April 1981 FORM: OM-180

Effective With Serial No. JA428799

MODEL
SQUAREWAVE 1000

OWNERS
MANUAL

MILLER ELECTRIC MFG. CO.

718 S. BOUNDS ST. P.O. Box 1079
APPLETON. WI 54912 USA

ADDITIONAL COPY PRICE 65 CENTS

NWSA CODE NO. 4579

PRINTED IN U.S.A.
 LIMITED WARRANTY
EFFECTIVE: JUNE 1, 1979

This warranty supersecies all previous MILLER warranties and is ex

clusive with no other guarantees Or warranties exoressed or implied.

LIMITED WARRANTY Subject to the terms ana conditions

-
As a matter of general policy Only. Miller may honor claims
hereof, Miller Electric Mfg. Co., Appleton. Wisconsin warrants submitted by the original user within the foregoing periods.
to its Distributor/Dealer that all new and unused Equipment

( furnished by Miller is free from defect in workmanship and In the case of Millers breach of warranty or any other duty
material as of the time and place of delivery Ov Miller No war- with respect the quality of any goods, the exclusive remedies
to

ranty is made by Miller with respect to engines trdde ac therefore shall be, at Millers option Ill repair or (2) replacement
cessories or other items manufaclurea En. iithyrs Such or, where authorized in writing by Miller in appropriate cases, (3)

engines, trade accessories and other tOrus are Si)id SuOieCi to the reasonaole cost of repair or replacement at an authorized
the warranties of their respective rTrEirriir,iLEur.~~ .1 nw All Miller service 141 payment of or credit for the purchase
station or

engines are warranted by their manut,icir,ii: r n in y~ar 1mm price (less reasonable depreciation based upon actual usel upon
date of original purchase, return of the goods at Customers risk and expense. Upon receipt
of notice of apparent defect or failure, Miller shall instruct the clai- f~
Except as specified below. Miller , i-,:., : ~ tn,! duoiv mant on the warranty claim procedures to be followed,
to components having normal usOtu ~t~
-

~ i.e erie i II

veer, such as spot welder tips, ri~i,r. : ~-:: its ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
MILLERMATIC parts that come in i,:. .. n. eq ANY IMPL!ED WARRANTY, GUARANTY OR REPRESENTA- ?
wire including nozzles and nozzle ui~ii,E~ .. - . i (toes lION AS TO PERFORMANCE. AND ANY REMEDY FOR
rot result from defect in workmarisni i- -ri BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLiCATION, OPERATION OF LAW.
4/ Miller shall be required to horror.. .~ . ~.. ...ir CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
r~ ranted Equipment in the event of faiii~ i. r-~,,:.,, . I kOect ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF
within the following periods from hi n..l ~~uip PITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ment to the original user ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX
CLUDED AND DISCLAIMED BY MILLER.
1. Arc welders, power sources and ci)rnEOririrrts veer

2. Original main power rectifiers 3 years EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN

labor -

1 year Onlyi WRITING. MILLER PRODUCTS ARE INTENDED FOR

A 3. All welding guns and feeder, guns 90 days ULTIMATE PURCHASE BY COMMERCIAL, INDUSTRIAL
i(j~ 4. All other Millermatic Feeders 1 year USERS AND FOR OPERATION BY PERSONS TRAINED AND
5. Replacement or repair parts, exclusive ci ,rbor 60 days EXPERIENCED IN THE USE AND MAINTENANCE OF
6. Batteries.. . ,
6 months \~~1ELDING EQUIPMENT AND NOT FOR CONSUMERS OR ~4
CONSUMER USE. MILLER WARRANTIES DO NOT EXTEND
provided that Miller is notified in wriirrq witren rn,r~ 30 lays TO, AND NO RESELLER IS AUTHORIZED TO EXTEND ?
of the date of such failure. MILLERS ~.ARRANTlES TO, ANY CONSUMER.

~. .r~. ~, JT,ii, jT, ~ ~ ~i, ,i~. :~ ~ ~ ~ J__!, ,J1. .~ J~ .?-o

The nameplate of this unit uses international symbols for labeling the front panel controls. The following definitions
should help the operator become familiar with the symbols and their meanings. The symbols also appear at the ap
propriate section in the text.

Nameplate Nameplate Nameplate

Callout Part Callout Part Callout Part
AMPERAGE POWER

A Ammeter ourpur
Output Ratings I ...~ 0 Power Switch
ON OFF

REMOTE VOLTAGE ADJUSTMENT

Input CONTACTOR
CON rEd
Remote Contactor
Requirements Control Receptacle ~J~v Voltage Control
REMOTE
11 5 Volts AC
-
VOLTAGE
VOLTAGE
115 V\.~ CONTROL
Voltmeter
Receptacle Remote Voltage I
V
Control Receptacle
 m mm

3.
C e~. ~ UI 0 ~. ~ 0. ~ ~ CD 3 CD -. D m E.
~a> ~ ~Lfl ~ P- UI m m .4 UI m C) Ca 0 701 0 a) a) V CD a 10 a) -.7 -.

III o rn -l I o Cl) m C) o2 I ~ 0C Im I o o~ 2

C-084
RCMOI(V01Th
z1Ei~r~ CONTRl, No.
~
JC24
Diagr m JC597143
7101
0FF Circuit Thru
io~I
JB58 5
No.
Serial
With
Efectiv
Source
Power
Welding
For

Diagr m
Circuit
7-1.
Figure

0 -. 0
 121
14510
ELCTROf ~
0
SI

MI I
C-085
w Ill
No.
-0
Diagr m
Circuit
JC59714
No.
Serial
With
Efectiv
Source
Power
Welding
For

Diagr m
SUIt S
Circuit
I
ClIl
OU
7-1.
S

lUl Figure
Add Figures 7-2 and 7-3.

SEE NOTE NOTE i: SEE MACHINE DIAGRAM FOR

+ + 15 V. PROPER AMMETER CONNECTION.
99
79; 78:
-I

HD1

SIC. OUT

L__..... --0
SEE NOTE 1

1~

12
6 13
5 14.

A50
BOTTOM
VIEW

isv, Circuit Diagram No. A-004 589-C

Figure 7-2. Circuit Diagram For HAl Hall Amplifier

+ iSV.

1
1~~
SIC. OUT

7~ ~2
6~ ~3
5LJ~
A 50

BOTTOM
GRD. VIEW

II
I ___ __

S V. Circuit Diagram No. A-082 268-B

Figure 7-3. Circuit Diagram For HA2 Hall Amplifier

>a a. -n C (-) C, C -V. 0 a) ca 3 -Il 0 -. C) 0 -4 -I 0 C) ~1 C.) C .4 C) -I a

0SS 494-A
C-072
conlar
I,
No.

Diagr m
Circuit
Card
Circuit
Control
For
COUPVAI
~ ~ Diagr m
A ~OTAG( AU
CIrcuit
7-4.
Figure

CF
AVI . N

OU
V

GA INPUT 3.~:c
ACA
 Dia. Part Replaced
**
Mkgs. No. With Description QuantitY
2-5 Ri 035 897 072 623 POTENTIOMETER, carbon 1 turn2 watt 1000 ohm 1
072 590 LOCK, shaft potentiometer
-
1
6-5 CR2 006 393 052 964 RELAY, enclosed 24 volts dc DPDT flanged (Eff W/JC597 144) 1
SR2 035914 RECTIFIER, integrated 30 amp 400 volts (Efl W/JC597144) 1
VR1 084278 VARISTOR. 0.6 watt 175 voltsdc (EffW/JB558855)
025 142 BRACKET, mounting capacitor (Eff W/JB558855)
-
1

*eFtrst
digit represents page no. digits following dash represents item no.
-

BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.

~ ~ ~
 TABLE OF CONTENTS

Section No. Page No.

SECTION 1 -
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE

1 -1. Introduction 1
1 - 2. General Precautions 1
1 - 3. Arc Welding 3
1 -
4. Standards Booklet Index 4

SECTION 2 - INTRODUCTiON

2 - 1. General Information And Safety 5

2 -
2. Receiving-Handling 5
2 - 3. Description 5

SECTION 3 - INSTALLATiON

3 -1. Location
3 2. Electrical Input Connections
-
6
3 3. Weld Output Connections
-
7
3 4. Remote Voltage And Contactor Control Connections
-
,
7
3 5. Remote Contactor Control Connection
- 8
3 6. Remote Contactor Control Switch
- 8
3 7. Remote Voltage Control Connections
- 8
3 -8. 115 Volts Receptacles 8
3 9. Remote Voltage Sensing Connections
- 8

SECTiON 4 - FUNCTION OF CONTROLS

4-1. PowerSwitch 8
4 -
2. Voltage Control 8
4. -
3. Remote Voltage Control Receptacle & Switch 9
4 - 4. Remote Contactor Control Receptacle & Switch 9
4-5. Meters 9
4-6. DutyCycie 10
4 - 7. Volt-Ampere Curves 10
4 -
8. Foldback Circuit Oceration 10

SECTION 5 -
SEQUENCE OF OPERATION

5 - 1. Submerged Arc Welding 10

5 -
2. Shutting Down 10

SECTION 6 -
MAiNTENANCE

6 -1. Fan Motor 10.

6 - 2. Internal Cleaning 10
6 -
3. Control Circuit Protection 10

SECTION 7 -
TROUBLESHOOTING
~SECTION i-SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE

1-1. INTRODUCTION harmful concentrations of toxic fumes. Adequate local

exhaust ventilation must be used, or each person in the area
We learn by experience, Learning safety through personal as well as the operator must wear an air-supplied respirator.

experience, like a child touching a hot stove is har~~ful, For beryllium, both must be used.
wasteful, anti unwise. Let the experience of others teach you.
Metals coated with or containing materials that emit toxic

fumes should not be heated unless coating is removed from

Safe practices developed from experience in the use of weld
the work surface, the area is wall ventilated, or the operator
ing and cutting are descnbed in this manual. Research, devel -

wears an air-supplied respirator.

opment. and field experience have evolved reliable equipment
and safe installation, operation, and servicing practices. Acci
Work in a confined space Only while is is being ventilated
denes occur when equipment is impropaily used
or main
tained. The and, if necessary. while wearing an air-supplied respirator.
for the safe practices may not always be
reason
given. Some are based on common sense, others may require
Gas leaks in a confined space should be *voided. Leaked gas
technical volumes to explain. It is wiser to follow the rules.
in large quantities can change oxygen concentration danger

Reed and understand these safe practices, before attempting Ously. Do not bring gas cylinders into a confined specs.
to instil, operate, or service the equipment. Comply with
these procedures as applicable to the particular equipment Ijaving confined space, shut OFF gas supply at source to
used and their instruction manuals, for personal safety and prevent possible accumulation of gases in the space if down
for the safety of others. stream valves nave been accidently opened or left open,
Qieck to be sure that the space is sate before re-entering it.
Failure to observe these safe practices may cause serious in
jury or death. When safety becomes a habit, the equipment Vapors from chlorinated solvents can be decomposed by the
can be used with confidence. heat of the arc (Or flame) to form PHOSGENE, a highly toxic
gas, and other lung and eye irritating products. The ultra
These safe practices are divided into two Sections: 1 violet radiant) energy of the arc can also decompose tn
-

Generai Precautions, common to arc welding and ctitting; and
2- Arc Welding land CuningHonlv(.
Reference standards: Published Standards on safety are also
available f or additional and more complete procedures than
chloroethylene and oerchloroetrlylene vapors to form phos
gene. 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 atmosoneres containing even
minute amounts of trichloroetnylene or perchloroethylene.

those given in this manual. They are listed in the Standards

Index in this manual. ANSI Z49.1 is the most complete. C. Fire and Explosion Prevention

The NationalElectrical Code. Occupational Safety and Causes of fire and explosion are: combustibles readied by the
Health Administration, local ndustrial codes, and Iocai in arc, flame. ftying sparks, hot slag or heated material; misuse

spection requirements also proviae a basis for equipthent in of compressed gases and cylinders; and short circuits.
stallation. use, and service.
BE AWARE THAT flying
or falling slag can pass
sparks
1-2. GENERAL PRECAUTIONS through cracks, along through windowz or doors, and
pipes,
through wall or floor openings, out of sight of the goggled
& Bum Prevention operator, Sparks and slag can fly 35 feet.

Wear protective clothing leather (or asbestos) gauntlet

- To prevent fires and explosion:
gloves, hat, and high safety-roe shoes. Button shirt collar and
pocket flaps, and wear cuffless trousers to avoid entry of Keep equipment clean and operable, free of oil, grease, and
sparks and slag, (in electrical parts) of metallic particles that can cause short
circuits.
Wear helmet with safety goggles or glasses with side shields If combustibles are in area, do NOT weld
or cut. Move the
underneath, appropriate filter lenses
or plates (protected by
work if practicable, free of combustibles. Avoid
to an area
clear cover glass). This is a MUST for welding or cutting, land
paint spray rooms, dip tanks, storage areas. ventulators. If the
chipping) to protect the eyes from radiant energy and flying
work cannot be moved, move combustibles at least 35 feet
metal, Reolace cover glass wnen broken, pitted, or spattered.
See 1-3A.2. away our of reach of sparks and heat: or protect against
ignition with suitable and snug-fitting, fire-resistant covers or
shields.
Avoid oily or greasy clothing. A spark may ignite them.
Walls touching combustibles on opposite sides should not be
Hot metal Such as electrode stubs and workpieces should welded on (or cut). Walls, ceilings, and floor near work
never be handled without gloves~ should be protected by heat-resistant covers or shields.

Medical first aid and eye tream,ent. First aid facilities and a Fire watcher must be standing by with suitable fire ex
qualified first aid person should oe available for cacti shift tinguishing equipment during and for some time after weld
unless medical facilities.are close by for immediate treaoi~ent ingot cutting if:
or flash burns of the eyes and skin bums.
a. appreciable combustibles (including building construc.
Ear plugs should be wom when working on overhead or in a tion) are within 35 feet
confined space. A hard hat should be worn when others work b. appreciable combustibles are further than 35 feet but can
ovemead, be ignited by sparks
c. openings (concealed or visible) in floors or walls within 35
Flammable hair preparations should not be used by persons feet may expose combustibles to sparks
intending to weld or cut. d. combustibles adjacent to wails, ceilings, roofs, or metal
partitions can be ignited by radiant or conducted heat.

B. Toxic Fume Prevention

Hot work pemuut should be abtained before operation to
ensure supervisors approval etat adequate precautions have
Adequate ventilation. Severe discomfort, illness or death can
been taken.
result from fumes, vapors, heat, or oxygen enrichment or
depletion welding (Or cutting) may produce. Prevent
that
After work is Cone, check tnat area us free of sparks, glowing
tj,em with adequate ventilation as descrrbeq in ANSI Stan
embers, and flames.
dard Z49.1 listed 1 in Standards index. NEVER ventilate
with oxygen. An emoty con~ainer that held combustiblu or that can pro
duce flartimaole or toxic vapors when heated, must never be
Laad -. cadmium , zinc ., mercury . and beryllium -
bearing welded on or cut, unless container nas first been cleaned as
ano similar materials, when welded (or cuti may produce described in AWS Standard A6.O. listed 3 in Standards index.

OM-180 Pacre 1
 This includes: thorough steam or caustic cleaning (or a
a Protect cylinders particularly valves from bumps, falls, falling
sOlvent or washing, depending on the combustibles
water obiects, and weather. Replace caps securely when moving
solubilityl followed by purging and inerting with nitrogen or cylinders.
carbon dioxide, and using protective equipment as recom
mended in A6.O. Waterfilling just below working level may Stuck valve. Do NOT use a hammer or wrench to open a
substitute for inerting. cylinder valve that can not be opened by hand. Notify your
A container with unknown contents should be cleaned (see supplier.
paragraph above). Do NOT depend on sense of smell or sight
todetennine if 5$ safe to weld or cut. Mixing gases. Never try to mix any gases in a cylinder.

l-lollow castinge or containers must be vented before welding Never refill any cylinder.
orcutvng. They can explode.
Cylinder fI rn~nge should never be modified or exchanged.
Explosive atmospheres. Never weld or cut where the air may
contain flammadle dust. gas, or liquid vapors (such as gao. 3. Hose
line).
Prohibited use. Never use floss other than that designed for
0. Compressed Gas Equipment the specified gas. A general hose identification rule is: red for
fuel gas, green for oxygen, and black for inert gases.
Standard precautions. Comply with precautions in this
manual, CGA Standard P-i. PRECAU
and those detailed in Use ferrules or clamps designed for the hose (not ordinary
TIONS FOR SAFE HANDLING OF COMPRESSED GASES wire or other substitute) as a binding to connect hoses to
IN CYLINDERS, listed 6 in Standards index. fitringe.

1. Pressure Regulators No copper tubing splices. Use only standard brass tithnge to

splice hose.
Regulator relief valve is designed to orotect only the regula
tor from overpressure; t is not intended to protect any Avoid long runs to prevent kinks and abuse. Suspend hose off
downstrean eQuipment. Provide sucn. protection with one or ground to keep it from being run over, stepped on, or other
more relief devices. wise damaged.

Never connect a regulator to a cylinder containing gas other Coil excess hose to prevent kinks and tangles.
than that for wnicn me regulator was cesigried.
Protect hose from damage dv sharp edges, and by sparks.
Remove faulty regulator from service mrneQiateiy for repair slag, and open flame.
(first close cyiincer vaivel. The following symptoms ndicate
a faulty regulator; Examine nose regularly for leaks, wear, and loose connec
tions. Immerse pressured hose in water; bubbles indicate
Leaks- if gas leaKs extemally. leaks.
Excessive Creep if celivery -
pressure continues to rise witn
downstream valve closed. Repair leaky or worn hose by cutting area out arid splicing
Faulty Gauge - f gauge pointer ooes not move oft stco pin (1-2D3). Do NOT use tape.
when pressurized, nor returns to stop pin after pressure
release. 4. Proper Connections

Repair. Do NOT attempt repa&z. Send faulty regulators for Clean cylinder valve outlet of impurities that may clog
repair to manufacturers designated repair center, where orifices and damage seats before connecting regulator. Except
special techrrtoues and tocis are used by trained personnel. for hydrogen, crack valve momentarily, pointing outlet away
from people and sources of ignition. Wipe with a clean lint-
2. Cylinders less cloth.

Cylinders must oe nanaleo carefully to prevent ea~s and Match regulator tO cylinder. Before connecting, check that
damage to their wails. vaives, or safety oevices: the regulator label and cylinder marking agree, and that the
regulator inlet and cylinder outlet match. NEVER CON
Avoid electrical circuit contact wim cylinders including triird NECT a regulator designed for a particular gas or gases. to a
ails, electrical ~v,res, or welding circuits. They can produce cylindercontaining any other gas.
short circuit arcs that may lead to a serious accident. See
1-3C,1
Tghten connections. When assembling threaded connections,
clean and smooth teats where necessary. Tighten. If connec
ICC DOT marking must be on
or each cylinder. It is an
tlOh leaks, disassemble, clean, and retighten using properly
assurance of safety wnen tne cylinder is properly handled.
fitting wrench.

Identifying gas content. Use only cylinders with name ot gas

marked on them: do not rely on color to identIfy gas con Adapters. Use a CGA adapter (available from your supplierl
tent. Notify supplier if unmarked. NEVER DEFACE or alter between cylinder and regulator, if one is reQuired. Use two
name, number, or other markings on a cylinder, It is illegai wrenches to tighten adapter marked RIGHT and LEFT
and hazardous, HAND threads.

Empties: Keep valves closed. replace cacs securely; mark MT; Regulator outlet (or hose) connections may be identified dv
ieep them separate from PULLS and return promptly. right hand threads for. oxygen arid left hand threads (with
grooved hex on nut or shankl for fuel gas.
Prohibited use. Never use a cylinder or its contents for other
than its intended use. NEVER as a support or roller. 5. Pressurizing Steps:

Locate Cylinders knocked

Drain regulator of gas through suitable vent pefore
esidual
or secure so they cannot be over.
opening cylinder manifold valvel dv turning adjusting
or

Screw in clockwise I. Draining prevents excessive compression

Passagewavs and work areas. Keeo cylinders clear Of areas heat at high pressure seat by allowing seat to open on pressur
where they may oe Struck. ization. Leave adjusting screw engaged slightly on single-stage
regulators.
Transoorting cyiinaers. Nuth a crane, use a secure support
Such as a platform or cradle. Do NOT lift ~yIinders off ~r,e Stand to side of regulator while opening cylinder valve.
ground by their valves or caps, or dv chains. slings. or mag

nets. Open cylinder

valve slowly so that regulator pressure in.
creases slowly. When gauge is pressurized )gauqe reaches regu
Do NOT exoose cvinoera to excessive neat. soarxs, slag, ana lator maximumnl leave cylinder valve in following position:
~Iame. etc. that may cause rupture. Do not allow contents to For oxygen. and inert gases, open fully to seal stem against
exceed 130F Cool with water spray where sucn exposure possible leax. For fuel gas, open to less than one turn so
exists. permit quick emergency shutoff.
 Use pressure charts (available from your supplier) for safe operation with tow-reflective, non-combustible screen or

and efficient, recommended pressure settings on regulators. panels. Allow for free air circulation, particularly at floor
level.

Check for leaks on first pressurization and regularly there

after. Brush with soap solution (capful of Ivory Liquid or Viewing the weld. Provide face shields for all persons who
equivalent per gallon of water). Bubbles indicate leak. Clean will be looking directly at the weld.
off soapy water after test: dried soap is combustible.
Others working in area. See that all persona ara wearing Ilash
E. User Responsibilities goggles.

Remove leaky or defective equipment from service immed Before starting to weld, make sure that screen flaps or bay
iately for repair. See User Responsibility statement inequip doors are closed.
mont manual.

F. Leaving Equipment Unattended B. Toxic Fume Prevention

Close gse supply at source and drain gas. Comply with precautions in 1-28~

G. Rope Staging-Support Generator engine exhaust must be vented to the outside air.
Carbon monoxide can kill.
Rope staging-support should not be used for welding or cut

ting operation: rope may burn. C. Fire and Explosion Prevention

1-3. ARC WELDING Comply with precautions in 1-2C.

Comply with precautions in 1-1, 1-2. and this section. Arc Do

Equipments rated capacity. not overload arc welding
Welding, properly done, is a safe process, but a careless opera fire.
equipment. It may overheat cables and cause a
tor invites The eQuipment carries high currents at
trouble.
significant voltages. The arc is very Drignt and hot. Sparks fly, Loose cable connections may overheat or flash and cause a
fumes rise, ultraviolet and infrared energy radiates, weld fire.
ments are hot, and compressed gases may be used. The wise

ooerator avoids unnecessary risks and protects himself and Never strike an arc on a cylinder or other pressure vessel. It
others from accidents. Precautions are described hero and in
createsa brittle area that can cause a violent njpn.ire or lead
standards referenced in index. to such a rupture later under rough handling.

A. Bum Protection 0. Compressed Gas Equipment

Comply with precautions in 1-2. Comply with precautions in 1-20.

The welding arc is intense and visibly bright Its radiation can E. Shock Prevention
damage eyes, penetrate lightweight clothing, reflect from
light-colored surfaces, and bum the skin and eyes. Skin burns Exposed hot conductors or other bare metal in the welding
resemble acute sunburn, those from gas-shielded arcs are circuit, or in ungrounded. electrically-HOT equipment can
more severe and painful. OO~JT GET BURNED; COMPLY fat~Iy shock a person whose body becomes a conductor. DO
WITH PRECAUTIONS. NOT STAND. SIT. LIE. LEAN ON. OR TOUCH a wet sur
face when welding, without suitable protection.
1., Protective Clothing
To protect against shock:
Wear lono-sleeve clothing iparticularly for gas-shielded arc) in
addition to gloves, nat and shoes ll-2A). As necessary, use Keeo body and ctothing dry. Never work in damp area with
additional protective clothing sucn ~ leather lacket or out adequate insulation against electrical snock. Stay on a
sleeves. ftarne-.prool aoron. and fire-resistant leggings. Avoid dry duckboard. or rubber mat when dampness or sweat can
outergannents of untreated cotton. riot be avoioed. Sweat, sea water, or. moisture between body
and an electrically HOT part or grounded metal reduces -

Bare skin protection. Wear dark. substantial clothing. Button the body-surface electncal resistance, enabling dangerous and
collar to protect chest and neck arid button pockets to pre possibly lethal currents to flow tflrough the body.
vent entry of sparks.

1. Grounding the Equipment

2. Eye and -Head Protection
When installing, connect the frames of each unit such as
Protect eves from exposure to arc. NEVER look at an ~lec
welding power source, control, work table, and water circula
inc arc without protection. tor to the building ground. Conductors must be adequate to
carry ground currens safely. Equipment made electrically
Welding helmet or shield containing a filter plate shade no.
HOT by stray current may shock, possibly fatally. Do NOT
12 or denser used wnen -welding. Place over face
must tie GROUND to electrical conduit. or to a pipe carrying ANY
before striking arc.
gas or a ftammable liquid such as oil or fuel.

Protect filter plate with a clear cover plate. Check phase reQuirement of equip-
Three-phase connection.
mont before installing. oniv 3-phase power is available,
If
Cracked broken helmet or snieid shouid NOT be worn:
or connect single-phase equipment to only two wires of the
radiation can pass tnrougfl to cause puma. 3.phase line. Do NOT connect the equipment ground lead to
the third (live) wire, or the ecuipment. will become electn
Cmacxed, broken, or loose filter piates must be replaced IM cailv HOT condition that can shock, possibly
a dangerous
MEDIATELY. Peolace clear cover plate-when broken, pitted. fatally.
or spattered.
Before welding, check ground for continuity. Be sure conduc
Piash goggles wim side Shields MUST be worn under the tors are touching bare rnetei of eauioment frames at connec
helmet to give some proteCtiOn to trio eves snould the helmet ti ons.

riot tie lowered over me lace oefore an arc is struck. Looking

at an arc momentarily with unorotected eyes (particularly a If a line cord with a ground lead is provided With the eauio
high intensity gas-snieided arci can cause a retinal burn that ment for connection to a swetcnbox. connect the ground lead
may leave a permanent oarl( area in in, field of Vision. to the grounded switcllbox. If a th rae-prong plug is added for
connection to a receptacle, the ground lead
grounded mating
3, Protection of Nearov Personnel must be connected ground prong only. If the line cord
to the

comes with a three-prong plug, connect to a grounded mating

Enclosed weiding area. Por production welding, a separate receptacle. Never remove the ground prong from a plug, or

room or enciosed bay is pest. ri open are~. surround the use a plug with a broken off ground prong.

Trademerk of Proctor & Gan,ole.

 2. Electrod. Holders Do not open power circuit or change polarity while welding.
If, in an emergency, it must be disconnected, guard against
Fully insulated electrode holderi should be used. Do NOT shock burns, or flash from switch arcing.
use holders with protruding screws.
Leaving equipment unattended. Always shut OFF and dis
3. Connectors connect all power so equipment.

Fully insulated lock-type connecto,s should be used to join Power disconnect switch must be available near the welding
welding Cable lengths. power source.

1-4. STANDARDS BOOKLET INDEX

4. Cables

For more information, refer to the following standards or

Frequently inspect cables for wear, cracks and damage.
thir latest revisions and comply as ~plicable:
IMMEDIATELY REPLACE thtee with excessively worn or
damaged insulation to avoid p~siblv lethal shock from
1. ANSI Standard Z49.1, SAFETYIN WELDING AND
based cable. Cables with damaged areas may be t~ed to give
CUTTING obtainable from the American Welding
resistance equivalent to original cable.
Society, 2501 NW 7th St. Miami, Fla. 33125.
l(ee cable dry, free of oil and grease, arid protected from
hot metal and marks. 2. ANSI Standard Z87.1. SAFE PRACTICE FOR OCCUPA
TION AND EDUCATIONAL EYE AND FACE PROTEC
5. Terminals And Other Exposed Part~ TION, obtainable from American National Standards
Institute, 1430 Broadway, New York, N.Y. 10018.
Terminals and Other exposed parts of electrical units should
have insulating covers secured before operation. 3. American Welding Society Standard A6.0, WELDING
AND CUTTING CONTAINERS WHICH HAVE HELD
6. Electrode Wire COMBUSTIBLES, obtainable same as item 1.

Electrode wire becomes electrically HOT Mien the power 4. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
switch of gas metal-arc welding equipment is ON and welding FOR WELDING AND CUTTING. obtainable from the
gun trigger is pressed. )(eep hanas and body clear of wire aria National Fire Protection Association, 470 Atlantic
other HOT parts. Avenue, Boston. Mass. 02210.

7 Safety Devices 5. NFPA Standard 51B, CUTTING AND WELDING PRO

CESSES. obtainable
same as item 4.
Safety aevices such as interlocks anc circuit breakers should
not be disconnected or shunted out. 6. Cc3A Pamphlet P.1. SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS, obtainable from the
8efore installaijon, inspection, or service, of equipment, shut Compressed Gas Association, 500 P~fth Avenue, New
0FF all power and remove line fuses (or lock or red-tag Yorlc,N, Y. 10036.
switches) to prevent ~cideotai turning ON of power Discon
nect all cables from welding power source, and pull all 115 7. OSHA Standard 29 CFR. Part 1910, Subpart 0, WELD
voite line-cord plu~. ING. CUTTING AND BRAZING.

8. Code for Safety in Welding and Cutting, CSA Standard

W117.2,

Page 4
 SECTION 2 -
INTRODUCTION
I Rated Welding I I Input At Rated Load Output Weight
I Current Amperes Voltage I Max. Open. 60 Hz. Single-Phase (Pounds)
1100% Duty Cycle I Range Circuit Voltage Amperes At 460V I kva I kw Net I Ship

1000 ' 44V 126-55V1 92V 1.82 f 84 I 54 99311145

Min. Welding Amperage 300A
tAll ratings are for 460 vole ac input. If low or high input voltage is encountered, ratings may differ.

Fgure 2-1 .Specifications

i~ I .ii v ~ ~ The power factor correcting cirefully followed could result in serious personal injury
capacitors supplied in this product contain no PCBs. or loss of life.
The dielectric material is an OS/IA C/ass I/I B fluid hav
ing a flash point of 440F. (227C.). Each individual CAUTION statements include installation, operating,
capacitor is protected by an internal (JL recognized procedures or practices which if not
and maintenance

pressure sensitive disconnect and an internal fuse. carefully followed could result in minor personai ~n~ury
or damage to this equipment.

2-1. GENERAL INFORMATION AND SAFETY

A third signal word, IMPORTANT, highlights instruc
A. General tions which need special emphasis to obtain the most
efficient operation of this equipment.
Information presented in this manual and on various
labels, tags, and plates on the unit pertains to equip 2-2. RECEIVING-HANDLING Prior to installing-

ment design, installation, operation, maintenance and this equipment, clean all packing material from around
troubleshooting which should be read, understood and the unit and carefully inspect for any damage that may
followed for the safe and effective use of this equip have occurred during shipment. Any claims for loss or
ment.
damage that may have occurred in transit must be filed
B. Safety by the purchaser with the carrier. A copy of the bill of
lading and freight bill will be furnished by the carrier on
The installation, operation, maintenance, and request if occasion to file claim arises.

troubleshooting welding equipment requires

of arc
practices and procedures which ensure personal safety
and the safety of others. Therefore, this equipment is to
be installed, operated and maintained only by qualified
When requesting information concerning this equip
ment, it is essential that Model Description and Serial
Number for the equipment be supplied.

persons in accordance with this manual and all ap

plicable codes such as, but not limited to, those listed at
the end of Section 1 Safety Rules For Operation Of
-
2-3. DESCRIPTION - This unit is a single-phase con

Arc Welding Power Source. stant potential ac arc welding power source with solid
state control. It produces ac weld current and is design
ed to be used in conjunction with automatic Submerged
Safety instructions specifically pertaining to this unit ap
Arc Welding (SAW).
pear througiiout this manual highlighted by the signal
words WARNING and CAUTION which identify dif
ferent levels of hazard. ~NARNING IMPROPER APPLICATION of this
__________

equipment can result in bodily injury.

WARNING statements include installation, operating, This power source is not intended for manual or

and maintenance procedures or practices which if not semi-automatic arc welding.

SECTION 3 -
INSTALLATION

3-1. LOCATiON A proper installation site should be

11
-

selected for the welding power source if the unit is to

provide dependable service, and remain relatively

maintenance free.

40
.A proper installation site permits freedom of air move

ment into and out of the welding power source, and

~
also least subjects the unit to dust, dirt, moisture, and
corrosive vapors. A minimum of 18 inches of
unrestricted space be maintained between the
must

welding power fror:It

source and rear panels and the
nearest obstruction. Also, the underside of the welding

power source must be kept completely free of obstruc

tions. The installation site should also permit easy 3/4
removal of the welding power source outer enclosure ~
for maintenance functions.
Add 3 for Lifting Eye
~7
Figure 3-1. DImensional Drawing
~ ~ ,;
 CAUTION RESTRICTED AIR FLOW causes The input conductors should be covered with an in
_________

overheating and possible damage to internal sulating material which conforms to local electrical stan
parts. dards. Table 3-1 is provided only as a guide for selecting
S Maintain at least 18 inches of unrestricted space the proper size input conductors and fuses.
on all sides of unit and keep underside free of
Table 3-1. Input Conductor and Fuse Size
obstzvcrions.
S Do not p/a ce any filtering device over the intake air
Input Conductor Fuse Size
passages of this we/ding power source.
Size AWG In Amperes
WarTanty is void if any type of filtering device is used.
-

Holes in the 460V 460V

are provided welding power source base for
mounting purposes. Figure 3-1 gives overall dimen 2/0
sions. (4)
.

On most-welding power sources a lifting device is pro

vided for moving the unit. However, if a fork lift vehicle
input conductor sizes are based on allowable am
is used for lifting the unit, be sure that the lift forks are
pacities of insulated copper conductors, having a
long enough to extend completely under the base. temperature rating of 75C, with not more than three
conductors in a raceway or cable. Numbers in ( ) are
tw~tiui.i~ IMPROPER LIFTiNG OF EQUIPMENT
equipment ground conductor sizes.
can result in personal injury and equipment
damage. Insert the two input conductors plus one ground con
Use equipment of adequate capacirj to lift the ductor through the access hole on the rear panel. This
unit. hole will accept standard conduit fittings.
If
using lift forks to handle this unit, be sure the lift
are long enough to extend out of the op
forks
IILAI ~] I t.i~17 ~ It is recommended that a terminal lug
posite side of the base.
of adequate amperage capacity be attached to the ends
Using lift forks too short will expose internal com
of the input and groundconductors. The hole diameter
ponents to damage should the tips of the lift forks
in the terminal lug must be of proper size to accom
penetrate the bottom of the unit.
modate the line and ground terminal studs.

3-2. ELECTRICAL INPUT CONNECTiONS

Connect the two input conductors to terminals 1.2 and
I~IPUT
1.3 on the contactor and connect the ground conductor
to the ground terminal. The remaining end of the
ground conductor should be connected to a proper
A. Electrical Input Requirements
ground. Use a grounding method that is acceptable to
-

the local electrical inspection authority.

This welding power designed
source is
be operated to
from a single-phase, 60 Hera, ac power supply which Line
has a line voltage rating that corresponds with the elec Terminals
trical input voltage shown on the nameplate. Consult
the local electric utility if there is any question about the
type of electrical system available at the installation site
or how proper connections to the welding power source

are to be made.
Ground ~
Terminal
B. Input Conductor Connections

LT)~~ It is recommended that a line disconnect Accese.

switch be installed in the input circuit to the we/ding Hole ~

power source. This would provide a safe and conve

nient means to completely remove a/I elecrrnal power
from the -we/ding power source whenever it is necessary
to perform any internal function an tire unit.
-

1~fl;tkl!~{e~ ELECTRIC SHOCK can kill.

Employ lockout! tagging procedures on input
line before making in put connections to the
we/ding power source.
Lockout/tagging procedures consist of padlocking line Figure 3-2. Input Connections
disconnect switch in open position, removing fuses
WARNING: ELECTRIC SHOCK canS kill.
from fuse box, or tagging circuit breaker or other
disconnecting device. Do not connect an input conductor to the ground
Connect input conductors to the we/ding power terminal fri the unit.
source before connecting to single-phase input Do not connect the ground conductor to an input
power. line terminal. -
 Table 3-2. Welding Cable Size

Welding Total Length Of Cable lCoooeri In Weld Circuit

Amperes, AC ~O 100 150 200 250 300 350 400
100 2 2 2 1 1/0 2/0 3/0 3/0
150 1 1 .1 1/0 2/0 3/0 4/0 4/0
200 1/0 1/0 1/0 2/0 3/0 4/0 2-2/0 2-2/0
250 2/0 2/0 2/0 3/0 4/0 2-2/0 2.3/0 2-3/0
300 3/0 3/0 3/0 4/0 2-2/0 2.3/0 2-3/0 2-4/0
350 3/0 3/0 3/0 4/0 2.2/0 2.3/0 24/0 2-4/0
400 4/0 4/0 4/0 2-2/0 2-310 2.4/0 500MCM I000MCM
500 4/0 4/0 2-2/0 2-3/0 2-4/0 500MCM I000MCM 1000MCM
600 4/0 4/0 2.3/0 2-4/0 500MCM 1000MCM 1000MCM 1000MCM
700 2-2/0 2-2/0 2-3/0 2-4/0 1000MCM 1000MCM 1000MCM I000MCM
800 2-3/0 2-3/0 2-4/0 500MCM 1000MCM I000MCM I000MCM 1000MCM
900 2-3/0 2-3/0 2-4/0 1000MCM 1000MCM 1000MCM I000MCM
1000 2-4/0 24/0 500MCM 1000MCM 1000MCM I000MCM

Ref. TA.052 784

NOTE: A. 50 FEET OR LESS.
3. CABLE SIZE IS BASED ON RMS ALTERNATING CURRENT, 100% DUTY CYCLE AND
EITHER A 4 VOLTS OR LESS DROP OR A CURRENT DENSITY OF NOT OVER 300
CIRCULAR MILS PER AMP.
C. WELD CABLE INSULATION WITH A VOLTAGE RATING TO WITHSTAND THE OPEN-
CIRCUIT VOLTAGE (OCV) OF THE WELDING POWER SOURCE MUST BE USED.
WHILE MOST WELDING POWER SOURCES HAvE AN OPEN-CIRCUIT VOLTAGE OF
LESS THAN 100 VOLTS. SOME WELDING POWER SOURCES OF SPECIAL DESiGN
MAY HAVE HIGHER OPEN-cIRCUIT VOLTAGE.

Incorrect input connections can result in an electrically 2. Use Table 3-2 as a guide for selecting correct
energized welding power source chassis. The ground cable size for the anticipated maximum weld cur
terminal is connected to the welding power source rent which will be used. Table 3-2 shows total
chassis and is for grounding purposes only. cable length, which includes the electrode and
work cable. Example: If the electrode holder
3-3. WELD OUTPUT CONNECTiONS To obtain -

the full rated output from this unit, it is necessary to

cable is 75 feet long and the work cable is 25 feet

select, install, and maintain proper welding cables. long, select the size cable that is recommended
Failure to comply in any of these areas may result in less for 100 feet at the maximum weld current that is
than to be used.
satisfactory welding performance.

WARNING ELECTRIC SHOCK can kill,

3. Do not use damaged or frayed cables.
Do nortouch five electrical parts.
4. Follow the electrode holder manufacturers in
Ensure that the unit is completely shut down
before making any weld output connections.
structions for installing the electrode holder onto
the electrode cable.
A. Location
5. Use correct tugs on the weld cables to connect
The ELECTRODE and WORK weld output terminals are the work clamp and to connect the cables to the
ocated on the lower portion of the front panel. weld output terminals.

B. Welding Cables 6. Ensure that all connections are clean and tight.

If welding cables were not ordered with this unit, the 3-4. REMOTE VOLTAGE AND CONTACTOR CON
steps listed should be followed to ensure the best TROL CONNECTiONS
welding performance: REMOTE
VOLTAGE R~MO1!
CON1ROL CONTACTOR

1. It is recommended that the welding cables be

-

kept as short as possible, be placed close

together, and be of adequate current carrying
capacity. The resistance of the welding cables R~];Ifi1k1~ A/though the term CONTACTOR is
and connections causes a voltage drop which is used the nameplate and throughout this manual, the
-

on

added to the voltage of the arc. Excessive cable ouwut is nor swircnedon or off by a physical seconda,y

resistance may result in overloading as well as ccnracror; rather, the ouwur is controlled by a Silicon
reducing the maximum current output capability Controlled Rectifier (SCRI stack which functions as a
of this unit. Proper operation is to a great extent conractor.

dependent on the use of welding cables and con

nections that are in good condition and of ade The REMOTE VOLTAGE and CONTACTOR CONTROL
quate size. An insulated electrode holder must receptacle, located on the front panel of the welding
be used to ensure the operators safety. power source, provides a junction point for connecting

OIV1EICI ~ 7
 a Remote Contactor and/or a Remote Voltage Control ELECTRIC SHOCK can kIll.
to the internal circuitry of the welding power source. To Properly insulate and rape leads before resuming
connect the Remote Contactor Control and/or Voltage operation.
Control to the REMOTE VOLTAGE and CONTACTOR
CONTROL receptacle, insert the five-pin plug from the 3-7. REMOTE VOLTAGE CONTROL CONNEC
Remote Control fully into the receptacle. Ensure that TIONS Remote control of the voltage is available
-

the plug keyway aligns with the receptacle key. Rotate through pins C, P. and E of the supplied amphenol
the plug threaded collar clockwise to secure the plug in plug.
the receptacle.
Using an18/3 conductor cord of the desired length,
3-5. REMOTE CONTACTOR CONTROL CONNEC connect the remote control wiper to pin E, the
TION The REMOTE CONTACTOR CONTROL recep
-
counterclockwise terminal to pin 0 and the clockwise
tacle provides a junction point for connecting a Remote terminal to pin C. See Figure 3-1 for location of pins.
Contactor Control device to the contactor control cir
cuitry in the welding power source. WARNING ELECTRIC SHOCK can kill.
_________

Properly insulate and rape leads before resuming

To connect the Remote Contactor Control to the operation.
REMOTE CONTACTOR CONTROL receptacle, insert
the two-pole plug from the Remote Contactor Control 3-8. 115 VOLTS DUPLEX RECEPTACLE The 115 -

device into the REMOTE CONTACTOR CONTROL VOLTS AC duplex receptacle

on the front panel will fur

receptacle and rotate the plug clockwise airection. nish 115 volts ac to operate external accessories.

For remote contactor control via this receptacle. 115 IMPORTANT The 115 volts auxiliar, power circuitry
______________

vac must be supplied to the receptacle to close the con is protected bycircuit breaker. Should an overload
a

tactor. condition occur, the circuit breaker would open and

suspend output at the receptacle. It is necesseiy to
3-6. REMOTE CONTACTOR CONTROL manually depress the circuit breaker to reset it.
SWITCH Remote control of the solid-state cantactor
-

in the welding power source can also be achieved 3-9. REMOTE VOLTAGE SENSING CONNEC
through use of a momentary/maintained-contact rocker TIONS This unit is shipped with the voltage sensing
-

switch. An 18/2 conductor cord of desired length will circuitry connected to read the voltage at the output ter
have to be supplied for making connections between minals. If more accurate voltage readings are desired,
the rocker switch leads and pins A and B for the sup remote voltage sensing leads be attached to the
can

plied amphenol plug. See Figure 3-1 for location of electrode and work. Terminal strip 1 T, located between
pins. the weld output terminals, is provided for making
will Pins
in be the approximate location
as shown when the notch in the con
remote voltage sensing connections. Reposition the
nector body is on top. jumper links on iT, across terminals 62 and 63, and 64
and 65. Connect No. 14 AWG leads between terminal
No. 65 and the workpiece and terminal No. 63 and the
electrode.

WARNING ELECTRIC SHOCK can kill~ INCOR

__________

RECT VOLTAGE SENSING CONNECTIONS can

Pin A
PinE damage equipment.
Pin B PinO
Ensure connections are made as instructed above.
Incorrect jumper link position can cause weld output to
,Pin C
-
TA~oO9 143 be available at the voltage sensing leads. No output may
result from remote voltage sensing leads not being con
Figure 3-1. Amphenol Plug Connections
nected.

SECTION 4 -
FUNCTION OF CONTROLS
4 - 1. POWER SWITCH (Figure 4-1)
4 - 2. VOLTAGE CONTROL (Figure 4-1)
~owu

VOLTAGI AQJU$TMINT

ON

Depressing the POWER switch ON push button will

V.
energize the welding power source and place the unit in
a ready-to-weld status. Depressing the POWER switch The VOLTAGE control provides a means of selecting
OFF push button will shut the welding power source the desired voltage within the -range of the welding
down. power source. Rotating the control in.a clockwise direc
tion increases the load voltage.
Should input power be interrupted during operation.
the unit shuts down and remains off until power is
IMPORTANT: The VOLTAGE control may be ad-
restored and the POWER switch ON push button is
jusred while welding.
depressea.
 Power Switch

/- .Clrcuit Break.,

Remote Contactor
I ~115 Volta
AC Duplex
Control Receptacle
Receptacle

Remote Contactor
Control
Switch

Electrode Output Terminal

4-

-
Figure 4-1. Front Panel View
The scale surrounding the VOLTAGE control is If a Remote Contactor Control is to be used, make con
calibrated in percent and should not be misconstrued as nections to the REMOTE VOLTAGE and CONTACTOR
a voltage reading. CONTROL receptacle as instructed in Section 3-4 or the
-
-

REMOTE CONTACTOR CONTROL receptacle

-

as in
4-3.REMOTE VOLTAGE CONTROL RECEPTACLE
structed in Section 3-5. Place the REMOTE CONTAC
& SWITCH If a Remote Voltage Control is to be us
-

TOR CONTROL switch in the ON position. Weld output

ed, make connections from the Remote Voltage Control
will be available when the POWER switch ON push but
to the REMOTE VOLTAGE and CONTACTOR CON
ton has been depressed and the remote contactor con
TROL receptacle as instructed in Section 3-4.
trol switch is closed..

When remote control of the voltage is desired, it is If a Remote Contactor Control is not to be used, place
essential that the REMOTE VOLTAGE
CONTROL the REMOTE CONTACTOR CONTROL switch in the
switch be placed in the ON position, likewise, if a
OFF position. When in the OFF position, weld output
Remote Voltage Control is not to be utilized, the switch
will be available after the ON push button is depressed.
must be in the OFF position. When in the OFF position
Weld output will continue until the OFF push button is
only the VOLTAGE control on the front panel will con
depressed.
trol the voltage.

4-4. REMOTE CONTACTOR CONTROL RECEP 45. METERS - This welding power source is equip
TACLE & SWITCH ped with an ac voltmeter. These
ammeter and an ac
meters are internally connected to the welding power
~ ELECTRIC SHOCK can kill. source weld output terminals. The ammeter indicates

Do nor touch output term/na/s when POWER the weld current output of the welding power source.
switch ON and the REMOTE CONTACTOR
is The vottmet~r indicates the ac voltage at the secondary
CONTROL switch is in the OFF position. terminals, but will not necessarily indicate the actual
If the REMOTE CONTACTOR CONTROL switch is in voltage at the welding arc. If the welding cables are ex
the OFF position, open-circuit voltage is present at the. cessively long, or have poor, loose connections, the dif
output terminalswhen the POWER push button is ference between actual arc voltage and the voltage at
depressed. Open-circuit voitage is present until the the welding power source secondary terminals may be
POWER OFF push burton is depressed. considerable. If actual arc voltage readings are
necessary, make remote voltage sensing connections as
The con-tactor control circuitry in this welding power instructed in Section 3-9. The voltmeter will then read
source enables the operator to remotely control the actual arc voltage regardless of weld cable length or

availabiiity of weld output from the work station. connections.

~l~ ~~I~! C~
 4-6. DUTY CYCLE (Figure 4-2J The duty cycle of a
- it is possible to determine the amperage required for a
welding power welding source. is the percentage of a specific load voltage. With reference to the volt-ampere
ten minute period that a welding power source can safe. curve (Figure 4-3), the curve shows the maximum and

ly be operated at a given output. This welding power minimum settings of the VOLTAGE control only.
source is ratedat 100 percent duty cycle. This means Curves of other settings will fall between the maximum
that the welding power source can be safely operated at and minimum curves shown.
rated load continuously.
~ MAX. O.C.V. 12
90
CAUTION EXCEEDING DUTY CYCLE RATING
_________
vSl*au VOLT AMP8RE CUR Vt
will damage the welding power source. 80-
Do nor exceed duty cycles indicated.
70
RATED OUTPUT
~
U360.
MAX

0
>
Q
01

30
1000

20

10

200 400 600 300 1000 1200

AC AMPERES
8-072789

000

SO
Figure 4-3. Volt-Ampere Curves
% OuTl crc~
8-072824
Figure 4-2. Duty Cycle Chart 4-8. FOLDBACK CIRCUIT OPERATION The -

foldback Circuit IS designed to prevent SCR failure caus

4-7. VOLT-AMPERE CURVES (Figure 4-3) -
The ed by sustained short-circuit conditions. This circuitry
volt-ampere curve shows the output voltage available at will automatically reduce the output until the short-
any given output current within the limits of the circuit condition is removed, at which time normal unit
minimum and maximum VOLTAGE control setting. operation will automatically resume. The circuitry will
Load voltage is predetermined to a large degree by arc not affect normal operation of the welding power
characteristics. With the use of the volt-ampere curve, source.

SECTION 5 -
SEQUENCE OF OPERATiON
IL1~i?1~C~ ELECTRIC SHOCK can kill; MOVING 3. a Remote Contactor Control is used, place the
If
PARTS can cause serious injury: IMPROPER AIR REMOTE CONTACTOR CONTROL switch in the
FLOW AND EXPOSURE TO ENV1RONMENT can ON position.
damage internal parts.
Keep a/I covers and panels in place while 4. a Remote Voltage Control is used, place the
If
opera ring. REMOTE VOLTAGE CONTROL switch in the ON
Warranty is void if the welding power source is operated position.
with any portion of the outer enclosure removed.
5. Depress the POWER switch ON button.
5-1. SUBMERGED ARC WELDING (SAW)
6. Rotate the VOLTAGE control to the approximate.
IYt1Ji1!I~~ ARC RAYS, SPARKS, AND HOT setting.
SURFACES can. burn eyes and skin; NOISE can
damage hearing. 7. Commence welding.
Wear correct eye, ear, and body protection.
FUMES AND GASES can seriously harm your
health. 1 Wi 1 ~.J I ~ The VOL TA GE control may be ad
Use enough ventilation to keep fumes and gases justed while we/ding.
from the breathing zone.
See Section 1 Safety Rules For Operation Of Arc
-
5-2. SHUTTING DOWN
Welding Power Source for basic welding safety infor
mation. 1. Break the arc.

1. Make electrical incut and weld output connec 2. Allow the welding power source to idle for 3
tions as instrucica in Sections 3-2 and 3-3. minutes with no load applied.

2. Make necessary remote control connections. 3. Depress the POWER switch OFF push button.
 SECTION 6 -
MAINTENANCE
I~t!4~lI~te~ ELECTRIC SHOCK can kill. ing. The fan motor is manufactured with lifetime sealed
Disconnect input power and employ bearings and no periodic attention is required.
lockout! tagging procedures before internally 6-2. INTERNAL CLEANING Occasional blowing
-

inspecting or servicing. out or vacuuming of the dust and dirt from around the
Lockout/tagging proceduresconsist of padlocking line internal components is recommended. This should be
disconnect switch in open position, removing fuses done periodically depending on the location of the unit
from fuse box, or tagging Circuit breaker or other
and the amount of dust and dirt in the atmosphere. The
disconnecting device. welding power source outer enclosure should be remov
ed and a clean, dry airstream or vacuum Suction should
iw I ~] I f~1 ~1 ~
Periodically inspect the labels on the be used for this cleaning operation.
unit for
legibility. All labels must be maintained in a
6-3. CONTROL CIRCUIT PROTECTION The en
dearly readable state and replaced when necessary. -

See~ Parts List for part number of all labels. tire control circuit of the welding power source is pro
tected by a cartridge type fuse FL This fuse is located
under the top cover beside the control transformer.
61. FAN MOTOR -
This unit is equipped with an ex Should this fuse open, the welding power source would
haust fan and relies on forced draft for adequate cool- completely shut down.
SECTION 7 -
TROUBLESHOOTING

I~!1~l~tIc~ ELECTRIC SHOCK can kill. It is assumed that proper installation has been made, ac
Do touch live electrical parts.
nor
cording to Section 3 of this manual, and that the
Disconnect unit from input power before internal
welding power source has been functioning propeily
ly inspecting or servicing. until this trouble developed.
MOVING PARTS can cause serious injury.
Keep c:ear of moving parts. Use this chart in conjunction with the circuit diagram
HOT SURFACES can cause severe burns. while performing troubleshooting procedures, If the
A/low cooling period before servicing. trouble is not remedied after performing these pro
Troubleshooting of internal parts to be performed only cedures, the nearest Factory Authorized Service Sta
by qualified persons. tion should be contacted. In all cases of equipment
malfunction, the manufacturers recommendations
The following chart is designed to diagnose and provide should be strictly followed.
remedies for some of the troubles that may develop in
this welding power source.

TROUBLE PROBABLE CAUSE REMEDY

Completely inoperative. Open line fusels). Replace open fusels).

Defective push button Replace defective push button POWER switch.

POWER switch.

Poor and/or improper input Refer to Section 3-2 for proper input connections.
,
connections.

No weld output; fan Poor electrical

input and/or Check electrical input and/or primary connections
operative, primary connections. at the contactor.

Improper electrical input Refer to Sections 3-2 and 3-3 for proper electrical

and/or secondary connec- input and secondary connections.

.

.
tions.

.
REMOTE CONTACTOR If remote contactor control is not desired, place
CONTROL switch in ON the REMOTE CONTACTOR CONTROL switch in
. position without a Remote the OFF position. If remote contactor control is
Contactor Control con- desired, retain the REMOTE CONTACTOR CON
nected to the welding TROL switch in the ON position and make Remote
.
power source. Contactor Control connections as instructed in
.

Section 3-4 or 3-5.

Printed circuit card PCi Check printed Circuit card PCi connection. If PCi
defective or loose at edge loose at connector, secure. If PCi defective,
connector. replace.
-

OM.180.Page 11
 TROUBLE PROBABLE CAUSE REMEDY

Umited output and low Poor and/or improper input Refer to Section 3-2 and 3-3 for proper input and
open-circuit voltage, and/or secondary connec- secondary connections.
tions. .

Erratic weld current or Incorrect welding cable Use proper size and type of cable. See Section
voltage, size. 3-3.

~
Loose welding cable con- TTghten all welding connections.
nection.

Improper wire feeding set- See INSTALLATION Section in Wire Feeder

~
up. Owners Manual.

Defective SCR in main rec- Replace defective SCR.

tifier SRi.

Printed circuit card PCi Check printed circuit card PCi connection. If PCi
defective or loose at edge loose at connector, secure. it PCi defective,
.

connector. replace.

High weld output; Printed circuit card PCi Check printed circuit card PCi connection. If PCi
VOLTAGE Control does not detective or loose in edge loose in connector, secure. If PCi defective,
vary output. connector. replace.

Remote voltage sensing Ensure that all connections are clean and tight.
leads loose. .

No output at 115 VOLTS Circuit breaker CB1 open. Reset circuit breaker C81.
AC receptacle.

Explosive starts. Run in speed too fast. Set run in speed to approximately 20 I.P.M. on
wire feed system.
 461
N5, G C-072
.ECTROU~ WORM
51
I

MO! OI HG No.
~(MO1( COn~ t
HI

1C24
Diagram
~UL~ Circuit

Diagr m
CIrcuit
7-1.
Figure

~.II
I
l1,I~:.
C
(Jo
 April 1981 FORM: OM-180

Effective With Serial No. JA423799

MODEL
SQUAREWAVE 1000

PARTS
LIST
 /111
~.
17
ftf ~j sau*s*w1fl~~ 4
bY ~ ~ ~,
~~~--r--r~-r-1-.-4 a .~.

~ ~:.~~-~ -~.PJr,sIt~~j ~
%M*I *~ZtS~ ttk LJ~ thL~tifl.~ ~tS1 -

-
;~ ~ ¶4
-

4
1
-
____

~
-

P %!~ s-4
4
~-
,-j_~, ~
~
~
~ ~ ~ I:

-
= .=~ ~___

15
~
k~
~ ~:
~
~ -
~ 1-- I
-
~
t ~ i

C.a.aa~~< W~4~ ~ j
14 ___.__1 0

I-

/ /
10 13

Figure A - Front View

Item Dia. Part
No. Mkgs. No. Description Quantity

Figure A Front View

1 V 025645 METER,voltsac0-100 1
2 A 071 234 METER, amp ac 5OMV 0-1 .5K 1
3 RC2 035 523 RECEPTACLE, 5socketMS-3102A-16S-8S 1
----....-.-

C20,21,
-

24,25 031 670 CAPACITOR, ceramic 0.05 uf 500 volts dc 4

4 S2,11 011 609 SWITCH, toggleSPDTl5amp l25volts 2
5 Ri 035 897 POTEN11OMETER, carbon 1 tum2 watt 1000 ohm 1
Special BRAKE, potentiometer : 1
019 609 KNOB, pointer 1
6 PL1 027 645 LIGHT, indicator- red lens 125 voltsac 1
7 P81 011 636 SWITCH, push button 10 amp 550 volts ac 1
8 CB1 020 278 SWITCH. Circuit breaker 15 amp 1
9 RC1 604 176 RECEPTACLE, straight- duplex grounded 2P3W 1
C4 007 9~7 CAPACITOR, metalized paper 1 xl uf 115 voltsac 1
10 038 612 TERMINAL, power output (consistingof) 2
038613 .TERMINALBOARD 1
038900 .ST1JD,1/2-13x2-1/4 2
601 840 NUT, hex-jam 1/2-13 4
601 839 NUT, hex-fuIIl/2-13 2
038 847 BUS BAR 1
602247 WASHER, flat-SAE1/2 2
605 787 .WASHER, lock internal tooth 1/2
-
2
C22,23 006 034 CAPACITOR, ceramic 0.003 uf 3000 volts 2
072 266 BRACKET, mounting terminal assembly
- 1
11 072272 BASE 1
12 iT 038 772 BLOCK, terminal 20 amp6 pole 1
13 010 493 BUSHING, snap 5/8 I0x7/8 mounting hole 1
14 072381 PANEL,front 1
15 605 583 CATCH, spnng loaded door
- 1
16 RC5 039 634 RECEPTACLE, twistlock flanged 2P2W 20.amp 250 volts
- 1
039 635 CONNECTOR BODY, twistlock 2P2W 20 amp 250 volts 1
17 RC6 039 686 RECEPTACLE, twistlock grounded 2P2W 15 amp 277 volts
- 1
18 NAMEPLATE (order by model & serial numbersl 1

Recommended Spare Parts.

BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.

c,l~ i~ ~icI ~ 1
11

!_ 5

i 6

j .4
7

Figure B -
Right Side View
Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 8 Right Side View

13 036 630 TRANSFORMER, control 100 VA 115-230/460 1

12 035 759 TRANSFORMER, control 115/36 1
2 Fl 604 259 FUSE, cartridge 3 amp 600 volts 1
012 638 HOLDER, fuse cartridge 30 amp 600 volts
- 1
3 Cl ,3 006 034 CAPACITOR, ceramic 0.003 uf 3000 volts 2
4 W 048597 CONTACTOR, 3 pole 110-120/208-240 (consisting of) 1
048 599 .COIL 1
048 600 KIT, points contact
- 3
5 FM 032 605 MOTOR, 1/4 Pip 230 volts ac 1625 rpm 1
6 014 425 BAR, support- windtunnel 2
7 Ti 072 834 TRANSFORMER, power main (consisting of)
- 1
072 243 COIL, primary/secondary .
1
072 244 COIL, primary/secondary 2
072 824 TRANSFORMER SUBASSEMBLY (consisting of) 1
072 709 STRIP, polyester 0.062 x 8 x 10 2.
072 708 STRIP, polyesterO.062x5x8-1/4 2
072 712 WEDGE. phenolic 1/2 8-3/4
x 1 x 4
072 711 WEDGE, phenotic 1/4 8-3/4
x I x 2
TP1 026 181 THERMOSTAT, normally closed (in transformer)
8 H02,HA2 072 379 BALANCE FEEDBACK (consisting of) 1
082 266 CIRCUIT CARD, amplifier (consisting of)
A50 008 971 INTEGRATED CIRCUIT, operational amplifier 1
C50 031 643 CAPACITOR, ceramic 0.01 uf 500 voltsdc 1
C51,52 031 670 CAPACITOR, ceramic 0.05 uf 500 volts dc 2
R50,52 035 825 RESISTOR, carbon film 0.25 uflKohm 2
AS 1 028 282 RESISTOR, carbon 0.5 watt220 ohm 1
R53 035 896 RESISTOR, carbon film 0.25 watt 33K ohm 1
R54 004 592 RESISTOR, WW fixed 3.25 watt 150 ohm
R55 039 352 POTENTIOMETER, cermet trimmer 25 turn 0.5 watt 1 00K ohm 1
R56 035 824 RESISTOR, carbon film 0.25 watt 270 ohm 1
R57 039 360 POTENTIOMETER, cermet trimmer 20 turn 0.5 watt25K ohm 1
9 072 579 BUS BAR, rectifier I
10 SRi 072 580 RECTIFIER, SCR main (consisting of)
- 1
C7-10 048 420 CAPACITOR, ceramic 0.01 uf 500 vorts dc w/terminals 4
SCR1-4 071 984 THYRISTOR. SCR 1200 amp 300 volts 4
044 267 CLAMP, thyristor 1
072 434 HEAT SINK 2
072 436 HEAT SINK 4
11 072410 CIRCUIT CARD, meter calibration
-

Recommended Spare Parts.

BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.

_.1.~i l).,~.
 3 4 5 6. 7

\\A\~\/
I

13

12

11

Figure C - Left Side View

Item Dia. Part
No. Mkgs.
-
No. Description Quantity

Figure C Left Side View

.
.

1 003 490 WINDTUNNEL,20inch 1

2 RiO 030 060 RESISTOR, WW adj 375 watt 20 ohm 1
3 R7 030 035 RESISTOR, carbon0.5watti meg ohm 1
4 072 253 STUD, ground magnum 10-32 x 1/2
- 1
5 CR2 006393 RELAY, enclosed 24 volts ac DPDT flanged 1
6 CR1 059 266 RELAY, enclosed 120 voltsac DPDT flanged 1
7 026 627 GASKET, lifting eye -
1
8 pci 072 892 CIRCUIT CARD, control main (Fig Cl Pg 8)
- 1
R~3 072 566 HOUSING, connector edge circuit card 8 pin
- 1
RC4 072 565 HOUSING, connector edge circuit card 18 pin
-
1
9 HD1,HA1 072413 CURRENT FEEDBACK (consisting of) 1
072 795 CIRCUIT CARD, amplifier (consisting of) 1
A50 008 971 .
INTEGRATED CIRCUIT, operational amplifier 1
C50 031 643 .
CAPACITOR, ceramic 0.01 uf 500 volts dc 1
C51,52 031 670 CAPACITOR, ceramic 0.05 uf 500 volts dc 2
R50,52 035 825 RESiSTOR, carbon film 0.25 uf 1K ohm 2
R51 028 282 .
RESISTOR, carbon 0.5 watt220 ohm 1
R53 035 896 RESISTOR, carbon film 0.25 wart 33K ohm 1
R54 004 592 RESISTOR. WW fixed.3.25 watt 150 ohm 1
R55 052 152 POTENTiOMETER, carbon 25 turn 0.5 watt 1 meg ohm 1
R56 035 824 RESISTOR, carbon film 0.25 watt 270 ohm 1
R57 039 360 POTENTiOMETER, cermet trimmer 20 turn 0.5 watt 25K ohm 1
072 412 STRIP, mounting current feedback
-
.
1
10 Zi 072823 REACTOR (consisting of) 1
072 228 COIL, reactor 2
072 707 STRIP, polyestero.062x3 x8 1
072 710 STRIP, polyester 0.125 x 3/4 x 8-1/2 1
072 713 WEDGE, phenolic 1/2 x 1 x 12 4
072 836 .STRIP, hardwood 1-1/2x3-3/4x9 2
C2 045 057 CAPACITOR, paperoii4ouf 460 volts 6
072 373 BRACKET, mounting capacitor
-
1
11 045383 PLATE, adapter power cord
-
1
12 072218 PANEL, rear 1
13 032616 BLADE, fan 60 Hz 20 inch 3 wing 21 deg 1
072 216 PANEL, side 2
072 219 COVER, top 1

BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
~O18 CB~ -ca -ca 1 157 -cj
R90

Q52(i~64 ASEMBLY 072892

116 1 156 1.64-fED
R68 I

+~

cI ID C53

1 13 c~ 61
-cj- C80 ~
111
1 70
Main

diodes pictorial.
CI ~)-~I- -cj-
C67 061 1 137 11
56~ -

Control
~II ~-1 Cl Q~ 1C1 ~ R72 Card.
board _ _ -(EJ- -
78
&

071
oii
+

C~1
J
~J- -Ca) - _C6SL CEJ -(EJ ~ -IEJ- R87 Circuit
1 126 0l5~6~ 1 138
1

L 1

isolder dentfid
to 1154 060 059 56
1180
1153 1176 ~ 35
R9.
-

- _ -C~J- -CJ- -C- -En- -t:J1 24 -CEJ- -CE]- 9(~- ~- -} -

C
3 1183 RI 1 59 1161 CI
Q5
~~1-
-~J- (EJ Figure
1

R58 0
not
-t
are are
89. 89
0540 R125r
050 115/ 1163 1156 R77 1 82 1151 053 1181 1 123 1 106

Q640 _ _ CE)- -C~]- -E~I]- -CEJ- -{E:J- . r-j

~z &

C88 C88 R55 A2 1 105

~

1150 _ _ 16
RI 1152 1179 8,. - ~~ -CE)- -CE}-
111

(~-~- ~ ~
011 + 10I~ R1 4 1 1 7 1 1 5
II

c~E~E~ c~B~
1
1196 1 163 1 159

-ca- -t~J- ~- _ _A3

I

R167 6
I
1162 Rib1h02 1 101

~ c:j- -CE]- -IEJ- -CE]- CE)- 1 92E)- ~ Rl04~ -D58 I

Q5Q( L86
_ _
Cal ~ ~- 078 116
 Dia. Part
Mkqs. No. .

Description Quantity

Figure Cl 072 892 CIrcuit Card, Control - Main (See Fig. C Pg 6 Item 8)

A1-3 052
133 AMPLIFIER, operational-quad 741 3
C50 039
481 CAPACITOR, electrolytic 3.3 uf 50 volts dc 1
C51 035
835 CAPACITOR, electrolytic 4.7 uf 35 volts 1
C52,53,59,61 059
122 CAPACITOR, ceramic 0.01 uf 500 volts 4
C54 003
065 CAPACITOR, mylar 0.15 uf 100 voltsdc 1
C55,56,81 034
286 CAPACITOR, poly film 1 uf 100 voltsdc 3
C57,80 007
742 CAPACITOR, electrolytic 10 uf 35 volts 2
C58 073
460 CAPACITOR, electrolytic 2 uf 50 volts .1
Note 1 053
991 CAPACITOR, ceramic 0.05 uf 500 volts 8
C83 071
112 CAPACITOR, metal film 1.5 uf 100 volts dc 1
C65,66 039
341 CAPACITOR, mylar 0.003 uf 100 volts dc 2
C67,70 059
228 CAPACITOR, ceramic 0.02 uf 500 volts 2
C68,69 081
319 CAPACITOR, metal film 0.47 uf 50 volts dc 2
C71,72,86 072
935 CAPACITOR, electrolytic 33 uf 35 voltsdc 3
C73-76 .035 833 CAPACITOR, mylar 0.033 uf 100 voltsdc 4
C78,79 000 859 CAPACITOR, electrolytic 2.20 uf 35 voltsdc 2
C84 031 714 CAPACITOR, metalizedpapero.68uf200voltsdc 1
C87 003 530 CAPACITOR, ceramic 1 uf 50 volts 1
D50,75 037 203 DIODE, zener 6.8 volts 1 watt 2
051-55,58- .

68,76-78 028 351 DIODE, signal 0.02 amp 75 volts straight polarity 19
056 037 084 DIODE, zener4.7 volts 1 watt straight polanty 1
057 037 250 DIODE, zsner 24 volts 1 watt straight polarity .
1
D69-74 026 202 DIODE, rectifier 1 amp 400 volts straight polarity 6
050,52,54,
55,63 037 201 TRANSISTOR, 200MA 40 volts PNP 5
051,53,57-
60,64 037 200 TRANSISTOR, 200MA 40 volts NPN 7
056 000 088 TRANSISTOR, 800 MA 40 volts NPN 1
061,62 039 354 TRANSISTOR, 4 amp 40 volts PNP 2
R50,71,111 039 327 RESISTOR, carbon film 0.25 watt220 ohm 3
R51,75,114,115 035 886 RESISTOR, carbonfilm0.25watt22Kohm 4
R52,78 038 584 RESISTOR, carbon film 0.25 watt 470K ohm 2
Note 2 039 331 RESISTOR, carbon film 0.25 watt4700 ohm 13
Note 3 035 827 RESISTOR, carbon film 0.25 watt 10K ohm 19
R55,161 003 272 RESISTOR,.carbonfilm0.25wattl megohm 2
Note 4 039 332 RESiSTOR, carbon film0.25wattl5Kohm 7
Note 5 035 825 RESISTOR, carbon film 0.25 watt 1 K ohm .
8
R65,72,109,
119,127,159 035 826 RESISTOR,carbonfilm0.25watt6800 ohm 6
R70,87,110 039 328 RESISTOR, carbon film 0.25 watt 1500 ohm 3
R76,1G4 039 333 RESISTOR, carbon filmU.25 watt 18K ohm 2
R73 039 334 RESISTOR, carbon film 0.25 watt 27K ohm 1
R79,141 ,144 039 330 RESISTOR, carbon film 0.25 watt 3900 ohm 3
R90,121 ,158. 039 106 RESISTOR, carbon film0.25 watt 470 ohm 3
R92 044 633 RESISTOR, carbon film 0.25 watt 1.2Kohm 1
R93 035 887 RESISTOR, carbon film~0.25 watt 3300 ohm 1
R94,105 053 572 RESISTOR,carbonfikii.O.25wattl2Kohm 2
R95 601 394 RESISTOR, carbon2wa~t10Kohm 1
R98,99,123, .

125,129,131 035 896 RESISTOR, carbon film 0.25 watt 33K ohm 6
R102 035 885 RESISTOR,carbonfilm0.25watt68Kohm 1
R107 082 178 POTENTIOMETER, cermet trimmer 25 turn 0.5 watt 10K ohm 1
 Dia. Part
Mkgs. No. Description Quantity

Figure Cl 072 892 CIrcuit Card, Control- Main (See Fig. C Pg 6 item 8) (Contd.)

R74,1 12,155 039 335 RESiSTOR, carbon film 0.25 watt 47K ohm 3
R113 082 179 POTENTIOMETER, cermet trimmer 20 turn 0.5 watt 25K ohm 1
R116 035 884 RESISTOR, carbon film 0.25 watt lOOK ohm 1
RuB 072 934 RESISTOR, carbon film 0.25 watt 8.2 meg ohm 1
R122.126,
128,132 035 824 RESISTOR, carbon film 0.25 watt270 ohm 4
R 133,136 035 888 RESISTOR, carbon film 0.25 watt 2200 ohm 2
Ri 40,142 028 282 RESISTOR, carbon 0.5 watt220 ohm 2
Ri 45,162 030 710 RESISTOR, carbon 1 wart270 ohm 2
Ri 47,149,
151,153 030 937 RESISTOR. carbon0.Swattl0ohm 4
R148,150,
152,154 030 090 RESISTOR, carbonO.5 watt47 ohm 4
Ri 56,157 035 829 RESISTOR, carbon film 0.25 watt 1500 ohm 2
A 163 081 833 RESISTOR. caroon film 0.25 watt 2.7 meg onm 1
A 166,167 072 559 RESISTOR, carbon film 0.25 wart22K ohm 2
A FC1 072 701 REACTOR. 1OHY3MA1500DCohm 1
SR 1,2 035 841 RECTiFIER, integrated 1 .5 amp 200 volts 2
TI -4 045 128 TRANSFORMER, puise 201 4
VR1 035 227 VARISTOR. 8 oule 150 volts 1
VR5O 081 832 REGULATOR, voltage 0.5 amp 15 volts 1
VR5 I 046 932 REGULATOR, voltage 15 volts I
072 563 CONNECTOR, edge 18 pin 1.
072 564 CONNECTOR, eage8 pin I

Note 1: C60,62,64,77,82,85,88,89
Note 2: R53,61 .62,80,81,84,88.97,100,134,135,137,138
Note 3: R54,56,59,63,66,68,82.33,86,96,103,106,108,1 17,139,143,146,160,165
Note 4: R57,60,64,67,69,77,101
Note 5: R58,85,89,91,104,120,124,130
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPI..ACEMENT PARTS.