintaining, or servicing. Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses, from fuse box, oF shutting off and red-tagging circuit breaker ot other disconnecting device. HOT SURFACES can cause severe bums. © Allow cooling period before servicing. Troubleshooting of internal parts to be performed only by qualified persons. Zirconium Wire Weekly inspect the nozzle and guide pad for an ac: cumulation of slag. Clean slag as necessary. 6-7. FUSES (Figure 4-1) ELECTRIC SHOCK can ‘Do not touch live electrical parts. © Shut down unit and disconnect input power ‘employing “lockout/tagging procedures” before inspecting, maintaining, or servicing. Lockout/ tagging procedures consist of padiocking line disconnect switch in open position, removing fuses from fuse box, oF shutting off and red-tagging circuit breaker or other disconnecting device. 0M-284 Page 16 IMPROPER FUSES can damage this unit. © IF replacement becomes necessary, use only fuses of the proper size, type, and rating (see Parts List Fuse F1 protacts the input of the cutting circuit against overload. Should FI open, the unit would shut down, Fuse F2 protects the control circuit against overload, Should F2 open, the unit would shut down. These fuses are located on the front panel of the power source. To replace fuses, proceed as follows: rotate fuse holder cover 1, Depress and counterclockwise. 2. Pull out fuse with cover when fuse holder cover is free, 3. Insert new fuse into fuse holder cover. 4. Install fuse with fuse holder cover back into unit 5. Depress and rotate fuse holder cover clockwise until cover is secure. 6 - 8. TROUBLESHOOTING QEOUIGE ELECTRIC SHOCK can kil. © Do not touch live electrical parts. © Shut cown unit nd disconnect input power ‘employing “lockout/tagging procedures” before inspecting, maintaining, or servicing. Lockout/tagging procedures consist of padiacking line disconnect witch in open position, removing fuses from fuse box, of shutting off and red-tagaing circuit breaker or other disconnecting device. HOT SURFACES can cause severe burns. © Allow cooling period before servicing. Troubleshooting of internal parts to be performed only by qualified persons. {tis essumed that proper installation has been made, ac cording to Section 3 of this manual, and that the power source has been functioning properly until trouble developed. The following chart is designed to diagnose and provide remedies for some of the troubles that may develop in this power source. Use this chart in conjunction with the circuit diagram while performing troubleshooting procedures. if the trouble is not remedied after performing these pro- cedures, the nearest Factory Authorized Service Sta tion should 9e contacted. In all cases of equipment malfunction, the manufacturer's recommendations should be strictly followed.‘TROUBLE PROBABLE CAUSE REMEDY No open circuit voltage; fan | Fuses F1 and/or F2. Cheok and replace F1 and/or F2 (see Section FM runs. 6-7). Contactor coil W. Replace contactor W. Contactor points. Replace points. Lack of high-frequency; dif- | Spark gap spacing incor- | Adjust spark gap (see section 6-4). ficulty in establishing are. | rect. Leakage of high-frequency | Replace cable. from torch cable, Timer TMD1 Replace TMD1 Contro! Relay CR1 Replace CR1 Double arcing during pilot | New nozzle with partially | install new electrode (see Section 6-5). are. used electrode. No air flow when torch trig- | Fuse F2. Check and replace F2 (see Section 6-7). ‘ger pressed. Air pressure switch $4. Replace Sé. Torch switch. Check torch switch Short circuit between noz- | Accumulation of siag on | Clean nozzle and guide pad (see section 6-6). ‘le and workpiece; cut edge | nozzle and guide pad. has undesired bevel. Poor cutting charae- | Excessive electrode wear. | Check and replace electroge (gee section 6-5). teristics; torch overheating. No cutting arc, Work cable loose or discon- | Check work cable. nected, Power light out; fan motor | Blown fuse or open circuit | Replace fuse or reset circuit breaker at line input, does not run, breaker at line input power. POWER switch $1. Replace $1. Power light out; fan motor | Blown fuse F2. Replace F2 (see Section 6-7). runs, READY light out. Blown fuse F2. Replace F2 (see Section 6-7), Inauticint alr peenaure, | Rencluet ar pressure {eue Figure 2-1 Specifica- tions) Air pressure switch $4. _| Replace S4. Control relay CRS. Replace CRE. Control relay CAS. Replace CRé, Thermal protector TP1 | Replace TP1 open. [ Control relay CRS Replace CRE. (0.284 Page 17‘TROUBLE PROBABLE CAUSE REMEDY READY light on, pilot starts | Resistor R1. Replace R1. but no low range. Diode 06. Replace D5. READY light on, pilot starts | RANGE switch $2. Replace $2. but no HI range. Control relay CR2. Replace CF2 Erratic or improper weld output. Poor and/or improper input and/or output connections. See Sections 3-6 and 3-7 for ‘output comections. roper input and Loose or dirty cable con- nections. Clean and tighten all connections, on-284 Page 18 re] Ha PE Occ | Circuit Diagram No. B-110 985 Figure 6 - 3. Circuit Diagram"SECTION 7 - CERTIFICATION FOR HIGH FREQUENCY ARC WELDING EQUIPMENT * 7-1. GENERAL - This following information is necessary to make @ proper instalation of the high fre- quency arc welding equipment described in this instruc- tion manual. In order to comply with Part 18 of the Rules and Regulations of the Federal Communications Commission, the certificate in front ofthis manual must be filed in completely and signed. The certificate must be kept WITH THE EQUIPMENT AT ALL TIMES to comply with the regulation. ‘The manufacturer of the equipment covered herein has, ‘conducted approved field tests and certifies that the radiation can reasonably be expected to be within the legal limits if the correct installation procedures, as ‘outlined, are followed. ‘The importance of a correct installation cannot be over- ‘emphasized since case histories of interference due to, high frequency stabilized arc Welding Machines have shown that invariably an inadequate installation was at, fault ‘The user of the equipment must complete the certifica- tion by stating that he has installed the equipment and is, using it, according to the manufacturer's instructions, ‘The user must sign the certification notice appearing in front of this instruction booklet indicating that he has complied with the requirements. In the event that interference with authorized services ‘occurs, in spite of the fact that the radiation from the ‘welding equinment is within the specified limits, the User is required to take suitable steps to clear the situa- tion. The factory personnel will assist the user by sup- plying technical information to clear the situation. In lieu cf complying with the installation requirements and the certification of each individual installation, the user may elect to certify his entire plant by having a reputable engineering firm make a plant radi survey. In such cases, the installation instructions incor- porated in this instruction booklet could vary well serve 8 a guide in minimizing interference that might be con- tributed by the high frequency arc welding equipment. 7-2. GENERAL INFORMATION - In a high fre- quency stabilized arc Welding Machine Installation, in- terfering radiation can escape in four distinct ways as outlined below: 1. Direct radiation from the welding machine. This, is radiation that escapes directly from the Welding Machine case. This is very pronounced if access doors are left open and unfastened and if the Welding Machine case is not properly grounded. Any opening in the metal Welding Machine_case will allow some radiation to escape. The high frequency unit of this certified equipment is adequately shielded to prevent direct radiation of any consequences if proper ‘grounding is carried out. 2. Direct feedback to the power line. High fre- quency energy may get on the power line by direct coupling inside the equipment or the high frequency unit, the power line then serving as a radiating antenna, By proger shielding and filtering, direct coupling is prevented in this certified equipment. Attoast 0 foot Sali Metallic Conduit ing tose and ‘Switch Box Good electrical joints High Froquoney Stabilized Welding Machin or Oscillator Figure 7 - 1. Power Ser Stabilized Arc Welding Machine 3. Direct radiation from welding leads. Direct radia- tion from the welding leads, although very pro- nounced, decreases rapidly with distance from the welcing leads. By keeping the weiding leads as short as possible, the operator can do a great deal to minimize interference from the source. ‘The intensity and frequency of the radiation can be altered over wide limits by charging the loca- tion and relative position of the welding leads land work. If possible, loops and suspended sec- tions should be avoided 4. Pick-up and reradiation from power lines. Even though welding lead radiation fatis off rapidly with distance, the field strength in the immediate inity of the welding area may be extremely high. Unshielded wiring and ungrounded metallic objects in this strong fiold may pick up the direct radiation, conduct the energy for some: istance, and produce a strong interference field in anothar area. This is usually the most troublesome source of interference, but careful adherences to proper i stallatior procedure as outlined in this booklet will minimize this type of interference. 7-3. POWER SERVICE - The specific installation i structions for making the proper primary connections to, the equipment as outlined in the instruction booklet fur- ished with the equipment, should be followed carefully with one exception as noted in the following paragraph. Frequentiy installation instructions specify that the primary power service shall be run in solid or flexible metallic condui:. Ordinary helically wrapped conduit designed for mechanical protection and is not suitable for electrical shielding. Only solid metallic conduit or conduit of “equivalent electrical shielding ability” should be used to enclose the primary power service leads. (0M -284 Page 19Solid metallic shieiding shall enclose the primary power service to the equipment from a point 50 feet from the equipment in an unbroken run, ‘This shielding shali be grounded at the farthest point from the equipment and should make good electrical contact with the casing of the equipment. The ground should be in accordance with the specifications outlined in the section entitled GROUNDS" and as shown in Figure 7-1. Care should be taken that paint or corrosion at the junction of conduit and case, does not interfere with good electrical contact. There shall be no gap in this shielding run. This simply means that within 50 feet of the equipment, no portion of the power wires serving the equipment shal! be un- shielded. If there is any question about the electrical ef- ficiency of the joints between individual conduit sec- tions, outlet boxes and the equipment case, bonding should be carried out by soldering a copper strap or wire across the joint as shown in Figure 7-2. ‘Sloan and sok oppar Solder r3 (a) Demountable Bonding Strep for Conduit Joints Copper Wire Solder met Solder cy UP 3 (b} Solid Bonding with Copper Wire for Conduit Joints Figure 7-2. Two Recommended Methods For Elec- trical Bonding Across Poor Conduct- ivity Condult Joints 7-4, WELDING MACHINE - The location of the equipment should be chosen with respect to nearness. 10 a suitable ground connection. The equipment case, firmly bonded to the power conduit, should be ground ed to the work terminal of the equipment with a copper, cable or braid with rated current carrying capacity equal to or greater than that of the power service wires. This “work” output terminal of the equipment should then be grounded to a “good electrical ground” (as. defined in section entitied GROUNDS") with a short length of welding cable of the same capacity as the "work lead”. (See Figure 7-3. Welding Machine Caso Tirmly bonded to Power Conduit Source of ‘Caze grounded to —~ ‘Work Terminal, Figure 7-3. Ground Connections At Welding Machine No change in the wiring or the location of parts inside the equipment, other than power service tap changes or other adjustments specifically covered shall be made. ‘The equipment shall not be modified in any way since (oM-284 Page 20 changes in the equipment can affect the radiation characteristics and may not be in accordance with the test data upon which the manufacturer bases his cer- tification, While the equipment is in operation, all access and ser- vice doors shall be closed and properly fastened. ‘Spark gap settings shall be maintained at the minimum seperation consistent with satisfactory welding results, 7-5. WELDING LEADS - In order to minimize direct weld lead radiation, the welding leads (electrode lead and work lead) must be kept as short as possibie. Cer tification tests on this machine have been made with leads 25 feet long. Considerable improvement in radia- tion minimization can be had by shortening the leads as much as possibi, Keeping the electrode lead and ground or work lead as close 2s possible and on the floor serves to reduce the radiation. (S3e Figure 7-4). Welding Machine. ‘or Oscilator Keep laade on around ‘or boards and 3/4" 10.1" apart Bloctrode Holder Werk ‘Koop leads #2 short as possible raver in axcees of 25 fast Figure 7- |. General Rules For Welding Leads 7-6. WIRING IN THE VICINITY OF THE WELDING AREA - As discussed in the general infor- mation section, the most serious source of interference is reradiation from wires that are located near the welding area, Any ungrounded electrical conductor in the strong “directly radiated” field, produced by the welding leads, serves as a pick-up device and may conduct the in- terference for some distance and reradiate strongly at another iocation. For purpose of simplification and standardization, the space all around the weld zone at a distance of 50 feet in all directions is referred to as the High Field Intensity (H.F.L. zone, (See Figure 7-5) ‘To minimize radiation of this type all wiring in the H.F. zone shall be in rigid metallic conduit, lead covered cable, copper braid or material of equivalent shielding efficiency. Ordinary flexible helically wrapped metali conduit, commonly referred to as “B.X.” is not satisfac- tory for shielding, and should not be used. The shield on all witing should be grounded at intervals of 50 feet and good electrical bonding between sections shall be main- tained, This shielding requirement applies to al! wiring, in- cluding telephone, inter-communication, signal “and control and incidental service,Grounded at 150 foot interval 7 a TA -_——~ Weiding F Work, Srovoded wires oot of \ Hoon te iment ove. XN oa Pe Figure 7-5. General Requirements to Mi Reradiation Pick-Up In the ‘the Weld Zone Extreme precaution should be taken to make sure that, the location of the zone is chosen so that none of the conditions are voided by unshielded wires off the premises but stil within the radial dimensions of the H.F.I. zone. This 50 foot H.F.I. zone is @ minimum that is imposed on the installation. Certification tests by the manufac- turer are based on this limit, Keeping unshielded wires farther than 50 feet from the weld zone will materially aid in minimizing interference. If itis impossible to relocate unshielded wires, that sec- tion within the H.F.1. zone, should be placed in conduit {and each end of the conduit section grounded. It must be emphasized that all ‘changes in power and lighting wiring should be mede by 2 qualified electrician and comply with the National Eectrical Code requirements. Any shielding or reloca- tion of telephone or signal wires must be done either by the service company concerned or with the specific per- mission of said company. 7 - 7. GROUNDS - Frequent reference is made to a "good ground” in previous sections. Although there is considerable leeway in the interpretation of this term, for the purpose covered in this booklet the following specifications apply: ‘A “ground” connection should be made to a driven rod at least 8 feet long and driven into moist soil, A cold water pipe can be used in place of the ground rod provided it enters the ground within 10 feet of the equipment to be grounded. All leads connecting the point to be grounded to the ground rod or pipe should be as short as possible since the ground lead itself can become an effective radiating antenna. The effectiveness of a ground in reducing interference depends upon the ground conductivity. In certain loca- tions it may bcome necessary to improve the ground conductivity by treating soil eround the ground rod with 2 salt solution. 7-8. METAL BUILDING - It is frequently thought that operating of high frequency stabilized are welding ‘equipment in metallic buildings will completely eliminate ‘troublesome radiation. This, however, is a false assumption. ‘Ammetallic building structure, if properly grounded, may sserve to reduce direct radiation from the weld zone but will have no effect on conducted interference and teradiation. As a result, all installation requirements necessary for certification must be complied with. If the metallic building is not properly grounded, bon- ding to several good electrical grounds placed around ‘the periphery of the building will give reasonable assurance that the building itself is not contributing to the radiation. 7-9. INDIVIDUAL INSTALLATION CERTIFICA- TION - Any cr all of the above installation re- uirements may be waived by the user if he desires 10 exercise the option of making an individual field survey Of the particuler unit installation (or the complete in- stallation if more than one unit is involved), and certify- ing on that bass, This survey shell be made by a competent engineer in accordance with the test procedure requirements as set forth in Part 18 of the Rules and Regulations of the Federal Communications Commission. ‘Surveys of this nature can cover a single uni: or multiple units or may include the complete plant structure. 7-40. CHECK LIST - The following questions may be used by the installer as @ check to see if all installation requirements have been met: 1. Has the equipment been located so that ground leads can be kept short? 2. Are the power leads, serving the unit, in condi 3. Is there good electrical contact between power ‘conduit and case? 4. Do the conduit couplings make good electrical ‘contact? (If in doubt, use bonding). Is there good electrical contact between conduit and switch on service boxes? 6. If rigid metallic conduit is not used, is the shielding used of equivalent shielding efficiency? (Copper sieving, lead covered cable, ete., is satisfactory. Spirally wound flexible metallic con- duit is not suitable.) 7. Is the conduit system grounded ata point at least 50 feet from the equipment? 8. Is the conduit run complete (without any gap) in \F.|, zone? 9. Is the equipment case connected to the work ter- ‘minal of the secondary? (0.284 Page2t10. " 12. 13. 14. 15. 16. 17. 18. 19. 20. Is the wire used for this connection of sufficient size? Is the work terminal connected to a good elec- tical ground? Is the cable or copperbraid used for this connec: tion equal to or greater in current carrying capacity than the welding lead? \s this cable es short as possible? Are the spark gaps set at .025 in. or less? ‘Are all service and access doors closed and bolted? ‘Are the welding leads less than 25 feet long? ‘Are they as short as possible? ‘Are the welding leads on the floor or placed on a suitable board? Are the welding leads approximately 3/4” to 1” ‘apart? Have you visualized the H.F.I. zone, a sphere with a 50 foot radius centered on the weld zone? ‘0M.-284 Page 22 21. Have the unshielded power and light wires originally in this H.F.1. zone been placed in (grounded shields or been relocated outside the zone? 22. Have all large metallic objects and any long guy ‘or supporting wires in the H.F.I. zone been ‘grounded? 23, Have you checked so that no external power or telephone lines off the premises are within the zone? 24. Are the grounds driven ground rods? 25. Is a cod water pipe used as ground? 26. If so, does it enter the ground 10 feet or less from the connection? 27. Are the connections to the ground clean and tight? 28. If operated within a metal building, is the building properly grounded? I your answer is “yes” to the above questions, you can ‘certify the installation by signing the certificate.July 1987 FORM: OM-284FFigure A - Nain AssemblyReplace Coils At Factory Or Factory Authorized Service Station. Item Dia. Part No. Mkgs. No. Description ‘Quantity Figure A Main Assembly i 095 336 TORCH (Fig P94)... 1 2 604 423 GRIP, handle ... 2 3 095 320 HANDLE. 2 4 095 343 WRAPPER |. 1 5 co 099 195 CAPACITOR, ceramic 0.003 uf 3000 volts. 1 6 605 946 PIN, cotter 1/8x1.. 2 7 602 246 WASHER, fiat 1/2 6 8 095 094 WHEEL, Sin dia. 2 a 095 319 AXLE . oe 2 10 096 520 FITTING, pipe-brass adapter bulk hd3/16 TRG... : 1 "1 095 325 TERMINAL BOARD, power output.......... 7 1 12 008 075 BRACKET, support-component ....-. 1 13, RZ 094 964 RESISTOR, WW fixed 375 watt 161 ohm» 1 140Tt 405 472 TRANSFORMER, power-main (200/230 volts) consisting of! 1 471 105 468 TRANSFORMER, power-main (460/575 volts} (consisting of) certs) 14 Ti +113 275 TRANSFORMER, power-main (380/415 volts 5) hz} (consisting of) ei Se eee te nee ee aera 1 15 PRI 105 254 . COIL, pri (200/230 volts) 1 15 PRI 105 256 “COIL, pri (460/575 volts) ae 7 1 18 PRI 113287 - COIL, pri(380/415 volts) . eee 1 15 PRI 113.288 - COIL, pri (220/380 volts) 7 1 16 SEC 113.288 | COIL, sec . 7 1 TP1 020 520 THERMOSTAT, NC. eee pea ta atie 1 7 Seger eercneeern aaa Becca 1 18 107 918 TRAY, tool ...... eae 1 199 Z 085 440 STABILIZER... : 1 20 072 082 BUSHING, 17/64 10 x31 /6400x 19/32... 1... 1 24 010 083 HANGER, minerallic No. 6 oe 1 22 C5 084. 961 CAPACITOR, electrolyte 2500 uf 450 volts do |... 1 23 TEI 088 020 TERMINAL ASSEMBLY, pri (200/230) 1220/880) (80/418) conscing o on. 1 23 TEI ‘106 373 TERMINAL ASSEMBLY, pri (460/575) (consisting of) ...... 1 24 026 631 . INSULATION, pristud barrier ....... a 3 24 026 631. INSULATION, pr stud barrier (460/875) 6 28 038 618 - LINK, jumper : 1 26 081 671 . TERMINAL BOARD... : 1 7 038 887 | STUD, 10-32% 1-3/8 w/hox collar. 22... 3 28 010 913 . WASHER, flat0.025 1D x 1/20Dx1/32 0.01.1... 3 29 010 913 | WASHER, fiat 0.025 ID x 1/2 OD x 1/32 (480/578) .. 6 23 601 835 | NUT, hex 10-32.....0... ‘| : 6 30 Figure E PANEL, rear sw/eomponents (P37) ‘| 1 3 097 614 FOOT, mig-unit .. sf i 1 32, 095 340 SKID BASE . 1 33 C10 087 337 CAPACITOR, ceramic 0.003 uf 3000 voits - aa 34 C11 (098 566 CAPACITOR, ceramic 0.003 uf 3000 volts Dod 35 Figure C PANEL, front-w/components (Pg 5) 1 36 010 006 TUBING, 5/8 OD x 12 ga wall x3-1/4 ; 4 a7 110 935 HF PANEL (Fig D Pg 6) . 7 7 2 1 096 397 HOSE, air30 inch w/fittings ee : 1 087 318 CLAMP, 1 inch x 13/32 ae el BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. 0M-286 Page?hem Part No. No. Description Quantity Figure B 095 336 Torch (Fig A Pg 2 Item 1) 1 095 793 TORCHHEAD ........ 1 2 095 481 AIR PLUNGER TUBE ....- 1 3 095 482 AIR ELECTRODES ......- 3 4 095 483 NOZZLES Mi6x 100.22. 2..22.. 6 5 095 484 DRILLPLATE.... i 2 6 095 485 GUIDEPADS....... 5 7 +096 950 REGULATOR/FILTER (consisting ot) 1 8 4112274 RING... 1 9 +117 125 | GAUGE, pressure 1 10 +010 368 CLAMP, ground 100 amp....2..2.2... ‘ 1 a +026 843 INSULATOR, vinyl-black 220.0000 000000002 1 2 +600 325 CABLE, weld No.6 (order by ft) 0.0000. 2oft 3 095 480 SCREWS CM3-3U : 3 14 095 479 SCREWS TF-90M3 20000000000 3 16 095 486 TORCH HANDLE. ; 1 16 095 477 NOZZLE SUPPLY CONDUITS. 1 7 095 476 GAS ELECTRICITY CONDUITS. 1 18 095 478 TRIGGER CONTROL (consisting of) 1 19 039 273 . PLUG, 5 pin MS-3106A-16S-8P 1 20 039 685 . CLAMP, cable 1 21 096 680 WRENCH, electrode & stem remover 1 22 +095 475 NEOPRENE SHEATH 1 23 095 487 TRIGGER HOUSING 1 + These items are not included with torch. BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. 0.286 Page dItem Dia, Part No._Mkgs.__No. i Description Quantity Figure © Front-W/Components (Fig A Pg 2 item 35) 1 NAMEPLATE (order by model & serial number) 1 2 +095 341 PANEL, front... eae i 3 S2 089.085 SWITCH, togale SPST 20 amp 125 volts ac... : 1 4 $2021 467 SWITCH, toggle SPST MC 3 amp 250 volts, 1 5 PLI.2 048 573 LIGHT, indicator-red lens 28 volts. 2 6 S1 045 834 SWITCH, toggle DPST 60 amp 600 volts. i 7 CRI 059 266. RELAY, enclosed 120 volts ac DPDT 1 & TOM2 095 934. TIMER, 20 seconds (includes R6) 1 9 R3 089.524 RESISTOR, WW fixed 5 watt 4.7K ohm i 10 TDM3 095 981 TIMER, 1 second (includes R7) i 11 _RB_ 000.039 RESISTOR, carbon 2 watt 680 ohm 1 12 TDMi 095 962. TIMER, 3 seconds {includes RB) 1 13 046 432 HOLDER, fuse 2 44 F1,2 *012.618 FUSE, miniature-glass 5 amp 2 15 095 727 LABEL, precautionary. 1 16 057 358 BUSHING, snap 1 10 x 1.37 mtg hole. 2 17 RC1 035 623 RECEPTACLE, 5 socket MS-3102A-16S-8S. 1 18 CR7 110 386 RELAY, enclosed 24 volts ac DPDT flanged 1 Figure C - Panel, Front - W/Components “Recommended Spere Parts +When ordering @ component originally displaying a precautionary label the labe! should also be ordered. BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. oM284 Pagestem Dia, Part No. _Mkgs. No. Description Quantity FigureD 110.935 HF Panel (Fig A Pg 2 Item 37) 1 000 687 STRIP, mtg-HF coil. 1 2 T2095 318 COIL, coupling-air 1 3 096 414 STRIP, reinforcing 2 4 020 622 HOLDER, points 2 5 G _*020 603 POINT, spark gap 2 6 13 074398 TRANSFORMER, HF 115 volts... i 7 110 936. MOUNTING BOARD, component 1 8 R12 110 360 RESISTOR, WW fixed 25 watt 10 ohm 1 9 CB&,7 096 761 CAPACITOR, mica 0.002 uf 10000 volts... 2 Figure D - HF Panel “Recommended Spare Parts BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. M24 Pages.Item Die. Part No. _Mkgs.__ No. Description Quantity Figure E Panel, Rear - W/Components (Fig A Pg 2 Item 30) 1 SRI 112.034 RECTIFIER, silicon diode (consisting off 1 2 D3-5 095 141. DIODE, 40 amp 1000 volts SP 3 3 D1,2._ 095 142 . DIODE, 40 amp 1000 volts RP 2 4 112 006: HEAT SINK 1 5 VR1 095 492 _ SUPPRESSOR ‘ 1 6 Cl-4 031 688 - CAPACITOR, ceramic 0.01 uf 500 volts de 4 7 CB 108 632. CAPACITOR, ceramic 0.05 uf 500 volts de 1 8 097 512 WINDTUNNEL, 11 inch a 1 9 032 662 BLADE, fan 60 hz 10 inch 5 : 1 10 096 918 PANEL, rear 1 u 600 313 CABLE, power 6 ga 3/c 600 volts (order by #) oft 12 044.426 CONNECTOR, clamp-cable 1 inch : 1 13 W1 034.895 INTERLOCK, contactor-no .... 1 1a 034 260 LINK, connecting-contactor terminal - : 2 18 CR2,3 035 519 CONTACTOR, 40 amp 3 pole 24 volts (consisting of) «.- 2 024 493 . COIL, 24 volts ac. 1 16 W 605855 CONTACTOR, 40 amp 3 pole 120 Vols consisting ad 1 032 349. COIL, 120 voltsac.. 1 7 095 317 LINK, connecting-contactor terminal . 2 18 CR4,5 110386 RELAY, 24 volts ac OPOT flanged ....- 2 19 010 296 FITTING, hose-elbow M 1/4 NPTx'/8.18 RH . i 20 071 270 FITTING, pipe-brass tee st 1/4 NPT... 1 21 010 869 FITTING, pipe-brass bushing 1/4 x 1/8 NPT 1 22 $4 094963 SWITCH, pressure-air 40-100 Ibs ...... 1 23 ASI 035 630 VALVE, 24 volts 2c 6 volts de2 way 1/4 IPS port 1/8 orifice 1 24 110 498 HOSE, air... vee 1 25 010 678 FITTING, pipe-brass elbow st 1/4 NPT 1 26 R097 495 RESISTOR. W/mta hardware... 1 27 FM 032 678 MOTOR, 1/50 hp 230 volts ac 1500 rpm. 1 BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. (0-288 Page Figure E - Panel, Rear - W/Components