Miller Electric KC237900 User Manual

OM-530J May 1993
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Descriptio n
Enables Welding Power Source to provide TIG as well as Stick capability
TIG-RIG (Basic) Models And Models With
Optional Pulser And Electroslope
Shielded Metal Arc (Stick) Welding
Automatic Welding
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.
That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you
Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001 Quality System Standard.
Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.
figure out what the problem is. The parts list will then help you to decide which exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.
Working as hard as you do – every power source from Miller is backed by the most hassle-free warranty in the business.
Miller offers a Technical Manual which provides more detailed service and parts information for your unit. T o obtain a Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMA W-P.
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1. General Information And Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Safety Alert Symbol And Signal Words 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – SPECIFICATIONS
2-1. Description 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION OR RELOCATION
3-1. Site Selection 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Transporting Methods 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Component Installation On Factory Installed Units 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Field Installation Of TIG-Unit 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Field Installation Of Pulser 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Field Installation Of Electroslope 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Procedure For Remote TIG-Unit Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Field Installation Of Optional Preflow Timer 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Field Installation Of Optional Spot Timer 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. Remote 14 Receptacle Information And Connections 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11. Gas Connections 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12. Coolant Connections (Optional) 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-13. 115 Volts AC Duplex Receptacle And Circuit Breaker 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – OPERATOR CONTROLS
4-1. Amperage Adjustment Control And Remote Amperage Switch 12. . . . . . . . . . . . . . . . . . . . . . .
4-2. Polarity Switch 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Gas/Coolant Switch 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Gas/Coolant Postflow Control 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Remote Hand Controls 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. High Frequency Switch 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. High Frequency Control 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Meters (Optional) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Pulser Switch (Pulser Models Only) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. % “On Time” Control (Pulser Models Only) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Pulses/Second Control (Pulser Models Only) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Background Control (Pulser Models Only) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Electroslope (Electroslope Models Only) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. Electroslope Switch (Electroslope Models Only) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15. Percentage Initial Amperage Control (Electroslope Models Only) 16. . . . . . . . . . . . . . . . . . . . .
4-16. Percentage Upslope Rate Control (Electroslope Models Only) 16. . . . . . . . . . . . . . . . . . . . . . .
4-17. Percentage Downslope Rate Control (Electroslope Models Only) 17. . . . . . . . . . . . . . . . . . . . .
4-18. Percentage Final Amperage Control (Electroslope Models Only) 17. . . . . . . . . . . . . . . . . . . . .
4-19. Preflow Time Control & Switch (Optional) 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-20. Spot Time Control And Switch (Optional) 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – SEQUENCE OF OPERATION
5-1. Gas Tungsten Arc Welding 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Shielded Metal Arc Welding With TIG-Unit 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Shutting Down 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – MAINTENANCE & TROUBLESHOOTING
6-1. Routine Maintenance 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Tungsten Electrode 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Spark Gap Adjustment 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Overload Protection 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Circuit Board Handling Precautions 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Troubleshooting 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-530J - 5/93
SECTION 7 – ELECTRICAL DIAGRAMS
Diagram 7-1. Circuit Diagram For TIG-Unit With Options 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 7-2. Circuit Diagram For Postflow Timer 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 7-3. Circuit Diagram For Pulser (Optional) 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 7-4. Circuit Diagram For Electroslope (Optional) 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 7-5. Circuit Diagram For Preflow Timer (Optional) 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 7-6. Circuit Diagram For Spot Timer (Optional) 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 – CERTIFICATION FOR HIGH FREQUENCY ARC WELDING EQUIPMENT
8-1. General 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Definitions 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. High-Frequency Radiation 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Location 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. General Installation Procedures 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Guidelines For Installation Of High-Frequency Assisted Arc Welding Power Sources 31. . . .
8-7. Installation Guidelines Checklist 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 – PARTS LIST
Figure 9-1. Main Assembly 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9-2. Panel, Control Rear w/Components 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9-3. HF Panel 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9-4. Panel, Front w/Components 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9-5. Switch, Polarity (300 & 400A Models) 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9-6. Pulser (Optional) 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9-7. Electroslope 9 (Optional) 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9-8. Switch, Polarity (500 & 600A Models) 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9-9. Panel, Control Front w/Components 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Equipment 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF CHARTS AND TABLES
Table 2-1. Specifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 6-1. Maintenance Schedule 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 6-2. Tungsten Size Chart 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 6-3. Troubleshooting 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1. GENERAL INFORMATION AND SAFETY A . General
Information presented in this manual and on various la­bels, tags, and plates on the unit pertains to equipment design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed for the safe and ef fective use of this equipment.
The nameplate of this unit uses international symbols for labeling the front panel controls. The symbols also appear at the appropriate section in the text.
B . Safety
The installation, operation, maintenance, and trouble­shooting of arc welding equipment requires 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 per­sons in accordance with this manual and all applicable codes such as, but not limited to those listed in the Arc Welding Safety Precautions in the welding power source Owner’s Manual.
SECTION 2 – SPECIFICATIONS
1-2. SAFETY ALERT SYMBOL AND SIGNAL WORDS
The following safety alert symbol and signal words are used throughout this manual to call attention to and identify different levels of hazard and special instruc­tions.
This safety alert symbol is used with the signal words WARNING and CAUTION to call atten­tion to the safety statements.
WARNING statements identify procedures or practices which must be followed to avoid seri­ous personal injury or loss of life.
CAUTION statements identify procedures or practices which must be followed to avoid minor personal injury or damage to this equipment.
IMPORTANT statements identify special instructions necessary for the most efficient operation of this equip­ment.
22-1/4 in. (565 mm)
35-3/4 in. (908 mm)
*Add 2-5/8 in. (67mm) For Lifting Eye
16-1/2 in.*
(419 mm)
3/4 in. (19.0 mm)
Dia. (1 Hole)
B
A
5/8 in. (15.9 mm)
Dia. (2 Holes)
F
Mounting Hole Dimensions
Inches Millimeters
A B C D E F G H
9/32 in. (7.1 mm) Dia. (6 Holes)
C
E
10
8-1/8
1
35-3/4 33-3/4
7-1/2
15
11-1/8
D
254.0
206.4
25.4
908.1
857.3
190.5
381.0
282.6
G
H
Figure 2-1. Overall Dimensions And Mounting Hole Layout
ST-059 587-A
OM-530 Page 1
Model
TIG-Unit
TIG-Unit 56
Table 2-1. Specifications
Rated
Amperes
400
600
Rated
Duty Cycle
60%
60%
SECTION 3 – INSTALLATION OR RELOCATION
Weight
175 lbs.
(79.4 kg)
183 lbs.
(83.9 kg)
2-1. DESCRIPTION
The TIG-Unit is an accessory package which enables the solid-state welding power source to provide Gas Tungsten Arc (GTAW) as well as Shielded Metal Arc Welding (SMA W) capability. This unit has high frequen­cy, polarity switch, gas and water valves, postflow timer, and 115 volts ac auxiliary power as standard, with me­ters, electroslope, pulser, preflow timer, and spot timer as options.
IMPORTANT: Read entire Section 8 on equipment that produces output in the radio frequency range, such as high-frequency starters, for site selection information and installation requirements before beginning the in­stallation procedures.
3-1. SITE SELECTION
Even though the TIG-Unit is an accessory package pro­viding Gas Tungsten Arc W elding (GTAW) capability for the solid-state welding power source, it is recom­mended that certain practices and procedures be fol­lowed to aid long life and efficient operation.
The TIG-Unit for 300 and 400 ampere welding power sources is convection-cooled. It does not have or need a fan to aide the cooling process. The TIG-Unit for 500 and 600 ampere welding power sources is fan-cooled. However, it is recommended that a suitable location be chosen to provide adequate airflow, not only for the welding power source, but for the TIG-Unit as well. See welding power source Owners Manual for proper instal­lation site information.
WARNING: RESTRICTED AIRFLOW can cause overheating and possible damage to internal parts.
Maintain at least 18 inches (457 mm) of
unrestricted space on all sides of unit, and keep underside free of obstructions.
Do not place any filtering device over the in-
take air passages that provide airflow for cooling this unit.
Warranty is void if any type of filtering device is used at intake air passages.
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other heavy accessories or devices.
Use equipment of adequate capacity to lift
the unit.
If lifting or moving this unit with lift forks under
the base, be sure that lift forks are long enough to extend beyond opposite side of the base.
Using lift forks too short can damage internal parts if tips of the lift forks penetrate the unit base, or may cause personal injury and/or equipment damage if unit falls off the lift forks.
3-3. COMPONENT INSTALLATION ON FACTORY INSTALLED UNITS (Figure 3-1)
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Shut down welding power source, and dis-
connect input power employing lockout/tagging procedures before inspecting or installing.
Lockout/tagging procedures consist of pad­locking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other discon­necting device.
IMPORTANT: Read entire Section 8 on equipment that produces output in the radio frequency range, such as high-frequency starters, for site selection information and installation requirements before beginning the in­stallation procedures.
3-2. TRANSPORTING METHODS
This unit is equipped with a lifting eye for moving during installation. W eight capacity of the lifting eye only allows for supporting the unit and welding power source.
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Disconnect input power conductors from
deenergized supply line BEFORE moving unit and welding power source.
OM-530 Page 2
The TIG-Unit was shipped installed on and wired into the welding power source. To prepare the TIG-Unit for operation, proceed as follows:
1. Open access door on lower front of TIG-Unit, re­move component bag, and route short intercon­necting cord (approximately 4 ft. or 1.2 m) with plug attached through access opening on left side of TIG-Unit. Connect plug to REMOTE 14 (Amperage And Contactor Control) receptacle on welding pow­er source; align keyway, insert plug, and rotate threaded collar clockwise.
Interconnecting
Cord
Positive Lead
Positive
Output
Terminal
(No. 17)
Negative Lead
Negative
Output
Terminal
(No. 12)
Figure 3-1. Component Installation
ST-059 589-A
2. Attach plug from remote control cord (long cord, ap­proximately 28 ft. or 8.5 m) to amphenol receptacle on left side of TIG-Unit (under front access door); align keyway, insert plug, and rotate threaded collar clockwise. Route remote control cord through ac­cess opening on left side of TIG-Unit to desired lo­cation.
3. Remove and discard bottom center sheet-metal screw from right side panel of welding power source.
4. Route welding cables (labeled POSITIVE and NEGATIVE) from rear of TIG-Unit down right side of welding power source.
5. Slide supplied clamps (in bag) over welding cables, and attach clamps with new sheet-metal screw (in bag) to bottom center hole on right side panel of welding power source. Before securing sheet-metal screw, route welding cables from rear of TIG-Unit to output terminals under front access door on welding power source and connect POSITIVE lead (No. 17) and NEGA TIVE lead (No. 12) to correspondingly la­beled terminals on the welding power source (see Figure 3-1). Secure clamps with sheet-metal screw; secure cables to terminals.
6. Make the necessary connections to the gas and wa­ter valves also located behind access door on lower front panel of TIG-Unit in a proper manner. The valves are labeled; ensure that connections are cor­rect (see Figure 4-1 and Sections 3-11 and 3-12).
7. Install proper welding cables (see welding power sources Owners Manual for correct size) to the weld output terminals behind access door on TIG­Unit (see Figure 4-1).
3-4. FIELD INSTALLATION OF TIG-UNIT
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Shut down welding power source, and dis-
connect input power employing lockout/tagging procedure before beginning this installation.
Lockout/tagging procedures consist of pad­locking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other discon­necting device.
IMPORTANT : Although this unit was primarily designed to be mounted directly to the welding power source, re­mote installation is possible if necessary. For remote in­stallation procedures, see Section 3-7. All directions, such as left or right, are with respect to the operator fac­ing the welding power source front panel. Retain all hardware removed during this procedure for reinstalla­tion. For installation onto 600 ampere welding power sources which require different mounting instructions, see Section 3-4C.
IMPORTANT: There are two methods for supplying power to the TIG-Unit, one of which must be chosen at the beginning of this installation. Never use both meth­ods. After choosing the desired method, follow the ac­companying instructions for that particular installation. The first method (A) is to connect the TIG-Unit to an out-
OM-530 Page 3
side 115 volts ac power supply. The second method (B) is to connect the TIG-Unit to 230 volts ac inside the welding power source.
A. Procedure When Using An External 115 Volts AC Power Supply
IMPORTANT: Read entire Section 8 on equipment that
produces output in the radio frequency range, such as high-frequency starters, for site selection information and installation requirements before beginning the in­stallation procedures.
1. Remove the six sheet-metal screws from top cover of welding power source (three from each end). It is not necessary to remove the two screws next to lift­ing eye (top cover of welding power source is not re­moved).
2. Remove top cover from TIG-Unit, and lay it aside.
IMPORTANT : The TIG-Unit is shipped with two 5 ft. (1.5 m) leads (with terminal lugs attached) inside component bag under front access door of TIG-Unit. These leads are for 230 volts ac internal connections only (Proce­dure B), and should be discarded when a 115 volts ac external power supply is used.
3. Place TIG-Unit on top of welding power source (controls facing same direction); lifting eye from welding power source fits through bottom of TIG­Unit (into U-shaped section at bottom of TIG-Unit’s lifting eye bracket.)
4. Insert supplied 3/4 in. (19mm) diameter bolt (in bag) through U-shaped section at bottom of TIG-Unit’s lifting eye bracket and lifting eye of welding power source; before securing bolt, align end hole in bot­tom of TIG-Unit with end holes in top of welding power source.
5. Install the six sheet-metal screws (removed in Step
1) into end holes to secure TIG-Unit to top of weld­ing power source. Secure 3/4 in. (19mm) diameter bolt.
6. Make up a cord (16/3 is recommended) of the de­sired length to connect the 115 volts ac power sup­ply.
7. Route cord through supplied connector on rear of TIG-Unit, and attach it to terminal labeled 115V on terminal strip TE1 located on center mounting panel toward back of TIG-Unit (see Figure 3-2). (A ground stud is provided at extreme rear end of this terminal strip; use if desired.) Secure cord in connector.
8. Attach an appropriate plug to the remaining end of the 115 volts ac cord.
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Do not connect the 115 volts ac plug to its
power supply until this entire installation is com­plete and the TIG-Unit is ready to be put in oper­ation.
OM-530 Page 4
9. Open access door on lower front of TIG-Unit, re­move component bag, and route short intercon­necting cord(approximately 4 ft or 1.2 m; see Figure 3-1) with plug attached through access opening on left side of TIG-Unit. Connect plug to REMOTE 14 (Amperage And Contactor Control) receptacle on welding power source; align keyway, insert plug, and rotate threaded collar clockwise.
10. Attach plug from remote control cord (long cord, a p ­proximately 28 ft. or 8.5 m) to amphenol receptacle on left side of TIG-Unit (under front access door); align keyway, insert plug, and rotate threaded collar clockwise. Route remote control cord through ac­cess opening on left side of TIG-Unit to desired lo­cation.
11. Ensure that the AMPERAGE control switch and OUTPUT (CONTACTOR) switch on welding power source are both in the REMOTE position.
12. Open access door on front of welding power source, and remove welding cables from the output termi­nals.
13. Reinstall welding cables to proper output terminals on front of TIG-Unit (labeled ELECTRODE and WORK).
14. Remove and discard bottom center sheet-metal screw from right side panel of welding power source.
15. Route welding cables (labeled POSITIVE and NEGATIVE) from rear of TIG-Unit down right side of welding power source (see Figure 3-1).
16. Slide supplied clamps (in bag) over welding cables, and attach clamps with new sheet-metal screw (in bag) to bottom center hole on right side panel of welding power source; before securing sheet-metal screw, route welding cables from rear of TIG-Unit to output terminals under front access door on welding power source; connect POSITIVE lead (No. 17) an d NEGATIVE lead (No. 12) to correspondingly la­beled terminals on the welding power source (see Figure 3-1).
17. If an Electroslope and/or Pulser is to be installed, see Section 3-5 and/or 3-6, and install the desired units at this point.
18. Reinstall cover onto TIG-Unit, and connect the nec­essary associated equipment (shielding gas, water, etc.).
B. Procedure When Using 230 Volts AC Internal Power
IMPORTANT: Read entire Section 8 on equipment that
produces output in the radio frequency range, such as high-frequency starters, for site selection information and installation requirements before beginning the in­stallation procedures.
1. Remove top cover from welding power source, and lay it aside.
2. Remove top cover from TIG-Unit, and place it on welding power source. Be sure that front of cover is
placed on front of welding power source. Secure in place with two sheet-metal screws, one on either side of lifting eye near center of cover. Do not install the remaining sheet-metal screws (three on each end) until instructed to do so.
3. Remove blank snap-in from access hole toward rear of cover installed on welding power source. In­stall supplied grommet into access hole.
4. Place TIG-Unit on top of welding power source (controls facing same direction); lifting eye from welding power source fits through bottom of TIG­Unit (into U-shaped section at bottom of TIG-Unit’s lifting eye bracket).
5. Insert supplied 3/4 in. (19 mm) diameter bolt (in component bag under front access door of TIG­Unit) through U-shaped section at bottom of TIG­Units lifting eye bracket and lifting eye of welding power source; before securing bolt, align end holes in bottom of TIG-Unit with end holes in top of weld­ing power source.
6. Install the six sheet-metal screws (three in each end) into end holes to secure TIG-Unit (and cover) to top of welding power source. Secure 3/4 in. (19 mm) diameter bolt.
7. Remove left side panel from welding power source.
8. Locate the two 5 foot (1.5 m) leads (with terminal lugs attached) inside component bag which are to be used for obtaining 230 volts ac from the welding power source.
9. Connect the two leads to the welding power source as follows:
a. For 60 Hertz Welding Power Sources
Locate fan motor leads 9 and 36. Trace these leads to the inside of the primary terminal board. Connect the 230 volts leads to the two terminals on inside (not jumper link side) of pri­mary terminal board where fan motor leads 9 and 36 are connected.
b. For 50 Hertz Welding Power Sources
Locate fan motor leads 9 and 20. T race lead 9 to the inside of the primary terminal board. Con­nect one of the 230 volts leads to this terminal on inside (not jumper link side) of primary termi­nal board where lead 9 is connected. Trace fan motor lead 20 to splice (covered with sleeving) near main transformer. Slide sleeving back to expose the connection, and splice remaining 230 volts lead to this connection in a proper manner.
10. Maintain a proper lead dress around fan and wind tunnel, and route leads through access hole in cover into TIG-Unit.
12. Repeat Steps 9 through 17 from method A.
13. Reinstall cover (set aside in Step 1) onto TIG-Unit and right side panel onto welding power source, and connect the necessary associated equipment (shielding gas, water, etc.).
C. Procedure When Mounting To 600 Ampere Welding Power Sources.
For installation onto 600 ampere welding power sources, the mounting procedure is different since the holes in t h e bottom of the TIG-Unit do not line up with the top of the welding power source. The rest of the installa­tion is the same. To mount the TIG-Unit to a 600 ampere welding power source, proceed as follows:
1. Remove top cover from TIG-Unit, and lay it aside.
2. Place TIG-Unit on top of welding power source (controls facing same direction); lifting eye from welding power source fits through bottom of TIG­Unit (into U-shaped section at bottom of TIG-Unit’s lifting eye bracket). Insert supplied 3/4 in. (19 mm) diameter bolt (in bag) through U-shaped section at bottom of TIG-Units lifting eye bracket and lifting eye of welding power source; do not secure bolt at this time.
3. Using bottom of TIG-Unit as a template, mark loca­tions for mo unting holes and location of lead access hole (if 230 volts ac from the welding power source is to be used for operational power).
4. Remove 3/4 in. (19 mm) bolt, and remove TIG-Unit from top of welding power source.
CAUTION: METAL FILINGS AND/OR TOOL CONTACT WITH INTERNAL COMPONENTS can damage unit.
Cover internal components.
Clean unit, and remove internal covering ma-
terial before resuming operation.
5. Drill six 5/32 in. (3.9 mm) holes in marked locations for mounting TIG-Unit to welding power source.
6. If desired, drill a 1/2 in. (12.7 mm) lead access hole in marked location.
7. Place TIG-Unit on top of welding power source, in­sert 3/4 in. (19 mm) bolt, and install the six supplied sheet-metal screws. Tighten screws and secure bolt. Install supplied grommet into access opening, if applicable.
1 1. Connect the two leads to the terminal labeled 230V
on rear terminal strip TE1 (on center mounting pan­el; see Figure 3-2).
8. Proceed to Section 3-4A Step 6, or Section 3-4B Step 7 as selected, and follow the remaining in­structions for the chosen procedure.
OM-530 Page 5
3-5. FIELD INSTALLATION OF PULSER
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Shut down welding power source, and dis-
connect input power employing lockout/tagging procedure before beginning this installation.
Lockout/tagging procedures consist of pad­locking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other discon­necting device.
1. Remove top cover from TIG-Unit, if applicable.
2. Remove right blank panel from front of TIG-Unit. Save screws; discard blank panel.
3. Examine inside of TIG-Unit behind front panel for lo­cation of lead harnesses, etc.
4. Carefully slide Pulser unit into opening on front pan­el of TIG-Unit. Secure Pulser with the four screws removed from blank panel in Step 2.
5. Route leads from Pulser down top of center mount­ing panel and then to right of terminal strip 1T. (The terminal strip is located on top of center mounting panel toward rear of TIG-Unit; the terminals are la­beled directly below the strip; see Figure 3-2.)
6. Remove jumper link 4 (across terminals 84 and 83) on terminal strip 1T. See Circuit Diagram 7-1.
7. Connect Pulser leads to correspondingly numbered terminals (41, 42, 43, 84, 83, 72) on terminal strip 1T. The leads from Pulser are all numbered.
8. Connect grey lead 42 from rear of Pulser case to front center mounting panel where existing grey lead 42 is connected to chassis (not to terminal strip).
9. Secure leads to existing harness with nylon cable ties or tape to maintain a proper lead dress.
10. Reinstall cover onto TIG-Unit, if applicable.
3-6. FIELD INSTALLATION OF ELECTROSLOPE
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Shut down welding power source, and dis-
connect input power employing lockout/tagging procedure before beginning this installation.
Lockout/tagging procedures consist of pad­locking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other discon­necting device.
1. Remove top cover from TIG-Unit, if applicable.
2. Remove left blank panel from front of TIG-Unit. Save screws; discard blank panel.
3. Examine inside of TIG-Unit behind front panel for lo­cation of lead harnesses, etc.
OM-530 Page 6
4. Carefully slide Electroslope unit into opening on front panel of TIG-Unit. Secure Electroslope with the four screws removed from blank panel in Step 2.
5. Route leads from Electroslope down top of center mounting panel and then to right of terminal strip 1T. (The terminal strip is located on top of center mount­ing panel toward rear of TIG-Unit; the terminals are labeled directly below the strip; see Figure 3-2.)
6. Connect grey lead 42 from rear of Electroslope case to front center mounting panel where existing grey lead 42 is connected to chassis (not to terminal strip).
7. Remove jumper links 1 (across terminals 3 and 2), 2 (across terminals 71 and 70), and 3 (across termi­nals 76 and 78) on terminal strip 1T. See Circuit Dia­gram 7-1.
8. For Models Effective With Serial No. HK261770: Connect Electroslope leads to correspondingly numbered terminals (3, 2, 5, 6, 7, 41, *42, 43, 71, 70, 56, 61, *42, 62, 76, 78, 72, 58, 59) on terminal strip 1T. Connect Electroslope leads 30 and 37 to corresponding terminal on terminal strip 2T. The leads from Electroslope are all numbered. Connect lead 60 from Electroslope to terminal 1 on relay CR2 (see Figure 3-2).
*Connect only one lead 42 to each 42 terminal. The leads are cut to proper length and will only reach the appropriate segment of the terminal strip.
9. For Models Prior To Serial No. HK261770: Connect Electroslope leads to correspondingly numbered terminals (3, 2, 5, 6, 7, 41, *42, 43, 71, 70, 56, 61, *42, 62, 76, 78, 72) on terminal strip 1T. Connect Electroslope lead 60 to terminal 1 on relay CR2.
If The Unit DOES NOT Have Preflow:
c. Replace existing connector on Electroslope
lead 59 with a 3/16 in. female friction connector, and connect lead 59 to terminal 4 on relay CR2.
d. Individually tape and tie remaining Electroslope
leads 30, 37, and 58 to existing wiring harness.
If The Unit DOES Have Preflow:
a. Replace existing connectors on Electroslope
leads 30 and 37 with a 1/4 in. piggyback (dual friction) connector.
b. Disconnect leads 30 and 37 from Preflow
switch S200.
c. Reconnect lead 30 (from Step b) to piggyback
connector on Electroslope lead 30, and recon­nect lead 37 (from Step b) to piggyback connec­tor on Electroslope lead 37.
d. Install piggyback connector on Electroslope
lead 30 onto terminal of Preflow switch from which lead 30 (from Step b) was removed.
e. Install piggyback connector on Electroslope
lead 37 onto terminal of Preflow switch from which lead 37 (from Step b) was removed.
f. Cut off and discard existing connectors on Elec-
troslope leads 58 and 59.
CAUTION: SOLDER can damage unit.
Do not allow solder to fall into unit.
Cover exposed area of unit when soldering
connections.
Remove cover(s) and clean unit when fin-
ished soldering.
g. Splice and solder Electroslope lead 59 to lead
59. (Make connection near Preflow Circuit Board.) Insulate connection with tape.
h. Connect lead 58, originating at Preflow Circuit
Board, to terminal 4 of relay CR2.
i. Splice and solder Electroslope lead 58 to lead
58. (Make connection near terminal 4 of relay CR2.) Insulate connection with tape.
10. Secure leads to existing harness with nylon cable ties or tape to maintain a proper lead dress.
11. Reinstall cover onto TIG-Unit.
Terminal
Primary Connection
Terminal Strip TE1
Strips
1T
Lifting
Eye
Relay CR2
Lead 60 From
Electroslope
TOP VIEW
Front Center
Mounting Panel
Terminal
Strip 2T
ST-081 854-C
Front Of
Tig-Unit
Figure 3-2. Location Of Relay CR2 And Other
Components
3-7. PROCEDURE FOR REMOTE TIG-UNIT IN­STALLATION
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Shut down welding power source, and dis-
connect input power employing lockout/tagging procedures before inspecting or installing.
Lockout/tagging procedures consist of pad­locking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other discon­necting device.
1. Remove top cover from TIG-Unit, and lay it aside.
IMPORTANT : The TIG-Unit is shipped with two 5 ft. (1.5 m) leads (with terminal lugs attached) inside component bag under front access door of TIG-Unit. These leads are for 230 volts ac internal connections only (Section 3-4, Procedure B), and should be discarded when a 1 15 volts ac external power supply is used.
2. Make up cord (16/3 is recommended) of the neces­sary length to connect to a 115 volts ac power sup­ply. (The 230 volts procedure from Section 3-4, Pro­cedure B must not be employed.)
3. Route cord through supplied connector on rear of TIG-Unit, and attach it to terminals labeled 115V on terminal strip TE1 located on center mounting panel toward back of TIG-Unit (see Figure 3-2). A ground stud is provided at extreme rear end of the terminal strip and must be used.
CAUTION: LACK OF GROUND CONNEC­TION will damage the Pulser.
Ground TIG-Unit back to welding power
source or to a good building ground whenever TIG-Unit is separated from welding power source.
4. Attach an appropriate plug to the remaining end of the 115 volts ac cord.
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Do not connect the 115 volts ac plug to its
power supply until this entire installation is com­plete and the TIG-Unit is ready to be put in oper­ation.
5. Open access door on lower front of TIG-Unit, re­move component bag, and route short intercon­necting cord (approximately 4 ft or 1.2 m) with plug attached through access opening on left side of TIG-Unit. Connect extension cord (not supplied; op­tional) to short cord from TIG-Unit, and then con­nect plug (remaining end) to REMOTE 14 (Amper­age And Contactor Control) receptacle on welding power source; align keyway, insert plug, and rotate threaded collar clockwise.
6. Attach plug from remote control cord (long cord, ap­proximately 28 ft. or 8.5 m) to amphenol receptacle on left side of TIG-Unit (under front access door); align keyway, insert plug, and rotate threaded collar clockwise. Route remote control cord through ac­cess opening on left side of TIG-Unit to desired lo­cation.
7. Ensure that the AMPERAGE control switch and OUTPUT(CONTACTOR) switch on welding power source are both in the REMOTE position.
8. Open access door on front of welding power source, and remove welding cables from the output termi­nals.
9. Reinstall welding cables to proper output terminals on front of TIG-Unit (labeled ELECTRODE and WORK).
10. Route welding cables (labeled POSITIVE and NEGATIVE) from rear of TIG-Unit in direction of welding power source.
1 1. Connect (with bolts) power cables (not supplied) of
adequate size and length to the welding cables of the TIG-Unit, and then connect the remaining ends
OM-530 Page 7
to proper output terminals on welding power source; ensure that proper polarity is maintained.
ELECTRIC SHOCK can kill.
Secure and insulate with sleeving any ex-
posed cable connections to prevent contact with personnel, equipment, etc.
12. If an Electroslope and/or Pulser is to be installed, see Section 3-5 and/or 3-6, and install the desired units at this point.
13. Reinstall cover onto TIG-Unit and connect the nec­essary associated equipment (shielding gas, water, etc.).
3-8. FIELD INSTALLATION OF OPTIONAL PRE­FLOW TIMER
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Shut down welding power source, and dis-
connect input power employing lockout/tagging procedure before beginning this installation.
Lockout/tagging procedures consist of pad­locking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other discon­necting device.
IMPORTANT: All directions, such as left or right, are with respect to the operator facing the welding power source front panel. Retain all hardware removed during this procedure for re­installation.
A. Mechanical Installation (Figure 3-3)
1. Remove TIG-Unit top cover and left side panel.
CAUTION: METAL FILINGS AND/OR TOOL CONTACT WITH INTERNAL COMPONENTS can damage unit.
Cover internal components.
Clean unit, and remove internal covering ma-
terial before resuming operation.
2. Mount Preflow ON/OFF switch S200 in the 1/2 in. (12.7 mm) diameter hole using supplied hardware.
3. Mount Preflow Time control with attached printed circuit card assembly TD2 in the 3/8 in. (9.5 mm) di­ameter hole using supplied hardware.
4. Affix supplied PREFLOW TIME label to front panel over both controls.
5. Attach supplied knob to Preflow Time control shaft.
B. Electrical Installation (Figure 3-2) IMPORTANT: Before preceeding with this installation
familiarize yourself with the circuit diagram provided in this manual.
For All Models:
1. Remove and discard jumper lead 70 from terminal 70 on terminal strip 1T and terminal 73 on terminal strip 2T.
2. Connect new lead 70 from the preflow timer assem­bly to terminal 70 on 1T.
3. Connect lead 73 from preflow timer assembly to ter­minal 73 on 2T.
4. Connect lead 33 from preflow timer assembly to ter­minal 33 on 1T.
5. For Models With Electroslope: a. Disconnect lead 6 from electroslope edge con-
nector pin X. Tape and tie off lead 6.
b. Insert new lead 92 into pin X where lead 6 was
removed in Step a.
c. Connect new lead 6 from preflow timer assem-
bly to terminal 6 on 1T.
6. For Models Without Electroslope: Tape and tie off leads 6 and 92.
7. For Models Effective With Serial No. JA373511: a. Remove jumper link 6 from terminals 58 and 59
on terminal strip 1T
b. Connect lead 32 from preflow timer assembly to
terminal 32 on 1T.
c. Connect new lead 30 from preflow timer as-
sembly to terminal 30 on 2T.
d. Connect lead 37 from preflow timer assembly to
terminal 37 on 2T.
e. Connect lead 59 from preflow timer assembly to
terminal 59 on 1T.
OM-530 Page 8
f. Connect lead 58 from preflow timer assembly to
terminal 58 on 1T.
Pre-Flow
Assembly
1/2 in.
(12.7 mm) Dia.
Figure 3-3. Front Panel Mounting Hole Layout
g. Remove jumper link 7 from terminals 89 and 90
on 2T.
h. Connect lead 89 from preflow timer assembly to
terminal 89 on 2T.
i. Connect lead 90 from preflow timer assembly to
terminal 90 on 2T. j. Discard supplied leads 30, 37, and 58. k. Tape or tie new leads together to maintain a
proper lead dress inside the unit. l. Replace left side panel and top cover.
8. For Models Effective With Serial No. HK261770 Thru JA373510:
a. Remove jumper link 6 from terminals 58 and 59
on terminal strip 1T.
b. Connect lead 32 from preflow timer assembly to
terminal 32 on 1T.
c. Connect new lead 30 from preflow timer as-
sembly to terminal 30 on 2T.
d. Connect lead 37 from preflow timer assembly to
terminal 37 on 2T.
e. Connect lead 59 from preflow timer assembly to
terminal 59 on 1T.
f. Connect lead 58 from preflow timer assembly to
terminal 58 on 1T.
g. Disconnect lead 89, originating at CR1, from
terminal 89 on 2T.
h. Splice lead 89 (disconnected in Step g) to lead
90 originating at preflow timer switch S200.
i. Connect lead 89, originating at preflow timer
switch S200, to terminal 89 on 2T. j. Discard supplied leads 30, 37, and 58. k. Tape or tie new leads together to maintain a
proper lead dress inside the unit.
Spot Time Assembly
3/8 in.
(9.5 mm) Dia.
ST-048 698-A
l. Replace left side panel and top cover.
9. For Models Prior to Serial No. HK261770: a. Locate lead 32 between transformer T1 and in-
tegrated rectifier SR2. Splice lead 32, originat­ing at the preflow circuit card, onto lead 32 be-
tween T1 and SR2. b. Disconnect lead 30 from fuse F1. c. Connect lead 30, originating at CR3, to F1
where lead 30 was removed in Step b. d. Connect lead 30 disconnected in Step b to the
dual terminal friction connector on lead 30 at
F1. e. If applicable, insulate leads 89 and 90 from pre-
flow timer assembly, and secure to wiring har-
ness. f. For models with Electroslope proceed to Step
g. For all other models, isolate remaining wires
by taping ends and proceed to Step o. g. Remove electroslope box cover.
IMPORTANT: This procedure is only applicable on models with the proper electroslope. If questions arise, contact the factory Service Department.
h. Locate terminal FF on electroslope circuit card.
Route supplied lead 30 through the grommet in
the electroslope box and connect it to terminal
FF on the electroslope circuit card. Connect re-
maining end of lead 30 to fuse F1 in addition to
existing leads 30. i. Locate terminal GG on electroslope circuit
card. Route supplied lead 37 through the grom-
met in the electroslope box and connect it to ter-
minal GG on the electroslope circuit card. Con-
nect remaining end of lead 37 to preflow timer in
addition to existing lead 37. j. Remove lead 59 from control relay CR2. k. Splice lead 59, originating at the preflow circuit
card, to lead 59 that was removed from CR2.
OM-530 Page 9
l. Connect lead 58, originating at the preflow cir-
cuit card, to the terminal on CR2 where lead 59 was removed in Step j.
m. Locate terminal JJ on electroslope circuit card.
Route supplied lead 58, through the grommet in the electroslope box and connect it to terminal HH on the electroslope circuit card. Connect re­maining end of lead 58 to CR2 in addition to ex -
isting lead 58. n. Replace electroslope box cover. o. Cover all splices with electrical tape. Tape or tie
new or unused leads to existing wiring har-
nesses. p. Replace left side panel and top cover.
3-9. FIELD INSTALLATION OF OPTIONAL SPOT TIMER (Figure 3-3)
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Shut down welding power source, and dis-
connect input power employing lockout/tagging procedure before beginning this installation.
Lockout/tagging procedures consist of pad­locking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other discon­necting device.
IMPORTANT: All directions, such as left or right, are with respect to the operator facing the welding power source front panel. Retain all hardware removed during this procedure for re­installation.
2. Connect lead 32 from spot time assembly to termi­nal 32 on 1T.
3. Connect lead 89 from spot time assembly to termi­nal 89 on terminal strip 2T.
4. Connect lead 88 from spot time switch S201 to ter­minal 88 on 1T.
5. Connect lead 33 from S201 to terminal 33 on 1T.
6. Tape or tie new leads together to maintain a proper lead dress inside the unit.
7. Replace both side panels and top cover.
3-10. REMOTE 14 RECEPTACLE INFORMATION AND CONNECTIONS (Figure 3-4 And Figure 4-1)
REMOTE 14
AMPERAGE
A
OUTPUT
(CONTACTOR)
REMOTE 14 receptacle RC2 is used to connect any of the following equipment to the welding power source cir­cuitry:
a. Remote Contactor b. Remote Amperage control c. Combination of the above.
To make connections, align keyway , insert plug, and ro­tate threaded collar fully clockwise.
A. Mechanical Installation (Figure 3-3)
1. Remove TIG-Unit top cover and both side panels.
2. Mount Spot Time switch S201 in the 1/2 in. (12.7 mm) diameter hole using supplied hardware.
3. Mount Spot Time control with attached printed cir­cuit card assembly TD3 in the 3/8 in. (9.5 mm) diam­eter hole using supplied hardware.
4. Affix supplied SPOT TIME label to front panel over both controls.
5. Attach supplied knob to Spot Time control shaft.
B. Electrical Installation (Figure 3-2)
IMPORTANT: Before preceeding with this installation
familiarize yourself with the circuit diagram provided in this manual.
For All Models:
1. Remove jumper link 5 from terminals 33 and 88 on terminal strip 1T.
OM-530 Page 10
The following socket information is included in case the supplied cord is not suitable, and it is necessary to wire a plug or cord to interface with REMOTE 14 receptacle RC2.
IMPORTANT: When contact closure is provided be­tween sockets A and B, the welding power source out­put/contactor control circuit is energized.
Receptacle RC2 socket connections to the TIG-Unit control circuitry are as follows;
Socket A: Contactor control switch connection. Socket B: Contactor control switch connection. Socket C: Amperage control connection (maximum
side).
Socket D: Amperage control connection (minimum
side).
Socket E: Amperage control connection (wiper con-
tact).
IMPORTANT: The remaining sockets in the receptacle are not used.
AJ
K
B
L
C
M
D
I
NH
G
F
E
Ref. S-0004-A
Figure 3-4. Front View Of REMOTE 14 Receptacle
With Socket Locations
3-11. GAS CONNECTIONS (Figure 4-1)
3-12. COOLANT CONNECTIONS (Optional) (Figure 4-1)
COOLANT IN COOLANT OUT
CAUTION: OVERHEATING Gas Tungsten Arc Welding (GTAW) torch can damage torch.
If using a water-cooled torch and recirculating
coolant system, make connections from the coolant system directly to the torch hoses. Do not use water connections on the TIG-Unit.
The COOLANT IN and COOLANT OUT fittings have 5/8-18 left-hand threads. Obtain proper size, type, and length hose, and make connections as follows:
1. Connect hose from coolant supply to COOLANT IN fitting.
2. Connect coolant hose from torch to COOLANT OUT fitting.
3-13. 115 VOLTS AC DUPLEX RECEPTACLE AND CIRCUIT BREAKER (Figure 4-1)
GAS IN GAS OUT
The GAS IN and GAS OUT fittings have 5/8-18 right­hand threads. Obtain proper size, type, and length hose, and make connections as follows:
1. Connect hose from shielding gas supply regulator/ flowmeter to GAS IN fitting.
2. Connect shielding gas hose from torch to GAS OUT fitting.
115V 15A AC
ON OFF
OVERLOAD
PRESS TO START
A grounded duplex receptacle, located behind the front access door of the TIG-Unit, is provided to furnish up to 2 kva of 115 volts ac to operate external accessories. A 15 ampere circuit breaker, located next to the recep­tacle, protects this circuit in case overloading of the du­plex receptacle occurs.
OM-530 Page 11
SECTION 4 – OPERATOR CONTROLS
Electroslope
Remote 14 Receptacle
Interconnecting
Cord
Coolant Valve
Inlet
Coolant Valve
Outlet
Remote
Meters Pulser
Amperage
Switch
Amperage
Adjustment
Control
Polarity
Switch
Postflow
Control
Gas/Coolant
Switch
High
Frequency
Control
High
Frequency
Switch
Circuit Breaker
(See Section 6-4)
115 Volts AC
Duplex Receptacle
Gas Valve
Outlet
Gas Valve
Inlet
Work
Output
Terminal
Preflow Time
Control And
Switch
Figure 4-1. Front Panel View
4-1. AMPERAGE ADJUSTMENT CONTROL AND REMOTE AMPERAGE SWITCH (Figure 4-1)
14
A
AMPERAGE
ADJUSTMENT
IMPORTANT: The AMPERAGE ADJUSTMENT con-
trol may be adjusted while welding.
A. Without Electroslope
When not using an Electroslope and the AMPERAGE switch on the TIG-Unit is in the PANEL position, the AM­PERAGE ADJUSTMENT control on the TIG-Unit al­ways functions as a fine amperage adjustment (cali­brated in percent) of the AMPERAGE ADJUSTMENT control on the welding power source. If a remote control is used and the AMPERAGE switch on the TIG-Unit is in
OM-530 Page 12
A
AMPERAGE
PANEL
Spot Time
Control And
Switch
Electrode
Output
Terminal
TB-059 588-A
the REMOTE 14 position, the remote control always functions as a fine amperage adjustment (in percent) of the AMPERAGE ADJUSTMENT control on the welding power source.
B. With Electroslope IMPORTANT : For the TIG-Unit to function properly, en-
sure the the AMPERAGE control switch on the welding power source is always in the REMOTE 14 position. Th e position of the OUTPUT (CONTACTOR) control switch on the welding power source is determined by the situa­tion. If Remote Contactor Control is desired, place the switch in the REMOTE 14 position. If Remote Contactor Control is not desired, place the switch in the ON posi­tion.
When using an Electroslope, the AMPERAGE switch on the TIG-Unit must be in the PANEL position and then the AMPERAGE ADJUSTMENT control on the TIG­Unit has complete control of the current of the welding power source.
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