Miller M-180 User manual

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7

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October

1969

FORM:

IOM-

114A

Effective

with

serial

No.

N295574

MODEL

STOCK

NO.

M-180

900001

M-180P

900010

M-225

900019

M-225P

900

028

1

Astallation

IfiperatioN

~

E~1

aioteoance

Manual

mIIcr

ELECTRIC

MIGU

CO.

APPLETON,

WISCONSIN,

U.S.A.

54911

-

-

USt.

NWSA

CODE

NO.

4579

SECTION

1-

SAFETY

RULES

FOR

OPERATION

OF

ARC

WELDING

MACHINE

1.1.

GENERAL

DA.

These

rules

apply

to

ac

and

dc

welding

generators,

ac

transformer

and

ac/dc

welding

machines,

and

dc

transformer

rectifier

welding

machines.

DB.

In

arcwelding

operations,

where

electrically

en

ergized

parts

are

exposed,

observe

the

following

safety

rules

to

insure

maximum

personal

safety

and

protect

nearby

persons.

DC.

Failure

to

observe

these

safety

precautions

may

expose

not

only

you,

but

fellow

workers

as

well,

to

serious

injuries.

Once

these

rules

are

learned

and

kept

in

mind,

proceed

with

maximum

assurance.

WELDING

MACHINE

ciA.

Never

use

welding

cables

at

currents

in

excess

of

their

rated

capacity.

It

will

cause

overheating

and

rapid

deterioration

of

the

insulation.

It

is

also

uneconomical.

DONT

use

worn

or

poorly

connected

cables.

DB.

Inspect

the

cables

frequently.

Immediately

repair

all

breaks

in

the

insulation

with

rubber

and

friction

tapes.

Tighten

all

cable

connections

and

adequately



insulate

any

joints

where

a

connector

may

have

an

exposed

conductive

part.

In

addition

to

the

potential

hazard

to

life,

a

hazard

occurs

when

exposed



sections

of

cable

come

in

contact

with

grounded

metallic

objects,

causing

an

arc.

Unprotected

eyes

may

be

injured

and

fire

may

result

if

combustible

materials

such

as

oil

or

grease

are

in

the

vicinity.



The

efficiency

and

quality

of

welding

will

be

im

proved

by

elimination

of

these

dangerous

grounds,

and

by

keeping

connections

tight.

1.3.

ELECTRODE

HOLDER

DONT

use

electrode

holders

with

defective

jaws.

ciA.

Keep

the

jaws

of

the

electrode

holder

tight

and

the

gripping

surfaces

in

good

condition

to

provide

close

contact

with

the

electrodes.

Defective

jaws

will

permit

the

electrode

to

wobble,

making

control

of

the

welding

operations

difficult.

DONT

use

electrode holder

with

loose

cablecon

nections.

Keep

the

connections

of

the

electrode

lead

to

the

holder

tight

at

all

times.

Use

only

fully

insulated

electrode

holders

(and

with

out

protruding

screwheads.)

Never

touch

two

electrode

holders

from

two

separate

welding

machines

at

the

same

time.

1.4.

CODE

CONFORMANCE

ciA.

The

machine

and

its

equipment

must

be

installed

and

maintained

in

accordance

with

the

National

Electrical

Code

and

local

requirements.

1.5.

PARALLEL

CONNECTIONS

ciA.

See

diagrams

in

the

instruction

manual

applying

to

the

welding

machine

used.

1.6.

POWER

DISCONNECT

SWITCH

DA.

If

the

welding

machine

does

not

include

a

power

disconnect

switch,

install

one

at

or

near

the

machine.

1.7.

POLARITY

SWITCH

DONT

operate

the

polarity

switch

under

load.

ciA.

The

polarity

switch

(when

supplied)

is

provided

for

changing

the

electrode

lead

from

positive

(reverse

polarity)

to

negative

(straight

polarity).

Never

move

it

while

under

the

load

of

a

welding

current.

Operate

this

switch

only

while

the

machine

is

idling

and

the

welding

circuit

is

open.

The

potential

dangers

of

opening

the

circuit

while

carrying

high

current

are:

0(1)

An

arc

will

form

between

the

contact

surfaces

of

the

switch

and

severely

burn

them.

0(2)

The

person

throwing

the

switch

may

receive

a

severe

burn

from

this

arcing.

1.8.

RANGE

SWITCH

DONT

operate

the

range

switch

under

load.

ciA.

The

range

switch

(when

supplied)

is

provided

for

obtaining

required

current

settings.

It

must

never

be

operated

while

the

machine

is

under

the

load

of

welding

current.

Operate

the

range

switch

only

while

the

machine

is

idling

and

the

welding

circuit

is

open.

Thepotenialdangerofswitchingthe

circuit

while

carrying

high

current

is

the

formation

of

an

arc

between

the

contact

surface

which

will

severely

burn

them.

Repeated

occurrences

of

this

arcing

will

eventually

prevent

operation

of

the

contacts.

1.9.

EXHAUST

GASES

DONT

use

gas

engine

units

in

confined

spaces

without

venting

the

exhaust

gases.

ciA.

If

gasoline

or

other

fuel

driven

welding

machines

are

operated

indoors,

provide

means

to

pipe

the

exhaust

gases

to

the

outside

air

to

avoid

carbon

monoxide

poisoning.

1.2.

WELDING

CABLES

DONT

overload

cables.

DB.

DC.

DD.

I

~1/

,--

I..

-

IOM-114A-

Page

1

DONT

use

welding

machine

without

grounding

frame

or

case.

I

_

I

DA.

Ground

the

ground

cable

of

every

power

circuit

to

prevent

accidental

shock

by

stray

current.

The

potential

danger

is

that

development

of

a

stray

cur

rent

may

give

a

fatal

shock

should

a

person,

for

example,

place

one

hand

on

thewelding

machine

and

the

other

on

the

switch

box,

or

other

grounded

equipment.

Do

not

ground

to

pipelines

carrying

gases

or

flammable

liquids

and

conduits

carrying

electrical

conductors.

Be

sure

conductors

can

safely

carry

the

ground

current.

When

con

necting

the

welding

machine,

properly

ground

the

machine

frame

or

case.

WELDING

OPERATIONS

1.11.

CONTAINERS

WHICH

HELD

COMBUSTIBLES

DONT

weld

on

containers

which

have

held

com

bustible

or

flammable

materials

or

materials

which,

when

heated,

give

off

flammable

or

toxic

vapors

without

proper

cleaning,

purging,

or

inerting.

DA.

Welding

on

containers

which

have

heldflammable

or

combustible

materials

may

be

extremely

danger

ous.

To

prevent

afireorexplosionof

the

container,

follow

the

recommendations

of

the

American

Weld

ing

Society

Pamphlet

A6.O

Welding

or

Cutting

Con

tainers

Which

Have

Held

Combustibles.

DONT

depend

on

your

eyes

or

nose

to

decide

if

it

is

safe

to

weld

on

a

closed

container.

DB.

Find

out

what

was

in

the

container

or

use

an

explosimeter.

A

very

small

amount

of

residual

flammable

gas

or

liquid

can

cause

a

serious

explosion.

NEVER

use

oxygen

to

ventilate

a

container.

DC.

When

you

know

the

container

held

a

gas

or

liquid

which

will

readily

dissolve

in

water:

D(1)

Flush

out

with

water

several

times

and

then

fill

with

water

as

far

as

work

permits,

posi

tioning

container

to

permit

introduction

of

as

much

water

as

possible.

D(2)

Before

welding

be

sure

there

is

a

vent

or

opening

to

provide

for

release

of

air

pressure.

EW.

When

you

know

the

container

held

a

gas

or

liquid

which

will

not

readily

dissolve

in

water.

D(1)

Clean

out

thoroughly

with

steam

or

a

cleans

ing

agent

and

purge

all

air

or

inert

with

a

gas

such

as

carbon

dioxide

or

nitrogen

before

re

pairing.

Carbon

dioxide

is

heavier

than

air

and

will

tend

to

remain

in

the

container

if

the

open

ing

is

at

the

top.

D(2)

Use

steam

to

clean

out

light

material.

D(3)

Use

a

strong

caustic

soda

solution

to

clean

out

heavy

oils

or

grease.

0(4)

Be

sure

to

purge

all

air

or

inert

with

a

gas,

such

as

nitrogen

or

carbon

dioxide,

no

matter

how

well

you

have

cleaned.

There

may

still

be

traces

of

oil,

grease,

or

other

readily

oxidizable

material

under

the

seams.

DE.

Be

careful

when

cleaning

with

steam

or

caustic

soda

wear

goggles

and

gloves.

DONT

clean

where

there

is

poor

ventilation.

OF.

Ventilation

is

necessary

to

carry

away

harmful

or

explosive

vapors.

DONT

clean

where

there

are

open

flames.

0G.

When

scraping

or

hammering

to

remove

heavy

sludge

or

scale,

use

a

spark

resistivetool

and

keep

it

wet

to

avoid

sparks.

OH.

Keep

your

head

and

arms

as

far

away

from

your

work

as

possible.

1.12.

HOLLOW

CASTINGS

DONT

weld

on

hollow

(cored)

castings

that

have

not

been

properly

vented.

The

casting

may

explode.

NEVER

weld

in

or

near

explosive

atmospheres,

Such

atmospheres

can

be

created

by

flammable

gas

leaks

or

by

vapors

from

flammable

liquids

(gasoline,

alcohol,

etc.)

or

by

combustible

dusts.

1.14.

VENTILATION

DONT

weld

in

confined

spaces

without

adequate

ventilation.

DA.

When

welding

in

confined

spaces,

provide

ventilation

in

accordance

with

United

States

of

America

Stand

ard

Z49.1,

1967.

Always

provide

adequate

ventila

tion

by

blowers,

air

lines,

or

other

acceptable

means.

Never

use

compressed

oxygen.

The

depletion

of

the

oxygen

supply,

the

heat

of

welding,

and

the

fumes

given

off

may

cause

severe

dis

comfort

or

a

serious

illness.

OB.

When

toxic

fumes

from

lead

or

cadmium

bearing

materials

or

any

other

substances

are

present

in

harmful

concentrations,

always

use

an

air

supplied

respirator.

L

--



J

--

1.10.

POWER

CIRCUIT

GROUND

1

_--I

1.13.

EXPLOSION

HAZARDS

Page

2

1.15.

SOLVENTS

DA.

Do

not

weld

where

chlorinated

hydrocarbon

vapors

from

degreasing,

cleaning,

or

spraying

may

reach

or

he

drawn

into

air

surrounding

the

welding

operation.

The

heat

of

the

arc

can

decompose

solvent

vapors

to

form

phosgene,

a

highly

toxic

gas

and

other

irritating

decomposition

products.

OB.

Do

not

weld

where

ultraviolet

lightfrom

the

electric

arc

can

penetrate

air

containing

even

minute

amounts

of

vapors

from

solvents

such

as

trichlo

roethylene

or

perchloroethylene.

Ultraviolet

light

can

decompose

the

vapors

to

form

phosgene,

a

highly

toxic

gas,

and

other

irritating

products.

1.16.

FIRE

HAZARDS

DONT

weld

near

flammable

or

combustible

materials.

DA.

Fires

can

be

caused

by

the

arc,

by

contact

with

the

heated

metal,

by

slag,

or

sparks.

Keep

com

bustibles

at

least

35

feet

from

the

arc

or

suitably

protected.

If

welding

must

be

done

in

a

particular

area,

move

the

combustibles

away.

If

they

cannot

be

moved,

cover

them

completely

with

fire

resistive

screens.

Cover

cracks

or

openings

in

floors

or

walls;

sweep

floor

free

of

combustibles

and wet

down,

if

wood,

being

sure

welder

wears

insulation

shoe

coverings.

Avoid

welding

on

partition

walls

in

contact

with

combustibles.

Heated

metal

on

the

other

side

of

partition

wall

being

welded

upon

can

ignite

combustibles

in

contact

with

the

partition.

Where

other

than

a

minor

fire

might develop,

have

a

fire

watcher

stand

by

with

suitable

fire

extin

guishing

equipment

for

at

least

one-half

hour

after

the

welding

is

completed.

1.17.

ELECTRICAL

SHOCK-VOLTAGE

OPEN

power

circuits

before

checking

machines.

DA.

Before

working

on

the

wiring,

switches,

controls,

etc.,

open

the

power

line

disconnect

switch.

In

most

welding

shops

the

power

supply

used

for

arc

welding

machines

is

230

or

460

volts.

Open

circuit

voltages

are

usually

less

than

100

volts

and

welding

or

arc

voltage

drops

are

still

lower.

How

ever,

all

of

these

voltages

are

capable

of

developing

a

harmful

or

fatal

current

to

the

body.

DONT

touch

electrically

hot

parts.

DB.

Never

touch

any

exposed

or

non-insulated

part

of

the

cables,

cable

connectors,

clamps,

electrode

holders,

electrodes~

or

the

power

supply

equipment

to

prevent

harmful

or

fatal

electric

shock

or

burns.

1.18.

ELECTR

ICAL

SHOCK-DAMPNESS

NEVER

work

in

a

damp

area

without

suitable

in

sulation

against

shock.

Keep

hands,

feet,

and

clothing

dry

at

all

times.

DA.

To

pievent

harmful

body

shocks,

keep

hands,

feet

and

clothing

dry.

Never

stand

or

lie

in

puddles

of

water,

damp

ground,

or

against

grounded

metal

when

welding

without

suitable

insulation

against

shock.

Always

find

a

dry

board

or

rubber

mat

to

stand

on

when

water,

moisture,

or

perspiration

cannot

be

avoided.

Dampness

between

the

body

and

an

en

ergized

or

grounded

metallic

part

lowers

the

resistance

to

the

passage

of

current

to

the

body

which

may

produce

a

harmful

or

fatal

shock.

Salt

in

perspiration

or

sea

water

dangerously

1ower~

contact

resistances.

1.19.

STARTING

UNDER

LOAD

DONT

leave

an

uninsulated

electrode

holder,

or

a

live

electrode

on

the

table

topor

in

contact

with

a

grounded

metallic

surface.

When

it

is

not

in

use,

never

place

an

electrode

holder

in

contact

with

the

table

top

or

other

metallic

surface

in

contact

with

welding

ground.

Provide

an

insulated

hook

or

holder

for

the

electrode

holder.

A

potential

danger

is

that

a

holder

in

contact

with

the

ground

circuit

provides

a

dead

short

circuit

on

the

welding

machine.

If

the

machine

should

be

started

up,

this

short

circuit

would

cause

an

ex

cessive

load

on

the

machine

and

may

damage

the

insulation.

1.20.

FACE

PROTECTION

DONT

use

cracked

or

defective

helmets

or

shields.

Keep

the

helmet,

hand

shields,

or

face

shield

in

good

condition,

If

cracks

occur

in

the

fibre

material,

replace

the

shield,

since

the

leakage

of

arc

rays

may

cause

serious

burns.

1.21.

EYE

PROTECTION

NEVER

under

any

circumstances,

look

at

an

electric

arc

without

eye

protection.

CAUTION

Make

sure

that

flash

goggles

are

used

under

the



welding

helmet

at

all

times,

particularly

while

gas

shielded-arc

welding.

DA.

In

some

type

of

arc

welding,

such

as

gas

shielded-

arc

welding.ultraviolet

and

infrared

radiation

from

the

arc

is

particularly

intense

and

requires

constant

attention

to

avoid

arc

flashes

to

the

welder

when

striking

an

arc

and

to

avoid

exposure

to

other

welders.

NEVEB

strike

an

arc

without

ascertaining

that

nearby

persons

either

have

the

necessary

pro

tective

equipment

or

are

looking

in

the

opposite

direction.

DB.

For

welding

operations

in

open

areas,

provide

portable,

nonreflecting

screens

to

shield

persons

nearby

from

the

rays

of

the

arc.

Eye

burns

from

the

arc,

though

not

generally

permanent

injuries,

are

exceedingly

painful.

Such

burns

frequently

referred

to

as

flashes,

feel

like

hot

sand

In

the

eye.

For

eye

burns

consult

your

first

aid

station

or

doctor.

IOM-114A-Page

3

N

EVER

use

cracked,

ill-fitting,

or

defective

plates.

EC.

The

filter

glass

plate

provided

in

the

helmets

and

shields

must

be

of

reputable

manufacture

conform

ing

to

the

latest

USA

Standard

Z2.1.

Replace

cracked

or

ill-fitting

filter

plates

promptly.

NEVER

use

filter

plates

without

a

protecting

cover

glass.

ED.

Keep

a

clean

cover

glass

in

front

of

the

filter

plate

for

the

protection

thereof.

Frequent

renewal

of

these

cover

glasses

is

necessary,

since

they

become

covered

with

spatter,

reducing

vision.

1.22.

CLOTHING

NEVER

use

poor,

inadequate,

or

worn-out

cloth

ing.

Wear

heavy

shoes,

tightly

laced.

Keep

clothing

dry.

EA.

Proper

and

dry,

oil-free

clothing

is

essential

for

the

welders

protection.

Clothing

must

not

only

keep

off

the

spatter

and

molten

particles,

but

must

also

abstruct

the

rays

of

the

arc

and,

when

nec

essary,

insulate the

body

from

harmful

electrical

currents.

EB.

Wear

leather

or

asbestos

gloves

at

all

times

to

protect

the

hands

and

wrists.

Dark

colored

shirts

are

preferred

to

light

ones

because

light

ones

reflect

arc

rays

to

exposed

parts

of

the

body.

In

the

case

of

gas

shieldedarc

welding,

light

colors

are

more

reflective

and

may

cause

eye

burns

due

to

the

intense

ultraviolet

rays

given

off

by

the

process.

Avoid

cotton

fabrics

when

gas

shielded

arc

welding.

EC.

An

arc

burn

on

the

skin

resembles

a

sunburn,

except

that

it

is

usually

more

severe.

Clothing

can

be

made

flame

resistant

by

treatment

with

a

solution

of

3/4

pound

of

sodium

stannate

in

1

gal

lon

of

water,

then

wrung

out

and

dipped

in

a

solution

of

1/4

pound

ammonium

sulphate

per

gal

lon

of

water.

Dont

wash

clothing

so

prepared

in

water,

but

dry

clean.

ED.

When

welding

operations

are

to

be

performed

in

vertical

and

overhead

positions,

leather

sleevelets,

aprons,

and

in

some

cases

leggings

and

ear

plugs

should

be

used

to

prevent

severe

burns

from

spatter

and

molten

metal.

1.23.

HOT

METAL

BURNS

NEVER

pick

up

hot

objects.

EA.

Never

pick

up

pieces

of

metal

which

welded

or

heated,

or

the

stub

ends

which

have

been

discarded.

1.24.

GRINDING

AND

CHIPPING

EA.

Whenever

it

is

necessary

to

grind

or

chip

metal,

wear

protective

goggles

specifically

designed

for

this

purpose.

Serious

eye

injuries

may

result

from

failure

to

wear

protective

goggles.

NEVER

do

any

chipping

or

grinding

without

pro

tective

goggles.

1.25.

COMPRESSED

GAS

CYLINDERS

NEVER

strike

an

arc

on

compressed

gas

cylin

ders.

EJA.

Avoid

accidental

contact

of

the

electrodes,

electrode

holder,

or

other

electrically

energized

parts

with

a

compressed

gas

cylinder

or

any

other

pressure

vessel.

Serious

accidents

or

fires

may

result.

EB.

Use

I.C.C.

cylinders.

They

are

manufactured

and

maintained

in

accordance

with

I.C.C.

requirements

and

are

safe

so

long

as

they

are

properly

handled.

Dont

drop

cylinders.

EC.

Identify

gas

content

by

the

name

marked

on

the

cylinder.

If

the

cylinder

is

unmarked,

do

not

use

it.

Return

it

to

the

supplier.

Do

not

rely

on

color

code.

ED.

Never

use

a

cylinder

or

its

contents

for

other

than

intended

purposes.

EE.

Keep

oil

and

grease

away

from

oxygen

cylinders

and

cylinder

valves.

EF.

Keep

cylinders

away

from

exposure

to

sparks,

hot

slag,

open

flame

and

all

possible

sources

of

ignition

or

excessive

heat.

EG.

Be

careful

that

cylinders

are

not

placed

so

as

to

become

a

part

of

an

electrical

circuit.

Avoid

third

rails,

wires

and

electric

welding

circuits.

EH.

When

transporting

cylinders

by

crane,

use

cradle,

platform

or

other

suitable

support.

El.

Never

lift

the

cylinders

by

slings,

by

the

caps

or

by

electric

magnets.

EJ.

Never

use

cylinders

as

supports

or

rollers.

EK.

Never

try

to

mix

any

gases

in

a

cylinder.

EL.

Never

try

to

refill

a

cylinder.

EM.

Mark

empty

cylinders

Empty

or

MT.

EN.

Send

Emptys

back

to

the

supplier

promptly.

EO.

Keep

Emptys

and

Fulls

separate.

EP.

Never

tamper

with

or

alter

cylinder

numbers

or

other

markings.

This

is

not

only

foolish

but

may

be

illegal.

EQ.

Do

not

tamper

with

or

change

fittings

on

cylinders.

ER.

If

valves

cannot be

opened

by

hand,

do

not

use

hammer

or

wrench.

Notify

supplier.

ES.

Protect

cylinder

valves

from

bumps,

falls,

falling

objects,

and

from

weather.

Keep

them

covered

with

cylinder

caps

when

moving

cylinders.

LIT.

Keep

valves

closed

on

empty

cylinders.

EU.

See

that

your

cylinders

are

clear

of

passageways

and

active

work

areas

and

that

they

are

secured

against

falling.

LIV.

If

adapter

is

required

between

cylinder

an~l

reg

ulator,

always

use

a

standard

adapter.

These

may

be

obtained

from

your

supplier.

Where

right

and

left

hand

threads

are

used

on

adapter,

use

two

wrenches

to

insure

leak

proof

connections.

EW.

Do

not

store

cylinders

in

unventilated

areas.

1/

~

have

just

been

of

electrodes

Page

4

SECTION

2-

INTRODUCTION

2-1.

GENERAL

This

manual

has

been

prepared

especially

for

use

in

familiarizing

personnel

with

the

design,

in

stallation,

operation

and

maintenance

ofthewelding

machine.

In

some

cases,

the

contents

of

this

pub

lication

are

generalized.

All

information

presented

in

this

manual

should

be

given

careful

consideration

to

assure

optimum

performance

and

service

of

the

equipment.

Process

information

is

available

by

contacting

your

welding

distributor.

2-2.

RECEIVING-HANDLING

To

prepare

the

welding

machine

for

installation,

several

items

should

be

checked.

Clean

all

packing

material

from

around

the

unit

and

carefully

inspect

for

damage

that

may

have

been

caused

by

shipping.

Any

claims

for

loss

or

damage

that

may

have

oc

curred

in

transit

must

be

filed

by

the

buyer

with

the

carrier.

Copy

of

bill

of

lading

and

freight

bill

will

be

furnished

on

request

ifoccasiontofileclaimarises.

Be

sure

to

read

all

the

instructions

before

at

tempting

to

operate

the

welding

machine.

When

requesting

information

concerning

the

weld

ing

machine,

be

sure,

to

furnish

serial

and

model

numbers.

2-3.

DESCRIPTION

This

welding

machine

is

designed

for

use

in

light

industrial

plants,

metal

fabrication

shops,

auto

motive

repair

shops

and

for

general

light

welding

applications.

Two

welding

current

ranges

are

available.

The

high

range

provides

ample

normal

open

circuit

volt

age

for

average

electrode

sizes.

The

low

range

pro

vides

maximum

open

circuit

to

permit

the

use

of

smaller

electrode

sizes.

The

180

amp

machine

uses

natural

updraft

cooling

and

the

225

amp

machine

uses

a

fan,

both

which

help

ensure

that

the

internal

components

are

kept

below

the

critical

operating

temperatures,

pro

viding

the

duty

cycle

ratings

are

not

exceeded.

2-4.

SAFETY

Before

attempting

to

make

primary

or

secondary

connections,

change

parts

or

make

repairs,

be

sure

the

welding

machine

is

completely

disconnected

from

the

main

power

line.

Before

the

welding

machine

is

put

into

operation,

read

the

complete

safety

section

at

the

front

of

this

manual.

This

will

help

avoid

any

possible

injury

due

to

misuse

or

improper

welding

applications.

SECTION

3

-

INSTALLATION

3-1.

LOCATION

(Figure

3-1)

Proper

component

operating

temperatures

on

the

225

amp

model

are

maintained

by

the

air

stream

produced

by

thefan

assembly.

On

the

180

amp

model

air

cooling

is

provided

by

means

of

natural

updraft

through

the

vented

bottom.

Therefore

the

air

passages

in

the front

and

bottom

of

the

welding

ma

chine

must

be

kept

open.

The

rear

of

the

welding

machine

should

be

kept

a

minimum

distance

of

18

inches

from

the

wall

to

help

ensure

proper

cooling.

The

location

should

be

such

that

a

minimum

amount

of

dust

and

dirt

will

be

drawn

into

the air

stream.

Preventive

maintenance

consists

of

re

moving

the

wrapper

and

blowing

out the

dust

ac

cumulation

inside

the

welding

machine,

For

this

reason

it

is

desirable

to

locate

the

unit

so

that

the

wrapper

can

be

removed

without

any

difficulty.

Four

mounting

holes

are

provided

in

the

welding

machine

base

for

machines

that

require

mounting.

Figure

3-1

gives

overall

dimensions

and

the

base

mounting

hole

layout

for

console

installation

or

other

installations

that

may

require

this

infor

mation.

3-2.

PRIMARY

CONNECTIONS

(Figure

3-2

&

3-3)

Most

rural

and

residental

power

systems

are

of

the

115/230

volt,

single

phase

type.

This

ac

arc

welding

machine

is

a

single

phase

unit

and

must

be

connected

to

a

single

phase

power

line.

Consult

the

local

power

and

light

company

if

there

is

any

question

about

type

of

system

used

locally

or

the

proper

connection

to

obtain

single

phase

power

service

to

the

welding

machine.

All

models

are

ordinarily

supplied

with

an

attach

ed

three

conductor

cable.

Models

requiring

208

or

230

volt

primary

input

are

equipped

with

a

three

prong

polarized

plug

and

wall

receptacle.

The

wall

receptacle

should be

installed

in

a

con

venient

location

by

a

competent

electrician.

The

wall

receptacle

should be

installed

with

the

grounding

MODEL

WELDING

CURRENT

RANGE

AMPERES

RATED

CURRENTOUTPUT

AT25

VOLTS.

20%

DUTY

CYCLE

CURRENT

OUTPUT

AT3OVOLTS.

20%

DUTY

CYCLE

OPEN

CIRCUIT

VOLTS

POWER

INPUT

AT

RATED

LOAD

50/60

Hz.

AMPERES





23OVOLTS

SINGLE

PHASE

kw

kva

DIMENSIONS

OVERALL

WEIGHT

HEIGHT

WIDTH

DEPTH

NET

SHIPPING

180

Amp.

180

Amp.

*

225

Amp.

225

Amp.

*

20-180

20-180

30-225

30-225

180

180

225

225

200

200

55180

55/80

55/80

55/80

37

30

44.4

38.5

5.4

5.4

7.2

7.2

8.5

6.9

10.2

8.8

17

12-1/2

20-1/2

130

Lbs.

138

Lbs.

17

12-1/2~~

20-1/2~

135

Lbs.

142

Lbs.

17

12-1/2

20-1/2

135

Lbs.

142

Lbs.

17

12-1/2~

20-1/2~~

140

Lbs.

147

Lbs.

~With

Power

Factor

Correction.

Figure

2-1.

Specifications

Figure

3-1.

Dimensional

Drawing

AA-500

001-1

IOM-114A-

Page

5

terminal

at

the

top

as

this

then

permits

the

power

cord

to

hang

downward

without

undue

bending

or

twisting.

Models

with

other

than

230

volt

only

primary

input

voltages,

are

equipped

with

a

voltage

changeover

terminal

strip

and two

jumper

links.

This

terminal

strip

is

accessible

by

opening

the

access

door

on

the

rear

panel.

The

terminal

strip

is

located

at

the

rear

of

the

welding

machine

base.

If

the

welding

machine

is

furnished

with

a

pri

mary

voltage

changeover

terminal

strip,

connect

the

jumper

links

to

the

indicated

voltage

terminals

to

match

the

primary

input

voltage.

Whenever

only

one

jumper

link

connection

is

necessary

for

the

proper

input

voltage,

connect

both

jumper

links

across

the

same

two

terminals.

This

will

help

prevent

losing

the

second

jumper

link.

Refer

to

Figure

3-2

for

proper

jumper

link

connections.

Welding

machines

are

shipped,

unless

otherwise

ordered,

with

the

jumper

links

connected

in

the

highest

voltage

position.

This

welding

machine

should

be

operated

from

a

separately

fused

or

circuit

breaker

protected

cir

cuit.

The

maximum

capacity

of

the

welding

machine

is

affected

by

the

line

voltage

and

if

the circuit

is

overloaded,

the

performance

of

the

welding

machine

will

be

impaired.

Install

a

cable

of

two

primary

wires

plus

one

ground

wire

(see

Table

3-1

for

proper

wire

and

fuse

sizes)

from

the

line

disconnect

switch

or

circuit

breaker

to

the

WALL

RECEPTACLE.

See

Figure

33.

For

models

without

a

three

prong

plug,

a

60

am

pere

plug

may

be

installed

to

the

welding

machine

primary

input

cable

and

the

receptacle

to

the

line

disconnect

switch.

A

grounding

wire

must

be

run

to

a

suitable

ground

ing

medium

such

as

the

electrical

conduit

system,

the

water

system

or

a

regular

driven

ground

rod.

Check

with

the

local

inspection

authority

if

there

is

any

question

as

to

an

accepted

grounding

method.

Models

with

a

three

prongpolarizedplug,plugin

to

the

wall

receptacle.

For

models

without

a

three

prong

plug,

connect

the

No.

10

green

wire

to

the

ground

wire

or

connection

in

the

line

disconnect

switch

and

the

two

No.

8

wires

to

the

power

leads.

3-3.

SECONDARY

(WELDING)

CONNECTIONS

It

is

recommended

that

the

welding

cables

be

kept

as

short

as

possible,

placed

close

together

and

be

of

adequate

current

carrying

capacity.

The

resistance

of

the

welding

cables

and

connections

cause

a

volt

age

drop

which

is

added

to

the

voltage

of

the

arc.

Excessive

cable

resistance

may

result

in

over

loading

as

well

as

reducing

the

maximum

current

output

of

which

the

welding

machine

is

capable.

When

welding

with

ac,

longer

cables

if

coiled

up,

will

generate

a

magnetic

field

that

can

reduce

the

output

of

the

welding

machine.

The

welding

cables

from

the

work

and

electrode

holder

to

the

welding

machine

should

be

taped

together

at

short

intervals.

The

proper

operation

of

any

arc

welding

machine

is

to

a

great

extent

dependent

on

the

use

of

welding

cables

and

connections

that

are

in

good

condition

Table

3-2.

Secondary

Welding

Cable

Size

WELDING

AMPERES

TOT

AL

LENGTH

OF

CABLE)

COPPER)

IN

WELD

CIRCUIT

50

100 150

200

250

300

100

2

2

1

1/0

2/0

3/0

150

2

1

2/0

3/0 4/0

200

2

1/0

3/0

4/0

250

2

2/0

4/0

300

1

3/0

NOTE:

A.

50

FEETOR

LESS

B.

CABLE

SIZE

IS

BASED

ON

DIRECT

CURRENT

(DC),

20%

DUTY

CYCLE

AND

EITHER

A

4

VOLTS

OR

LESS

DROP

OR

A

CURRENT

DENSITY

OP

NOT

OVER

300

CIRCULAR

MILS

PER

AMP.

C.

WELD

CABLE

INSULATION

WITH A

VOLTAGE

RATING

TO

WITH

STAND

THE

OPEN

CIRCUIT

VOLTAGE

IO.C.V.)

OF

THE

WELD

ING

MACHINE

MUST

BE

USED.

WHILE

MOST

WELDING

MA

CHINES

HAVE AN

OPEN

CIRCUIT

VOLTAGE

OP

LESS

THAN

100

VOLTS,

SOME

WELDING

MACHINES

OF

SPECIAL

DESIGN

MAY

HAVE

HIGHER

OPEN

CIRCUIT

VOLTAGE.

~~1

Table

3-1.

Recommended

Primary

Wire

And

Fuse

Sizes

MODEL

PRIMARY

WIRE

SIZE

(From

source

to

line

disconnect

switch)

FUSE

SIZE

(AMPERES)

115V

208V 230V

460V

575V

115V

208V 230V

460V

575V

180

Amp

Model

Without

P.F.C.

180

Amp

Model

With

P.F.C.*

225

Amp

Model

Without

P.F.C.

225

Amp

Model

With

P.F.C.

No.

2

(No.

6)

No.4

(No.6)

No.

2

(No.

6)

No.3

(No.6)

No.

6

(No.

8)

No.8

(No.8)

No.

6

(No.

8)

No.6

(No.8)

No.

8

(No.

8)

No.

10

(No.

10)

No.

6

(No.

8)

No.8

(No.

8)

No.

12

(No.

12)

ND.

14

(No.

14)

No.

10

(No.

10)

No.

12

(No.

12)

No.

14

(No.

14)

No. 14

(No.

14)

No.

12

(No.

12)

No.

12

(No.

14)

150

110

175

150

80

70

100

80

70

60

90

75

35

30

45

35

30

25

35

30

Numbers

in

I

4

are

ground

mire

sizes.

Pomer

Factor

Correction.

AA-900

B23-9

Figure

3-3.

Primary

Connections

iee

SzS

voits

ate

voLts

373

VOLtS

:

A-BOO

g23-e

Figure

3-2.

Primary

Voltage

Link

Arrangement

Page

6

and

of

adequate

size.

Electrode

holder

and

ground

clamp

should

be

at

least

200

ampere

capacity

and

securely

connected

to

the

welding

cables.

An

in

sulated

electrode

holder

must

be

used

to

ensure

operators

safety.

Select

the

proper

size

welding

cable

from

Table

3-2.

A.

Jack

Plug

Installation

(Figure

3-4)

Two

jack

plugs,

enclosed

in

a

cloth

bag,

are

fur

nished

with

the

welding

machine.

Follow

instruc

tions

carefully

for

proper

installation

of

the

jack

plugs

to

the

welding

cables.

See

Table

32

for

proper

welding

cable

sizeS

Standard

jack

plugs

furnished

with

unit

will

accommodate

cable

sizes

ranging

from

6

to

1.

1.

Remove

3/4

inch

of

insulation

from

one

end

of

each

welding

cable.

2.

Clamp

the

welding

cable

in

a

vise

with

the

un

insulated

end

protruding

upward

out

of

the

vise

approximately

1-3/4

inches.

3.

Place

the

steel

tie

wire

(A)

approximately

1/4

inch

from

the

end

of

the

insulation.

4.

Make

a

half

turn

around

the

cable

bringing

the

looped

ends

of

the

tie

wire

together.

5.

Insert

a

rod

of

approximately

3/8

inch

diameter

through

the

two

looped

ends

of

the

tie

wireS

6.

Twist

the

tie

wire

(B)

until

the

entire

tie

wire

is

twisted

and

is

tight

around

the

insulation

of

the

welding

cable.

7.

Clip

off

the

looped

ends

of

the

tie

wireS

8.

Bend

the

twisted

tie

wire

over

alongthe

side

(C)

of

the

uninsulated

portion

of

the

welding

cable.

9.

Wrap

the

strip

of

copper

foil

tightly

around

the

uninsulated

end

of

the

welding

cable

and

the

twist

ed

tie

wire

(D).

10.

Place

the

jack

plug

on

the

end

of

the

welding

cable

and

push

it

onto

the

welding

cable

over

the

copper

foil

(E).

11.

Insert

the

1/4-20

allen

set

screws

into

the

center

CAUTION

cfl~

Figure

3-4.

Jack

Plug

Installation

and

upper

holes

in

the

jack

plug

and

tighten.

12.

Remove

the

welding

cable

from

the

vise

and

in

sert

the

jack

plug

into

the

fiber

sleeve.

Slide

the

fiber

sleeve

over

the

jack

plugandweldingcahle

until

the

hole

in

the

fiber

sleeve

lines

up

with

the

8/32

hole

in

the

jack

plug

(F).

13.

Insert

the

8/32

self

tapping

screw

through

the

hole

in

the

fiber

sleeve

into

the

jack

plug.

Tighten

the

screw

with

a

screw

driver.

Connect

a

Work

Clamp

to

one

of

the

unused

ends

of

one

of

the

cables.

Connect

an

Electrode

Holder

to

the

unused

end

of

the

other

welding

cable.

The

method

of

connecting

the

cables

to

the

work

clamp

and

electrode

holder

will

depend

on

the

manu

facturers

design.

SECTION

4

-

OPERATION

I

Never,

under

any

circumstances,

operate

the

weld

ing

machine

with

the

cover

removed.

In

addition

to

a

safety

hazard,

improper

cooling

may

result

in

damage

to

the

welding

transformer

and

the

welding

machine

components.

Be

sure

to

read

the

complete

safety

section

at

the

front

of

the

manual

before

oper

ating

the

welding

machine.

20

30

40

50

60

7080

100

%

DUTY

CYCLE

A-101

391A

Figure

4-1.

Duty

Cycle

Chart

4-1.

DUTY

CYCLE

(Figure

4-1)

The

duty

cycle

of

a

welding

machine

is

the

percentage

of

a

ten

minute

period

that

the

welding

machine

can

operate

safely

at

a

given

output.

This

welding

machine

is

rated

at

a

20

percent

duty

cycle.

This

means

that

the

welding

ma

chine

can

operate

safely

at

rated

load

if

the

ma

chine

is

on

for

no

more

than

two

minutes

and

off

for

eight

minutes.

If

the

output

is

increased

above

rated

load,

the

duty

cycle

must

be

reduced.

Figure

4-1

shows

the

percent

duty

cycle

compared

to

output.

This

chart

should

be

used

for

reference

by

the

operator

to

de

termine

the

operating

limits

or

ON

time

of

the

weld

ing

machine

if

it

is

operated

above

rated

output.

4-2.

OPEN

CIRCUIT

VOLTAGE

This

welding

machine

provides

80

volts

open

circuit

on

the

ac

LOW

range

and

55

volts

open

cir

cuit

on

the

ac

HIGH

current

range.

Open

circuit

voltage

is

the

voltage

present

between

the

electrode

and

work

before

an

arc

has

been

struck.

4-3.

ARC

VOLTAGE

Arc

voltage

is

the

voltage

between

the

electrode

and

work

while

a

welding

arc

is

being

maintained.

Two

open

circuit

voltages

permit

the

use

of

larger

electrodes

demanding

high

welding

amperages

with

minimum

power

requirements.

The

higher

open

cir

cuit

voltage

enables

the

welder

to

use

small

dia

meter

electrodes,

stainless

steel,

low

hydrogen

and

other

hard

to

run

electrodes

with

complete

satis

faction.

I I

FPL

~jI

AA-901

024-4

i/

U)

a

Li

cc

Li

£

0

C

U

Lii

I

225

200

175

150

125

100

go

80

0

IOM-114A-

Page

7

90

80

70

60

(#1

-J

0

40

C

30

20

10

0

cuit

voltage

to

reduce

power

demand.

The

LOW

ampere

range

utilizes

a

high

open

cir

cuit

voltage

to

assure

arc

flexibility

and

it

is

always

recommended

that

the

LOW

range

be

used

for

hard

surfacing,

alloy

application,

and

small

electrodes

where

the

average

current

used

is

155

or

less.

4-6.

FINE

CURRENT

CONTROL

Select

the

desired

welding

current

within

the

range

by

rotating

the

Fine

Current

Adjustment

Control

on

the

front

of

the

welding

machine.

A

current

indicator

on

the

upper

left

part

of

the

control

panel

shows

the

current

in

accordance

with

thecurrentrangeinuse.

4-7.

ON-OFF

POWER

SWITCH

The

Power

switch

controls

the

primary

line

power

to

the

welding

transformer.

When

the

switch

is

placed

in

the

ON

position,

open

circuit

voltage

will

be

impressed

across

the

Work

and

Electrode

re

ceptacles.

4-8.

SHIELDED

METAL-ARC

(SMAW)

WELDING

(Figure

4-3)

This

welding

machine

will

handle

all

good

quality

mild

steel,

ac

and

ac/dc

electrodes

from

5/64

to

3/16

diameter

with

the

exception

of

low

hydrogen

and

iron

powder

coated

electrodes.

Iron

powder

coating

requires

higher

arc

voltages

for

the

given

current.

The

use

of

iron

powder

coated

electrodes

in

the

excess

of

5/32

diameter

is

not

recommended

for

this

model

welding

machine.

The

high

open

circuit

voltage

of

80

volts

available

on

the

low

ac

current

range

of

this

welding

machine

makes

it

possible

to

use

some

of

the

so-called

hard

to

run

electrodes

such

as

stainless

steel

and

low

hydrogen

up

to

3/32

and

possibly

1/8

diameter.

4-4.

VOLT-AMPERE

CURVES

(Figure

4-2)

The

volt-ampere

curves

show

the

output

volt

age

available

at

any

given

output

current

within

the

limits

of

the

minimum

and

maximum

current

control

setting

on

each

range.

With

the

use

of

the

volt-am

pere

curves,

it

is

possible

to

determine

the

am

perage

required

for

a

particular

load

voltage.

In

metallic

arc

or

coated

electrode

welding,

it

is

impossible

for

the

operator

to

hold

an

arc

length

which

does

not

vary.

This

varyingarc

length

causes

arc

voltage

to

vary

which

in

turn

produces

core

sponding

changes

in

welding

current.

The

steeper

the

slope

of

the

volt-ampere

curve

within

the

weld

ing

range,

the

lower

the

current

change

for

a

given

voltage

change.

4-5.

CURRENT

RANGES

The

HIGH

ampere

range

utilizes

a

low

open

cir

1,

Insert

the

jack

plug

from

the

Work

Welding

Cable

into

the

WORK

receptacle

and

clamp

the

opposite

end

of

the

Work

Cable

to

the

work-

piece.

2.

Insert

the

Electrode

Holder

welding

cable

jack

plug

into

either

the

Electrode

LOW

or

HIGH

receptacle.

A

slight

twist

while

inserting

the

jack

plugs

into

the

receptacles

will

ensure

a

tight

connection.

If

the

required

current

is

in

both

ranges,

use

the

LOW

range

receptacle

as

this

will

provide

better

current

control.

3.

Turn

the

Fine

Current

Adjustment

Control

to

the

desired

welding

current.

4.

Place

the

Power

switch

In

the

ON

position.

5.

Place

an

electrode

of

proper

type

and

size

into

the

Electrode

Holder

and

commence

welding.

6.

Readjust

the

current

control

if

necessary.

7.

After

the

welding

job

is

completed,

break

the

arc

and

place

the

Power

switch

in

the

OFF

position.

4-9.

ARC

TORCH

OPERATION

A

carbon

arc

torch

may

be

usedwith

this

welding

machine.

With

a

carbon

arc

torch

it

is

possible

to

weld

and

braze

metals

that

ordinarily

are

considered

weldable

only

by

the

oxyacetylene

method.

Itis

es

pecially

adaptable

for

brazing,

soldering,

pre

heating

and

hard

surfacing.

A

carbon

arc

torch

maintains

a

high

temperature

arc

between

two

car

bons.

Welds

produced

with

this

type

of

torch

are

sound,

strong,

and

free

from

porosity.

The

parent

metal

or

welding

rod

is

used

as

a

filler.

25

50

75

100

125 150

175

200

225

AC

AMPERES

180

AMP

MODEL

96-900

001-1

90

80

70

60

~

50

-a

0

>

40

U

C

30

20

10

0

50

100

150

200

250

300

AC

AMPERES

225

AMP

MODEL

EB-900

019-1

Figure

4-2.

Volt-Ampere

Curves

AA-900

001-2

Figure

4-3.

AC

Welding

Connections

4

Page

8