Miller Electric SCE-1A User manual

February

1980

FORM:

OM-540A

.tcc

._

,

Effective

With

Serial

No.

HK321565

MODEL

SCE-1A

SCE-3A

SCE-5A

SCM-lA

SCM-3A

SCM-5A

OWN

RS

MANUAL

I11dIER

MILLER

ELECTRIC

MFG.

CO.

718

BOUNDS

ST.

P.O.

Box

1079

APPLETON,

54912

USA

NWSA

CODE

NO.

4579

PRINTED

U.S.A.

L~

~L~

L

L&P

LIMITED

WARRANTY

EFFECTIVE:

JUNE

1979

This

warranty

supersedes

all

MILLER

warranties

and

clusive

with

other

guarantees

warranties

expressed

implied.

LIMITED

WARRANTY-Subject

the

terms

and

conditions

matter

general

policy

on1y,

Miller

may

honor

claims

hereof,

Miller

Electric

Mfg.

Co.,

Appleton,

Wisconsin

warrants

submitted

the

original

user

within

the

foregoing

periods.

its

Distributor/Dealer

that

all

new

and

unused

Equipment

(

furnished

Miller

free

from

defect

workmanship

and

the

case

Millers

breach

warranty

any

other

duty

material

the

time

and

place

delivery

Miller.

war-

with

respect

the

quality

any

goods,

the

exclusive

remedies

ranty

made

Miller

with

respect

engines,

trade

ac-

therefore

shall

be,

Millers

option

11)

repair

(21

replacement

cessories

other

items

manufactured

others.

Such

or,

where

authorized

writing

Miller

appropriate

cases,

(31

engines,

trade

accessories

and

other

items

are

sold

subject

the

reasonable

cost

repair

replacement

authorized

the

warranties

their

respective

manufacturers,

any

All

Miller

service

station

141

payment

credit

for

the

purchase

engines

are

warranted

their

manufacturer

for

one

year

from

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

date

original

purchase.

return

the

goods

Customers

risk

and

expense.

Upon

receipt

notice

apparent

defect

failure,

Miller

shall

instruct

the

clai-

Except

specified

below,

Millers

warranty

does

not

apply

mant

the

warranty

claim

procedures

followed.

components

having

normal

useful

life

less

than

one

(1)

year,

such

spot

welder

tips,

relay

and

contactor

points,

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

MILLERMATIC

parts

that

come

contact

with

the

welding

ANY

IMPLIED

WARRANTY,

GUARANTY

REPRESENTA-

wire

including

nozzles

and

nozzle

insulators

where

failure

does

lION

AS TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

not

result

from

defect

workmanship

material.

BREACH

CONTRACT

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

IMPLICATION,

OPERATION

LAW,

Miller

shall

required

honor

warranty

claims

war-

CUSTOM

TRADE

COURSE

DEALING,

INCLUDING

ranted

Equipment

the

event

failure

resulting

from

defect

ANY

IMPLIED

WARRANTY

MERCHANTABILITY

within

the

following

periods

from

the

date

delivery

Equip-

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

ment

the

original

user:

ANY

AND

ALL

EQUIPMENT

FURNISHED

MILLER

CLUDED

AND

DISCLAIMED

MILLER.

Arc

welders,

power

sources

and

components

year

Original

main

power

rectifiers

years

EXCEPT

EXPRESSLY

PROVIDED

MILLER

(labor

year

onlyl

WRITING,

MILLER

PRODUCTS

ARE

INTENDED

FOR

All

welding

guns

and

feeder/guns

days

ULTIMATE

PURCHASE

COMMERCIAL/INDUSTRIAL

All

other

Millermatic

Feeders

year

USERS

AND

FOR

OPERATION

PERSONS

TRAINED

AND

Replacement

repair

parts,

exclusive

labor

days

EXPERIENCED

THE

USE

AND

MAINTENANCE

Batteries

months

WELDING

EQUIPMENT

AND

NOT

FOR

CONSUMERS

CONSUMER

USE.

MILLER

WARRANTIES

NOT

EXTEND

provided

that

Miller

notified

writing

within

thirty

(30)

days

TO,

AND

RESELLER

AUTHORIZED

EXTEND

the

date

such

failure.

MILLERS

WARRANTIES

TO,

ANY

CONSUMER.

.~,

TABLE

CONTENTS

Section

No.

Page

No.

SECTION



INTRODUCTION

General

Receiving-Handling

Description

1-4.

Safety

SECTION



INSTALLATION

Electrical

Input

Connections

Secondary

Connections

Shielding

Gas

Con

nØctions

Coolant

Connections

Contactor

Control

Receptacle

Emergency

Stop

Switch

Connections

Manual

Control

Connections

Sequence

SECTION

3

FUNCTION

CONTROLS

Sequence

Control

Function

Current

Control

Start

Switch

(SCE/SCM-1A

and

2A)

Weld

Switch

Manual

Control

Sequence

High-Frequency

Control

SECTION



SEQUENCE

OPERATION

Gas

Tungsten-Arc

Welding

(GTAW)

Shielded Metal-Arc

Welding

(SMAW)

Shutting

Down

SECTION

5

MAINTENANCE

High

Voltage

Capacitors

Spark

Gap

Adjustment

Bypass

Panel

Control

Circuit

Protection

SECTION

6

TROUBLESHOOTING

SECTION



CERTIFICATION

FOR

HIGH

FREQUENCY

ARC

WELDING

EQUIPMENT

General

Information

Power

Service

Welding

Machine

Welding

Leads

Wiring

The

Vicinity

Of The

Welding

Area

Grounds

Metal

Building

Individual

Installation

Certification

7-10.

Check

List

SECTION

INTRODUCTION

Dime

Height

nsions

(Inches)

Width

Depth

Weight

Net

(Pounds)

Shipping

33-1/4

26-1/4

10-3/4

168

230

Figure

1-1.

Specifications

1-1.

GENERAL

This

manual

has

been

prepared

especially

for

use

familiar

izing

personnel

with

the

design,

installation

operation,

main

tenance,

and

troubleshooting

this

equipment.

All

informa

tion

presented

herein

should

given

careful

consideration

assure

optimum

performance

this

equipment.

1-2.

RECEIVING-HANDLING

Prior

installing

this

equipment,

clean

all

packing

material

from

around

the

unit

and

carefully

inspect

for

any

damage

that

may

have

occurred

during

shipment.

Any

claims

for

loss

damage

that

may

have occurred

transit

must

filed

the

purchaser

with

the

carrier.

copy

the

bill

lading

and

freight

bill

will

furnished

the

carrier

request

occasion

file

claim

arises.

When

requesting

information

concerning

this

equipment,

essential

that

Model

Description

and/or

Stock

Number

and

Serial

(or

Style)

Numbers

the

equipment

supplied.

1-3.

DESCRIPTION

These

Sequence

Controls

are

specifically

designed

used

conjunction

with

electric

current

controlled

welding

power

source.

These

Sequence

Controls

provide

five

different

sequences

for

either

automatic

semi-automatic

operation

the

various

welding

processes.

The

function

each

sequence

described

Section

FUNCTION

CON

TROLS,

this

manual.

The

SCE

Models

are

equipped

with

electronic

timers

sequences

B, C,

and

The

SCM

Models

are

equipped

with

mechanical

timers

sequences

and

1-4.

SAFETY

Before

the

equipment

put

into

operation,

the

safety

sec

tion

the front

the

welding

power

source

welding

generator

manual

should

read

completely.

This

will

help

avoid

possible

injury

due

misuse

improper

welding

applications.

The

following

definitions

apply

CAUTION,

IMPORTANT,

and

NOTE

blocks

found

throughout

this

manual:

sonnel.

Under

this

heading,

installation,

operating,

and

main

tenance

procedures

practices

will

found

that

not

carefully

followed

may

result

damage

equip

ment.

NOTE

Under

this

heading,

explanatory

statements

will

found

that

need

special

emphasis

obtain

the

most

efficient

operation

the

equipment.

SECTION

INSTALLATION

2-1.

ELECTRICAL

INPUT

CONNECTIONS

Refer

the

Installation

Section

of the

welding

power

source

Manual

for

instructions

connecting

electrical

input

power

the

welding

power

source.

the

SCE/SCM-1A

and

Models,

inside

the

cabinet

the

lower

right

corner

above

the

control

transformer,

either

three

five

pole

terminal

block

with

one

jumper

link

attached.

The

primary

power

supply

the

Sequence

Control

connected

this

block.

The

jumper

link

must

connected

for

the

primary

power

supply

voltage

that

will

correspond

with

the

primary

power

supply

voltage

the

TA-040

107-4

Figure

2-1.

Line

Voltage

Jumper

Link

Arrangement

welding

power

source.

Refer

Figure

2-1

for

positioning

the

link

for

the

required

operating

voltage.

the

SCE/SCM-5A,

the

control

transformer

which

provides

the

primary

power

the

control

located

the

welding

power

source.

2-2.

SECONDARY

CONNECTIONS

(Figure

2-2)

unit

was

shipped

the

secondary

inte

connecting

cables

between

the

Sequence

Control

and

welding

power

source

unconnected.

therefore

necessary

route

and

secure

the

secondary

inter

connecting

cables

(already

attached

Sequence

Con

trol)

the

proper

weld

output

terminals

the

welding

power

source.

The

secondary

welding

cables

should

only

attached

the

output

terminals

Sequence

Control

achieve

proper

operation

this

Refer

Installation

Section

of the

welding

power

source

Owners

Manual

for

proper

weld

cable

size.

The

secondary

terminals

the

Sequence

Control

are

labeled

ELECTRODE

and

WORK.

Connect

the

electrode

holder

cable

the

terminal

marked

ELECTRODE

and

the

work

cable

the

terminal

marked

WORK.

2-3.

SHIELDING

GAS

CONNECTIONS

(Figure

2-2)

These

connections

are

located

the

front

panel

and

are

labeled

IN-GAS-OUT.

The

connections

have

right-hand,



Under

this

heading,

installation,

operating,

and

main

tenance

procedures

practices

will

found

that

not

carefully

followed

may

create

hazard

to per-

230/460

VOLTS



230

460

208/230/460

VOLTS





208

230 460

230/460/575

VOLTS

000

230

460 575

OM-540

Page

5/8-18

female

thread.

Connect

the

hose

from

the

shielding

gas

supply

the

connection

labeled

IN.

Connect

the

hose

from

the

electrode

holder

the

connection

labeled

OUT.

2-4.

COOLANT

CONNECTIONS

(Figure

2-2)

These

connections

are

located

the

front

panel

and

are

labeled

IN-COOLANT-OUT.

The

connections

have

left-

hand,

5/8-18

female

thread.

Connect

the

hose

from

the

coolant

supply

the

connection

labeled

IN.

Connect

the

hose

from

the

electrode

holder

the

connection

labeled

OUT.

This

three-prong,

twistlock

receptacle

provides

contactor

control

facilities.

Either

remote

hand

foot

switch

can

used

conjunction

with

this

receptacle.

2-6.

EMERGENCY

STOP SWITCH

CONNECTIONS

(Fig

ures

2-3

and

3-2)

five-pole

terminal

block

with

two

jumper

links

attached,

located

the

inside

lower

left

corner

the

cabinet,

provides

means

emergency

stop

connections

weld

sequences

B, C,

desirable

connect

emergen

stop

switch

the

circuit,

remove

the

jumper

link

that

connected

across

the

fourth

and

fifth

terminals,

counting

left

right.

Connect

normally-closed

switch

the

terminals

from

which

the

link

was

removed.



portable,

self-contained

coolant

system

used

with

this

unit,

ensure

that

the

coolant

pump

has

bypass

capability

avoid

possible

damage

the

motor

when

the

coolant

valve

closes

and

coolant

flow



stops.

2-5.

CONTACTOR

CONTROL

RECEPTACLE

(Figure

2-2)

Figure

2-2.

Front

Panel

View

With

the

WELD

switch

the

AUTOMATIC

position,

weld

sequences

may

interrupted

any

time

opening

the

emergency

stop

switch.

Opening

this

switch

will

initiate

sequence

(post-flow

time).

2-7.

MANUAL

CONTROL

CONNECTIONS

QUENCE

(Figures

2-3

and

3-2)

five-pole

terminal

block,

with

two

jumper

links

attached,

located

the

inside

lower

left

corner

the

cabinet,

provides

means

external

switch

control

sequence

connect

external

switch

for

manual

control

sequence

remove

the

jumper

link

connected

across

the

first

and

second

terminals

counting

left

right.

Connect

normally-open

switch

the

terminals

from

which

the

link

was

removed.

SECTION

FUNCTION

CONTROLS

WELD

SWITCH

AMMETER

WORK

TERMINAL

HIGH-FREQUENCY

SWITCH

START

SWITCH

(ONLY

SCE/SCM-1



GAS

CONNECTIONS

COOLANT

CONNECTIONS

CTO

CONTROL

RECEPTACLE

ELECTRODE

TERMINAL

TA-OlO

566

Figure

2-3.

Terminal

Block

For

External

Switch

Operation

PRE-FLOW

ANT

GAS

CWFLD

POST-FLOW

GAS

COOLANT

DFINISH

~

E

~i~I77~ffl7~A

~START

FINISH

TIME

Figure

3-1.

Sequence

Time

Chart

TA-040

107-6

Page

3-1.

SEQUENCE

CONTROL

FUNCTION

(Figure

3-1)

This

Sequence

Control

five

sequence automatic

control

designed

for

Gas

Tungsten-Arc

Welding

)GTAW).

The

function

each

sequence

follows:

PRE-FLOW:

gas

and

coolant;

adjustable

mechanical

time

1/4

seconds.

START

current:

adjustable

control

and

timer

preset

magnitude

current

and

time.

WELD

current:

adjustable

control

and

timer

provide

exact

values

current

and

time.

Sequence

can

manually

controlled.

Sequence

SLOPE

current:

adjustable

control

and

timer

are

preset

determine

magnitude

and

time

duration

current

end

weld.

Sequence

POST-F

LOW:

gas

and

coolant;

adjustable

mechanical

time

sequence

seconds

minutes.

3-2.

CURRENT

CONTROL

(Figure

3-2)

The

welding

current

for

sequences

and

governed

the

setting

of the

control

immediately

above

each

sequence

timer.

These

controls

are

calibrated

percentages

and

function

remote

controls,

that

they

are

fine

amperage

adjustments

the

AMPERAGE

ADJUSTMENT

control

the

welding

power

source.

The

REMOTE

AMPERAGE

CONTROL

switch

the

welding

power

source

must

the

STANDARD

position

for

proper

operation

the

Sequence

Control.

NOTE

The

AMPERAGE

ADJUSTMENT

control

the

welding

power

source

must

the

one

hundred

percent

(maximum)

position

for

maximum

control

the

selected

range.

value

from

the

minimum

the

maximum

of the

selected

current

range

the

welding

power

source.

Slope

Weld

Amperage

Control

(Sequence

The

SLOPE

control

provided

for

selecting

the

slope

weld

current

value.

The

control

adjustable

and

can

set

for

any

value

from

the

minimum

the

maximum

the

selected

current

range

the

welding

power

source.

For

normal

finish

the

control

should

set

for

value

less

than

the

WELD

(sequence

setting.

3-3.

START

SWITCH

(SCE/SCM-1A)

(Figure

2-2)

This

switch

provides

choice

selecting

either

normal

fast

start

sequence

(START

weld).

Normal

Position

With

the switch

the

NORMAL

position,

the

starting

current

will

start

value

less

than

the

setting

the

START

weld

amperage

control,

but

will

rapidly

increase

the

setting

the

START

weld

amperage

control.

Fast

Position

With

the

switch

the

FAST

position,

the

starting

current

will

start

the

value

the

START

weld

amperage

setting.

3-4.

WELD

SWITCH

(Figure

2-2)

This

switch

provides

choice

selecting

either

automatic

semi-automatic

operation

the

Sequence

Control.

Automatic

Position

With

the

switch

the

AUTOMATIC

position,

the

Sequence

Control

will

operate

automatically

through

all

sequences

with

the

use

contactor

control

switch

connected

the

CONTACTOR

CONTROL

receptacle.

Start

Weld

Amperage

Control

(Sequence

The

START

control

provided

for

selecting

the

start

weld

current

value.

The

control

adjustable

and

can

set

for

any

value

from

the

minimum

the

maximum

the

selected

current

range

the

welding

power

source.

For

normal

start

the

control

should

set

for

value

less

than

the

WELD

(sequence

setting.

Weld

Amperage

Control

(Sequence

The

WELD

control

provided

for

selecting

the

normal weld

current

value.

The

control

adjustable

and

can

set

for

any

START

WELD

AMPERAGE

CONTROL

PILOT

LIGHT

FOR

GAS

AND

WATER

GAS

AND

COOLANT

PRE-FLOW

TIME

CONTROL.~~,

Manual

Position

With

the

switch

the

MANUAL

position,

the

timers

sequences

and

are

removed

from

the

circuit.

However,

the

weld

sequence

current

value

will

controlled

the

WELD

amperage

control

the

Sequence

Control.

Closing

the

contactor

control

switch

will

initiate

sequence

)PRE-FLOW).

Upon

completion

sequence

the

WELD

sequence

will

initiated

automatically.

The

Sequence

Control

will

continue

operate

the

WELD

sequence

until

the

contactor

control

switch

opened.

Opening

this

switch

will

extinguish

the

WELD

sequence

and

initiate

sequence

(POST-FLOW

gas

and

coolant

time).

SLOPE

WELD

1

AMPERAGE

CONTROL

GAS

AND

COOLANT

POST-FLOW

CONTROL

SLOPE

WELD



TIME

CONTROL

WELD

.T!~TIME

CONTROL

VOLTAGE

CHANGEOVER

TERMINAL

BLOCK

FOR

CONTROL

TRANSFORMER

Sequence

PILOT

LIGHT

FOR

WELD

EACH

WELD

SEQUENCE

AMPERAGE

CONTROL

START

WELD

TIME

CONTROL

TERMINAL

BLOCK

FOR

EXTERNAL

SWITCH

OPERATION

AND

EMERGENCY

STOP

SWITCH

CONNECTION

HIGH

FREQUENCV

SPARK

GAP

Figure

3-2.

Control

Panel

View

OM-540

Page

3-5.

MANUAL

CONTROL

SEQUENCE

Provisions

are

provided

for

manual

timing

sequence

allow

Continuous

welding

for

any

desired

time.

This

accomplished

connecting

external

switch

into

the

Circuit.

Refer

Section

2-7

for

information

connecting

the

external

switch.

The

Sequence

Control

functions

auto

matically

through

sequences

and

but

the

time

duration

sequence

controlled

the

external

switch.

Closing

the

external

switch

will

extinguish

sequence

and

initiate

the

SLOPE

weld

time

(sequence

3-6.

HIGH-FREQUENCY

CONTROL

(Figure

2-2)

The

high

frequency

controlled

through

the

Direct-Air

coupling

jumper

links

and

the

HIGH-FREQUENCY

switch

labeled

START-OFF-CONTINUOUS.

Direct-Air

Coupling

Located

each

side

of the

high-frequency

panel

are

three

terminals

and

one

jumper

link.

The

positions

the

links

are

labeled

DIRECT

and

AIR.

These

links

provide

facilities

for

connecting

the

high-frequency

transformer

for

either

direct

air

coupling

which

governs

the

amount

high-frequency

intensity.

increase

the

intensity,

connect

both

links

the

SECTION

SEQUENCE

4-1.

GAS

TUNGSTEN-ARC

WELDING

(GTAW)

For

Gas

Tungsten-Arc

Welding

(GTAW(.

check

and

adjust

the

controls

follows:

Check

that

shielding

gas

and

coolant

connections

are

described

Sections

2-3

and

2-4.

Check

that

secondary

connections

are

described

Section

2-2.

Determine

the

type

welding

current

required

(AC,

DCSP,

DCRP(,

and

position

the

Polarity

switch

Selector

switch

the

welding

power

source

accord

ingly.

Place

the

Range

switch

the

welding

power

source

the

desired

current

range.

Rotate

the

AMPERAGE

ADJUSTMENT

control

the

welding

power

source

the

maximum

position.

Rotate

the

START

weld

amperage

control,

WELD

amperage

control,

and

the

SLOPE

weld

amperage

control

the

Sequence

Control

the

desired

setting.

Place

the

WELD

switch

the

desired

position.

The

AUTOMATIC

position

generally

used,

but

the

MANUAL

position

may

employed.

SCE/SCM-1A

Models,

place

the

START

switch

the

desired

position

according

the

welding

appli

cation.

Place

the

HIGH-FREQUENCY

switch

the

START

position

for

welding,

and

the

CONTINUOUS

position

for

welding.

10.

Adjust

the

shielding

gas

and

coolant

pre-flow

and

post-flow

timers

for

the

desired

time

setting.

11.

Select

the

proper

size

tungsten

for

the

welding

application

from

Table

4-1.

12.

Connect

normally-open

switch

into

the

CON

TACTOR

CONTROL

receptacle.

welding,

imperative

that

proper

protective

clothing

(welding

coat

and

gloves)

and

eye

protection

(glasses

and

welding

helmet)

put

on.

Failure

comply

may

result

serious

and

even

permanent

bodily

damage.

position

labeled

DIRECT.

decrease

the

intensity,

connect

both

links

the

position

labeled

AIR.

This

unit

was

shipped

with

the

links

connected

the

DIRECT

position.

Off

Position

With

the switch

the

OFF

position,

high

frequency

is1

removed

from

the

weld

circuit.

This

position

must

used

for

Shielded

Metal-Arc

Welding

(SMAW).

Start

Position

With

the

switch

the

START

position,

high

frequency

induced

into

the

weld

circuit

aid

starting

the

arc.

When

welding

arc

established,

the

high

frequency

will

automatically

shut

off.

This

method

recommended

for

Gas

Tungsten-Arc

Welding

(GTAW).

Continuous

Position

With

the

switch

the

CONTINUOUS

position,

high

fre

quency

induced

into

the

weld

circuit

during

all

three

welding

sequences,

long

the

contactor

energized.

This

method

recommended

for

Gas

Tungsten-Arc

Welding

(GTAW).

OPERATION

14.

the

contactor

control

switch

and

commence

welding.

15.

Readjust

the

controls

necessary

for

proper

welding

condition.

4-2.

SHIELDED

METAL-ARC

WELDING

(SMAW)

For

Shielded

Metal-Arc

Welding

(SMAW)

check

and

adjust

the

controls

follows:

Disconnect

shut

off

the

shielding

gas

and

coolant

supplies.

Check

that

secondary

connections

are

described

Section

2-2.

Determine

the

type

welding

current

required

(AC,

DCSP

DCRP),

and

position

the

Polarity

switch

Selector

switch

the

welding

power

source

accord

ingly.

Place

the

Range

switch

the

welding

power

source

the desired

current

range.

Rotate

the

AMPERAGE

ADJUSTMENT

control

the

welding

power

source

the

maximum

position.

Rotate

the

WELD

amperage

control

(sequence

the

Sequence

Control

for

the approximate

percentage

weld

current

desired

within

the

range

selected

the

welding

power

source.

Place

the

WELD

switch

the

MANUAL

position.

SCE/SCM-1A

Models,

adjust

the

START

weld

amperage

control

approximately

the

same

setting

the

WELD

amperage

control

setting.

SCEISCM-1A

Models,

place

the

START

switch

the

desired

position

according

she

welding

application.

10.

Place

the

HIGH-FREQUENCY

switch

the

OFF

position.

11.

Connect

normally-open

switch

into

the

CON

TACTOR

CONTROL

receptacle.

welding,

impera

that

proper

protective

clothing

(welding

coat

and

gloves)

and

eye

protection

(glasses

and

welding

helmet)

put

on.

Failure

comply

may

result

serious

and

even

permanent

bodily

damage.

13.

Place

the

POWER

switch

the

welding

power

source

the

position.

Page

12.

Place

the

POWER

switch

the

welding

power

source

the

position.

13.

the

contactor

control

switch

and

commence

welding.

14.

Readjust

the

controls

necessary

for

proper

weld

condition.

4-3.

SHUTTING

DOWN

Break

the

arc.

Allow

the

welding

power

source

idle

for

minutes

with

load

applied.

Place

the

POWER

switch

the

OFF

position.

Turn

off

the

shielding

gas

supply

used.

~ding

performed

confined

area,

failure

_______________

turn

off

the

gas

supply

could

result

buildup

gas

fumes,

endangering

personnel

reentering

the

welding

area.

_______________

SECTION

MAINTENANCE

~ng

the

WER

switch

the

OFF

position

oes

not

remove

power

from

all

the

welding

power

source

internal

circuitry.

Completely

terminate

all

electrical

power

the

welding

power

source

employing

machinery

lockout

procedures

before

attempting

any

inspection

work

the

inside

the

welding

power

source

the

Sequence

Control,

the

welding

power

source

connected

disconnect

switch,

padlock

the

switch

open

position.

connected

fuse

box,

remove

the

fuses

and

padlock

the

cover

the

closed

position,

the

unit

connected

circuit

breaker,

other

disconnecting

device

without

locking

facilities,

attach

red

tag

the

device

warn

others

that

the

circuit

being

worked

on.

Widening

the

spark

gaps

through

normal

operation

may,

not

corrected,

increase

the

high

voltage

capacitors

and

thus

contribute

their

premature

failure.

Cleaning

dressing

the

point

not

recommended

the

material

the

points

tungsten

and

impossible

file.

The

entire

points

should

replaced

when

they

become

extremely

pitted

burned

such

extent

that

little

tungsten

left.

adjust

spark

gaps

proceed

follows:

Loosen

screws

(A)

both

sides.

Place

.008

inch

feeler

gauge

spark

gap

area

(C).

Apply

slight

pressure

against

spark

point

(B)

feeler

gauge

held

firmly

between

the

two

points,

Tighten

screws

(A),

5-1.

HIGH

VOLTAGE

CAPACITORS

These

parts

are

rarely

source

trouble.

Any

local

radio

repair

shop

Can

readily

determine

the

condition

of the

capacitors.

one

the

high

voltage

capacitors

fail,

operation

may

continued

with

one

capacitor

until

new

one

can

secured.

prevent

excessive

overload

the

remaining

single

capacitor,

the

spark

gap

point

setting

should

reduced

about

.004

inches.

5-2.

SPARK

GAP

ADJUSTMENT

(Figure

5-1)

The

spark

gaps

can

readily

inspected

opening

the

door

the

Sequence

Control.

The

spark

gaps

are

set

.008

inches

when

shipped.

will

necessary

periodically

readjust

these

after

extended

operation.

Usually,

inspection

and

adjustment

every

three

four

months

will

suffice.

Readjustment

indicated

when

intermittent

operation

the

gaps

noted.

Usually

this

occurs

when

the

gap

setting

has

increased

.012

inches

greater.

The

high-frequency

output

varies

directly

(up

certain

point)

with

the

spark

gap

spacing.

extreme

cases

where

the

greatest

amount

high

frequency

needed,

may

necessary

adjust

the

gap

setting

.010

inches

greater.

This

increases

the

high-frequency

radiation;

therefore,

suggested

that

the

minimum

gap

setting

(.008

inches)

consistent

with

good

welding

operation,

used.

Figure

5-1.

Spark

Gap

Adjustment

TA-020

623

Table

4-1

Guide

For

Selecting

Electrode

For

Gas

Tungsten-Arc

Welding

PURE

TUNGSTEN

CURRENT

RANGE

Electrode

Dta.

lIn.l

ACHF-Argon

DCSP.Argon

DCSPHelium

.010

.020

.040

20w

30 to

1/16

125

50 to

135

6Oto

150

3/32

1/8

100

160

150

210

125

225

215

360

140

250

240

400





5/32

3/16

190

280

250

350

450

720

390

500

800

1/4

300

500 720

990

800

1100

AND

THOR ATED

TUNG

STEN

.010

.020

15to35

15to50

20to60

.040

to 80 25 to

80 30

100

1/16

140

145

160

3/32

130

250

135

235

150

260

1/8

225

350

225

360

250

400

5/32

300

450

360

450

400

500

3/16

400

650

450

720

500

800

1/4

500

800

720

990

800

1100

TA-gO

190-3

OM-540

Page

5-3.

BYPASS

PANEL

5-4.

CONTROL

CIRCUIT

PROTECTION

The

purpose

the

bypass

panel

reduce

the

high-fre

quency

feedback

into

the

transformer

the

welding

power

source.

defective

capacitor

this

Circuit

would

reduce

high-frequency

output,

and

might

evident

loss

oil

from

the

capacitor

case.

doubt

the

condition

the

capacitors,

have

them

checked

radio

repair

shop.

The

resistors

the

Circuit

would

show

evidence

failure

they

are

cracked.

Failure

this

circuit

rare,

and

would

suspected

only

last

resort.

The

Sequence

Control

equipped

with

fuses

protecting

the

control

circuit

components.

The

diagram

markings

and

quantity

fuses

may

vary

depending

the

model.

Normally

the

fuses

can

easily

inspected

opening

the

cabinet

door

and

examining

the

interior

the

unit.

Consult

the

circuit

diagram

beginning

welding

power

source

Owners

Manual

for

specific

information

this

unit.

The

proper

information

about

specific

fuses

can

determined

from

the

Parts

List.

Hazardous

voltages

are

present

the

internal

Cir

cuitry

this

Unit

long

power

connected.

Disconnect

power

before

attempting

any

inspection

or work

the

inside

the

Unit.

Troubleshooting

internal

circuitry

should

performed

qualified

personnel

only.

The

following

chart

designed

diagnose

and

provide

remedies

for

some

the

troubles

that

may

develop

this

unit.

It is

assumed

that

proper

installation

has

been

made,

according

Section

this

manual,

and

that

the

unit

has

been

functioning

properly

until

this

trouble

developed.

Use

this

chart

conjunction

with

the

circuit

diagram

while

performing

troubleshooting

procedures.

the

trouble

not

remedied

after

performing

these

procedures,

the

nearest

Factory

Authorized

Service

Station

thould

contacted.

all

cases

equipment

malfunction,

the

manufacturers

recommendations

should

strictly

followed.

Tt~~i~

SECTION

TROUBLESHOOTING

TROUBLE

PROBABLE

CAUSE

SUGGESTED

CHECK

AND/OR

REMEDY

All

sequences

inoperative;

output.

Gas

and

coolant

flows

for

brief

period

and

then

shuts

off

(transformer

energized).

Fuse

open.

~Replace

fuse

(see

Section

5.4).

Remote

Hand

Switch

not

tight in

receptacle

Rd.

Ensure

that

Remote

Hand

Switch

secure

receptacle

RC1.

All

sequences

inoperative;

output.

Gas

and

coolant

does

not

flow

(transformer

energized).

Fuse

open.

~Replace

fuse

(see

Section

5-4).

Sequence

Control

entirely

moper-

ative

(transformer

not

ener

gized).

Fuse

open.

~RepIace

fuse

(see

Section

5-4).

Normal

output;

high

frequency.

High-frequency

switch

OFF

position.

Place

high-frequency

switch

proper

position.

Incorrect

spark

gap.

Check

spark

gap.

Adjust

required.

See

Section

5-2.

Shorted

high

voltage

capacitor(s).

Replace

capacitor(s).

Normal

output.

Low

high

frequency.

Incorrect

spark

gap.

Check

setting

for

.008

inch.

See

Section

5-2.

High-frequency

leaks.

Check

all

connections

for

high-frequency

leaks.

Incorrect

direct-air

coupling.

Check

that

both

links

are

connected

for

the

same

coupling.

Erratic

weld

current.

Poor

tungsten.

Check

tungsten

and

replace

contaminated.

Incorrect

polarity.

Check

polarity.

Incorrect

welding

cable

size

loose

connections,

Check

for

proper

weld

cable

size

(see

Section

2-2).

Tighten

all

welding

cable

connections.

Poor

ground

workpiece.

Check

ground

connections.

Contactor

pulls

in.

Incorrect

operating

voltage

relay

CR3.

Adjust

slider

resistor

relay

CR3

pulls in

open-circuit

voltage.

Weld

current

does

not

shut

off.

Incorrect

operating

voltage

relay

CR3.

Adjust

slider

resistor

relay

CR3

drops

out

when

welding

arc

initiated.

Contactor

does

not

pull

in.

Blown

fuses

and/or

control

circuitry.

~Replace

fuses

and/or

(see

Section

5-4).

becomes

necessary

replace

any

fuse

this

unit,

ensure

that

fuse

the

proper

size

used.

See

beginning

welding

power

source

Owners

Manual

for

circuit

diagram.

Page

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