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INSTRUCTION MANUAL
WIRE ARC POWER SOURCE
F-15-434
November, 1997
This manual provides complete instructions for the following power sources starting with Serial No. M0RI737001:
230/460 Vac, 3 Ph., 60 Hz ............................ 36934
230/460/575 Vac, 3 Ph., 60 Hz ..................... 36936
220/400 Vac, 3 Ph., 50 Hz CE ...................... 36935
These INSTRUCTIONS are for experienced operators. Do NOT permit untrained persons to install, operate, or
maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully
understand these instructions. If you do not fully understand these instructions, contact your supplier for
further information. Be sure to read the Safety Precautions before installing or operating this equipment.
Be sure this information reaches the operator.
You can get extra copies through your supplier.
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USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/
or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment
must be checked periodically. Malfunctioning equipment should not be used. Parts that are broken, missing, worn, distorted
or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer
recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of
this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance,
damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
TABLE OF CONTENTS
SECTION TITLE PAGE
PARAGRAPH
SECTION 1 DESCRIPTION ................................................................................................................................... 5
1.1 General ............................................................................................................................................... 5
1.2 Receiving-Handling ............................................................................................................................ 5
1.3 Description.......................................................................................................................................... 5
1.3.1 Power Source ..................................................................................................................................... 5
1.3.2 Volt-Ampere Characteristics .............................................................................................................. 5
1.5 Safety ................................................................................................................................................. 6
SECTION 2 INSTALLATION ................................................................................................................................. 7
2.1 Location .............................................................................................................................................. 7
2.2 Receiving, Unpacking and Placement ............................................................................................... 7
2.3 Primary (Input) Electrical Connection ................................................................................................ 7
2.4 Secondary (Output) Welding Connections......................................................................................... 9
2.5 Power Source/Wire Feeder/Control Interconnections ....................................................................... 9
2.5.1 Wire Feeder Control ........................................................................................................................... 9
2.5.3 Auxiliary 115 V ac Receptacle ........................................................................................................... 9
2.5.4 42 V Circuit Breaker ........................................................................................................................... 9
2.5.5 115 V Circuit Breaker ......................................................................................................................... 9
SECTION 3 OPERATION ...................................................................................................................................... 11
3.1 Controls .............................................................................................................................................. 11
3.1.1 Power Switch (ON-OFF) .................................................................................................................... 11
3.1.5 Over Temperature Indicator ............................................................................................................... 11
3.1.7 Fault Indicator ..................................................................................................................................... 11
3.1.8 Over Current Protection ..................................................................................................................... 11
SECTION 4 MAINTENANCE ................................................................................................................................. 12
4.1 General ............................................................................................................................................... 12
4.2 Cleaning ............................................................................................................................................. 12
4.3 Inspection and Service....................................................................................................................... 12
4.3.1 Fan Motor ........................................................................................................................................... 12
4.3.2 Transformer ........................................................................................................................................ 12
4.3.3 Control Circuits................................................................................................................................... 12
4.3.4 Over Temperature Protection ............................................................................................................ 12
SECTION 5 TROUBLESHOOTING....................................................................................................................... 13
5.1 General ............................................................................................................................................... 13
5.2 Testing and Replacing Bridge Assembly Components ..................................................................... 13
SECTION 6 PARTS ................................................................................................................................................ 19
6.1 General ............................................................................................................................................... 19
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SAFETY PRECAUTIONS
WARNING: These Safety Precautions are for
your protection. They summarize precautionary information from the references listed in
Additional Safety Information section. Before
performing any installation or operating procedures, be
sure to read and follow the safety precautions listed below
as well as all other manuals, material safety data sheets,
labels, etc. Failure to observe Safety Precautions can result
in injury or death.
PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any work
area, even if welding helmets, face shields, and goggles
are also required.
2. Use a face shield fitted with the correct filter and cover
plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and
not to expose themselves to the rays of the electric-arc
or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve
shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against
arc rays and hot sparks or hot metal. A flameproof apron
may also be desirable as protection against radiated
heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should be
kept buttoned, and open pockets eliminated from the
front of clothing
5. Protect other personnel from arc rays and hot sparks
with a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and explosions. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective nonflammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and
coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in floors or wall openings and cause a hidden
smoldering fire or fires on the floor below. Make certain
that such openings are protected from hot sparks and
metal.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might produce flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use,
such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.
5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
hazard.
6. After completing operations, inspect the work area to
make certain there are no hot sparks or hot metal which
could cause a later fire. Use fire watchers when necessary.
7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with live
electrical parts and ground can cause
severe injury or death. DO NOT use AC
welding current in damp areas, if movement is confined, or if there is danger of
falling.
1. Be sure the power source frame (chassis) is connected
to the ground system of the input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatal
shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables,
torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated from
work and from ground.
7. Do not stand directly on metal or the earth while working
in tight quarters or a damp area; stand on dry boards or
an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
for specific grounding recommendations. Do not mistake
the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields
(EMF). Welding and cutting current creates EMF around welding cables and
welding machines. Therefore:
1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are
unknown.
3. Welders should use the following procedures to minimize
exposure to EMF:
A. Route the electrode and work cables together. Secure
them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work
cables. Route cables on the same side of your body.
D. Connect the work cable to the workpiece as close as
possible to the area being welded.
E. Keep welding power source and cables as far away
from your body as possible.
TAFA -11/97
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FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area by
natural or mechanical means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel,
copper, zinc, lead, beryllium, or cadmium unless positive
mechanical ventilation is provided. Do not breathe fumes
from these materials.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic
gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation
while operating, this is an indication that ventilation is not
adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to
operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
3. Maintain cables, grounding wire, connections, power cord,
and power supply in safe working order. Do not operate
any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces, wet
conditions such as water puddles, oil or grease, corrosive
atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position and
in good repair.
6. Use equipment only for its intended purpose. Do not
modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for electric
wire arc spraying, please refer to safety section in owners manual.
This symbol appearing throughout this manual
means Attention! Be Alert! Your safety is
involved.
The following definitions apply to DANGER, WARNING,
CAUTION found throughout this manual:
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not
perform any electrical work unless you are qualified to
perform such work.
2. Before performing any maintenance work inside a power
source, disconnect the power source from the incoming
electrical power.
Used to call attention to immediate hazards which, if not avoided, will result in
immediate, serious personal injury or loss
of life.
Used to call attention to potential hazards which could result in personal injury
or loss of life.
Used to call attention to hazards which
could result in minor personal injury.
TAFA -11/97
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SECTION 1
DESCRIPTION
1.1 GENERAL
This manual has been prepared for use by an experienced operator. It provides information to familiarize the operator with the design, installation and
operation of the power sources. DO NOT attempt to
install or operate this equipment until you have read
and fully understood these instructions. The information presented here should be given careful consideration to ensure optimum performance of this equipment.
1.2 RECEIVING-HANDLING
Upon receipt, remove all packing material and carefully inspect for any damage that may have occurred
during shipment. Any claims for loss or damage that
may have occurred in transit must be filed by the
purchaser with the carrier. A copy of the bill of lading
and freight bill will be furnished by the carrier on
request.
Table 1-1. Specifications
When requesting information concerning this equipment, it is essential that Item number, Serial number
and Model number of the equipment be supplied.
1.3 DESCRIPTION
1.3.1 Power Source
The power source is a constant potential, Silicon
Controlled Rectifier (SCR), three phase, star-connected transformer/rectifier type dc unit with solid
state contactor and control circuitry. It provides the
volt-ampere characteristics desired for conventional
MIG, flux cored and submerged arc welding.
1.3.2 Volt-Ampere Characteristics
The curves shown in Figure 1-1 represent the voltampere static characteristics for the power source.
The slant of these curves is referred to as the "slope"
and is generally defined as the "voltage drop per 100
amperes of current use". These curves show the
OPEN CIRCUIT VOLTAGE (U0) 52 Vdc
DUTY CYCLE 60% 100%
RATED
OUTPUT
RATED
INPUT
3 Phase
Current (I
Voltage (U
60 Hz
)550 A450 A
2
) 42 V 38 V
2
Volts (U
) Current (I1) Flat Current (I1) Flat
1
230 V 84 A 74 A
460 V 42 A 37 A
575 V 34 A 30 A
220 V 87 A 78 A
50 Hz
400 V 48 A 43 A
Power Factor at Rated Output
Welding Range 550 A/42 V - 50 A/14 V
Auxiliary Power 115 V ac @ 10 A, 60 Hz
PHYSICAL S PECIFICATIONS 60 Hz. 50 Hz.
Height 25.0" (62.2 cm)
Width 18.8" (48.3 cm)
Depth 32.5" (81.9 cm)
83%
Net Weight 355 lbs (161 kg) 392 lbs (178 kg)
Shipping Weight 365 lbs (166 kg) 402 lbs (185 kg)
NOTE: The power source may also operate from a 200 (208)-volt a.c. primary input using the 230-volt changeover connections. However,
when connected to this source (200-volt), the output voltage is derated from 38-volts to 35-volts @ 450 amps.
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output voltage available at any given output current
from the minimum to the maximum setting of the
voltage control. Because the volt-ampere slope is
fixed, it is possible to select welding conditions by
estimating the open-circuit voltage required for the
load current.
1.5 SAFETY
Before the equipment is put into operation, the safety
section at the front of this manual should be read
completely. This will help avoid possible injury due to
misuse or improper installation.
The definitions relating to the:
safety notations are described at the end of the Safety
Section in the front of this manual read them and
their specific text references carefully.
DESCRIPTIONSECTION 1
Figure 1-1. Volt-Ampere Curves
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SECTION 2
INSTALLATION
2.1 LOCATION
A proper installation site is necessary for the power
source to provide dependable service. A proper installation site permits freedom of air movement
through the unit while minimizing exposure to dust,
dirt, moisture, and corrosive vapors. A minimum of 18
inches (46 cm) is required between the side and rear
panels of the power source and the nearest obstruction. Also, the underside of the power source must be
kept completely free of obstructions.
The selected site should also allow easy removal of
the power source outer enclosure for maintenance.
See Table 1-1 for overall dimensions of the unit.
2.2 RECEIVING, UNPACKING AND
PLACEMENT
A. Immediately upon receipt of the power
source, inspect for damage which may have
occurred in transit. Notify the carrier of any
defects or damage.
B. Remove the power source from the con-
tainer. Remove all packing materials. Check
the container for any loose parts.
C. Check air passages at front and rear of
cabinet, making sure that no packing materials that may obstruct air flow through the
power source.
D. Install the lifting ring furnished with the power
source into the top of the unit.
For lifting purposes and for keeping dust, moisture, and other foreign material from entering the
power source, the lifting eyebolt must be fully
tightened with a tool.
2.3 PRIMARY (INPUT) ELECTRICAL
CONNECTION
This power source is a three-phase unit and must be
connected to a three-phase power supply. It is recommended that the unit be operated on a dedicated
circuit to prevent impairment of performance due to
an overloaded circuit.
ELECTRIC SHOCK CAN KILL! Before making
electrical input connections to the power source,
"Machinery Lockout Procedures" should be employed. If the connections are to be made from a
line disconnect switch, place the switch in the off
position and padlock it to prevent inadvertent
tripping . If the connection is made from a fusebox,
remove the corresponding fuses and padlock the
box cover. If it is not possible to use padlocks,
attach a red tag to the line disconnect switch (or
fuse box) warning others that the circuit is being
worked on.
A. The primary power leads must be insulated
copper conductors. Three power leads and
one ground wire are required. Either rubber
covered cable or conduit (flexible or solid)
may be used. Table 2-1 provides recommended input conductors and line fuse sizes.
B. Remove the top cover. Identify primary power
input connections on the power switch, chassis ground lug on the "A" frame, and primary
input terminal board. Refer to Figures 2-1
and 2-2.
Table 2-1. Recommended Sizes for Input
Conductors and Line Fuses
E. After selecting an installation site (see para-
graph 2.1), place the power source in the
desired location. The unit may be lifted either
by using the lifting ring or by forklift truck. If
a forklift is used for lifting the unit, be sure that
the lift forks are long enough to extend completely under the base.
Do not use filters on this unit as they would
restrict the volume of intake air required for
proper cooling. Output ratings on this unit are
based on an unobstructed supply of cooling air
drawn over its internal components. Warranty is
void if any type of filtering device is used.
Rated Input
@ 100% Duty Cycle
Volts Amps
208
220
230
400
460
575
* Sized per National Code for 80 °C rated copper conductors @ 30 °C
ambient. Not more than three conductors in raceway or cable. Local
codes should be followed if they specify sizes other than those listed
above.
** Wire per National Electric Code Table 310-16 using 90° C rated conduc-
tors (e.g. THW-2, THWN, THHN).
7
81
78
74
43
37
30
Input &
GND
Conductor*
CU/AWG
No. 6**
No. 6**
No. 6**
No. 8
No. 8
No. 10
Fuse Size
Amps
150
100
100
75
50
50
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INSTALLATIONSECTION 2
ON-OFF Power
Switch (S1)
3 Power Leads
L3
L2
L1
Rear Panel (Inside View)
Ground Lead
(Green or Green w/ Yellow Stripe)
Connect to Ground Lug (GND1)
Located on A-Frame, Right Side
Strain Relief
Recommended Cable Strip Lengths
Figure 2-1. Connecting Primary Power Leads
C. When using the provided strain relief, refer to
Figure 2-1 for proper cable strip lengths. It is
important to follow the cable strip guide to
ensure that if the primary input cable is ever
pulled from the strain relief, the input conductors will be pulled from the ON/OFF power
switch before the ground lead is pulled from
the ground lug. Once stripped, thread the
input and ground conductors through the
large strain-relief in the rear panel of the
power source. Connect the ground wire to
the terminal lug located on the right rear Aframe leg inside the power source. Connect
the primary power leads to terminals L1, L2,
and L3 on the input power switch. Secure the
strain relief on the input cable.
The chassis must be connected to an approved
electrical ground. Failure to do so may result in
electrical shock, severe burns or death.
D. Check all connections for proper tightness.
Ensure all connections are correct and wellinsulated.
(220)
(220)
(400)
(220)
(220)
® Double Link Provided
( ) Connections for 50 Hz units.
(400)
(220)
(220)
(400)
Figure 2-2. Input Terminal Board
230/460 (220/400) V illustrated with voltage links in
the factory supplied 460 (400) volt configuration)
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SECTION 2
INSTALLATION
E. Figure 2-2 illustrates the input voltage termi-
nal board and the input voltage link connections. The particular voltages from which this
power source may be operated are stated on
the rating plate. The voltage links were factory set for highest voltage stated on the
rating plate. If the power source is to be
operated on another stated input voltage, the
links must be reset for that particular input
voltage. Always verify the input voltage and
check the link arrangement regardless of
factory setting. The voltage links are set up
by reconfiguring the copper link bars to the
silk-screened voltage designations for the
desired voltage.
2.4 OUTPUT WELDING CONNECTIONS
(SECONDARY)
Before making any connections to the power
source output terminals, make sure that all primary input power to the machine is off.
Table 2-2. Output Cable Sizes (Secondary)
Total Len gth (Fe e t) o f
Welding
Current
100
150
200
250
300
400
500
* Total cable length includes work and electrode cables. Cable size is based
on direct current, insulated copper conductors, 100-percent duty cycle and
a voltage drop of 4 or less volts. The welding cable insulator must have a
voltage rating that is high enough to withstand the open circuit voltage of
the machine.
50 100 150 200 250
6
4
3
2
1
2/0
3/0
Ca ble in Weld Ci rcuit *
4
3
1
1/0
2/0
3/0
3/0
3
1
1/0
2/0
3/0
4/0
4/0
2
1/0
2/0
3/0
4/0
4/0
2-2/0
1/0
2/0
3/0
4/0
4/0
2-2/0
2-3/0
2.5.2 Auxiliary 115 V AC Receptacle
A 115 Vac receptacle is provided to supply power to
accessories. The receptacle is rated 115 Vac / 10
amps with a floating neutral.
The output terminals are located on the front panel
(Figure 2-3). Two output terminals are provided. The
NEGATIVE (-) terminal is located at the bottom righthand corner and the POSITIVE (+) terminal is located
at the bottom left corner. The output cable connections will depend on the materials to be welded and on
the welding process desired. Table 2-2 provides the
recommended cable output sizes.
2.5 CONTROL CONNECTIONS
Refer to Figure 2-3.
2.5.1 Control Console
The Control Console cable connection is provided by
a 19-pin receptacle (J1) located on the left-hand side
of the power source front panel.
2.5.3 - 42V Circuit Breaker (CB1)
The 42V resettable circuit breaker (CB1) protects the
42 volt control circuitry against over current. (Table 52 provides troubleshooting information).
2.5.4 - 115V Circuit Breaker (CB2)
The 115V resettable circuit breaker (CB2) protects
the 115 volt auxiliary receptacle control circuitry against
over current. Table 5-2 provides troubleshooting information).
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10
A
M
P
10
A
M
P
115V AUX
INSTALLATIONSECTION 2
R
42V
115V
2.5.3
2.5.4
2.5.2, J3, 10 Amperes
WIRE
FEEDER
CONTROL
+
2.5.1 (19-PIN) J1
-
Output Receptacle
2.4
Figure 2-3. Connection Diagram
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SECTION 3
Never operate the power source with the cover
removed. In addition to the safety hazards, improper cooling may cause damage to the components. Keep side panels closed when unit is
energized. Welding helmet, gloves, and other
personal protection should always be worn when
welding.
3.1 CONTROLS (See Figure 3-1)
3.1.1 Power Switch (ON-OFF)/(I-O)
The power switch is located on the rear panel of the
power source. In the "off" ("O") position, the unit is
shut down; however, power is still present at the
switch itself. To fully shut down the power source,
power must be disconnected at the line disconnect
switch or the fuse box.
OPERATION
3.1.2 Over Temperature Indicator (Temp)
This amber light will indicate when an internal overheating condition has occurred and one of the thermal switches has opened. User control of the solid
state contactor will be interrupted and power source
output will shut down to protect critical components.
Once cooled to a safe temperature, the thermal
switch will automatically reset and output control will
be restored.
3.1.3 Fault Indicator
If an optional External Ground Conductor Protection
Kit was installed, this red light, when lit, will signal that
current was flowing through the external ground
conductor. It will also light if a short occurs (momentary or permanent) between the +12 volt J1-E; the
+10 volt (J2-E) and either the chassis ground or the
negative terminal of the power source. The power
source output terminals are de-energized and the
fault must be corrected before resuming operations.
With the switch in the "on" ("I") position power is
provided to the main transformer and the low voltage
control circuitry.
3.1.1.1 Power Indicator
This white light will indicate that the power switch is in
the on position and power has been applied to the
main transformer and low voltage circuitry.
3.1.1.1
3.1.2
3.1.3
V
3.1.4 Over Current Protection
The power source incorporates automatic over current protection. If an over current condition occurs,
the automatic circuitry will fold back the output
current to a level that will prevent damage to the
power source. The power source will remain in this
low current fold back mode until the arc is broken,
the torch trigger is released or the contactor switch is
reset.
3.1.1
(on rear panel)
Figure 3-1. Control Locations
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SECTION 4
4.1 GENERAL
If this power source does not operate properly,
stop work immediately and investigate the cause
of the malfunction. Maintenance work must be
performed by an experienced person, and electrical work by a trained electrician. Do not permit
untrained persons to inspect, clean, or repair this
power source. Use only recommended replacement parts.
Be sure that the branch circuit or main disconnect switch is off, or electrical input fuses are
removed, before attempting any inspection or
work inside the power source. Placing the power
switch in the off position does not remove all
power from inside the power source.
4.2 CLEANING
MAINTENANCE
Failure to replace worn or damaged cables may
result in a bare cable touching a grounded object.
The resulting electrical arc may injure unprotected eyes and will present a serious fire hazard.
Body contact with a bare cable, connector, or
conductor may result in severe electrical shock,
causing serious burns or death.
4.3 INSPECTION AND SERVICE
Keep the power source dry, free of oil and grease,
and protected at all times from damage by hot metal
and sparks.
4.3.1 Fan Motor
Keep the fan motor free of accumulated dust and lint.
4.3.2 Transformer
Other than periodically cleaning the dust and dirt from
the transformer, no maintenance is required. Ensure
that only clean, dry, low pressure air is used.
Periodically, remove the covers from the power
source and blow accumulated dust and dirt from the
air passages and interior components by using clean
low pressure air. The frequency of cleaning required
depends upon the environment in which the power
source is used.
It is imperative that all air passages be kept as clean
as possible in order to allow adequate air flow to
provide proper cooling.
After cleaning with low pressure air, check for and
tighten any loose hardware, including all electrical
connections. Check for frayed and/or cracked insulation on all power cables and replace if necessary.
4.3.3 Control Circuits
These circuits are protected by two 10 amp circuit
breakers mounted in the front panel. If these open,
the contactor and wire feeder will not operate.
4.3.4 Over Temperature Protection
If the power source reaches an abnormally high
internal temperature, the thermal protection will
deenergize the contactor circuit, shutting down the
power source but leaving the cooling fan on. After the
power source has cooled to a safe level, the thermal
protection will automatically reset. While deenerigized,
the console cannot be operated.
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SECTION 5
TROUBLESHOOTING
5.1 GENERAL
DISCONNECT primary power at wall switch, or
circuit breaker, before attempting inspection or
work inside the power source.
If the power source is operating improperly, the
following troubleshooting information may be used to
locate the source of the trouble.
Check the problem against the symptoms in the
following troubleshooting guide (Table 5-2.) The
remedy for the problem may be quite simple. If the
cause cannot be quickly located, open up the unit and
perform a simple visual inspection of all the components and wiring. Check for proper terminal connections, loose or burned wiring or components, blown
fuses, bulged or leaking capacitors, or any other sign
of damage or discoloration.
5.2 TESTING AND REPLACING BRIDGE
ASSEMBLY COMPONENTS
The SCRs used in the power source are devices
which allow current to flow in only one direction. The
SCRs are designed to provide long trouble-free operation; however, should a failure occur, they may
require replacement.
6. Check the gate circuit on the SCRs by installing a jumper from the gate lead to the anode
of the SCR. The meter should read less than
5 ohms. Remove the jumper from the gate.
The meter reading should increase (30-50
ohms).
IMPORTANT
When replacing SCRs, make sure mounting surfaces are clean. Using Alcoa No. 2 EJC Electrical
Joint Compound or an equivalent, apply a thin coat
to the SCR mounting surface and positively locate in
place on the heatsinks. Place the clamp in position
with the bolts through the holes in the heatsinks and
proceed as follows:
1. Tighten the bolts evenly until finger tight noting
that the nuts are not rotating.
2. Tighten the bolts 3/4 turn plus an 1/8 turn using
a socket wrench on the bolt heads and rotating
only in 1/4 turn increments plus 1/8 turn alternating between the bolts noting that the nuts are
not rotating.
Table 5-1. PCB Voltage Tests*
NOTE
All voltage readings are taken with the front access
panel open and the power switch "ON".
A. Testing SCRs.
1. Remove top and right side panel from the
power source.
2. Locate the main rectifier assembly containing the SCRs.
3. Electrically isolate main bridge assembly by
disconnecting the capacitor bank and resistor R5.
4. With the ohmmeter on RX1 scale, place the
positive lead on the anode (end of SCR with
screw threads) and the negative lead on the
cathode (positive output terminal on the front
panel). The meter should read minimum of
5 megohms.
5. Reverse leads and check each SCR. All
readings should again show high resistance.
The SCRs are bad if they show low resistance in either direction.
Electrical service and repair should be attempted
only by a trained electrician.
SCR VOLTAGES (OUTPUT)
FROM TO READING
P8-5 OTB+ +10 V dc
P8-7 OTB+ 0-10 V dc**
P6-6 (SCR1)
P6-5 (SCR2)
P6-4 (SCR3)
P6-3 (SCR4)
P6-2 (SCR5)
P6-1 (SCR6)
* Refer to Schematic Diagram
** Varies with VCP (R1)
OTB+ .3 V dc with
contactor on
13
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SECTION 5
Table 5-2. Troubleshooting Guide
CONDITION ACTION
TROUBLESHOOTING
Unit Inoperative A.
B.
C.
D.
E.
F.
G.
No Output -- Fan
Runn ing
Limited Output or Low
Open-Circuit Voltage
Erratic Sp ray Current A.
A.
B.
C.
D.
A.
B.
C.
D.
B.
C.
D.
No input power. Check main line (user’s) switch fuse s -- replace i f needed.
Poor or improper input (terminal board) connections.
Defective on/off switch on rear panel -replace.
Thermal light on. Main transformer overheating. Also check for proper cooling, proper
primary hookup, or shorted turn on secondary.
Thermal light on. Fan motor not operating -- check motor and leads.
Exter nal Gr o und Cond uctor fault i nd icator " O N". - C he c k for c ause a nd c orre c t. Turn
power switch "OFF" then "ON" to reset.
Loss of primary phase. Check that LED on control PCB is not lit. If lit, find & replace
defective fuse.
Poor or improper electrical input -- check input connections on TB .
Poor connections at output terminals/work station -- check, tighten or replace.
Main transformer overheating -- thermal switches tripped due to restricted cooling air.
Temperature light on front panel will be lit. Let unit cool down.
PC board defective or loose PC board connector(s) -- if loose, reinsert; if defective,
replace.
Input voltage jumper links on terminal board improperly set -- check for proper voltage.
Poor output connections. Take apart, cle an, and reassemble.
Panel-Remote switch in Remote position and remote voltage pot disabled.
Over curre nt condition had occ u rred. Unit is in “fo ld ba c k” mode. See Section 3.1.8.
Welding cable size too small -- use co rrect cables.
Loose welding cable connection (will usually get hot) -- tighten all connections.
Defective SCR in bridge rectifier.
PC board defective -- replace.
Hig h Outp ut, No
Voltage Control
No 115 Volt ac Output A. Circuit breaker tripped. Check 42V CB1 and 115V CB2 -- Reset.
Line Fuse Blows
When Power Source
is F irst Turned On
Control Console is
Inoperative
A. PC board defective or lo ose -- reset and/or replace board.
A.B.Shorted SCR in Main Bridge -- replace.
Shorted capacitor in Capacitor Bank.
A.B.Loose control console cable -- Check and tighten all connections.
A Circuit Breaker tripped -- Check 42V CB1 and 115V CB2 -- Reset.
14
Page 15
Figure 5-1. Power Source Schematic, 230/460 vac, 60 Hz and 220/400 VAC, 50 Hz
up-to-date information on your model, refer to the schematic on the inside cover of
the power source or contact the factory.
D-37009
NOTE: Recent modifications to the power source may not be reflected in this schematic. For
15
Page 16
D-37010
Figure 5-2. Power Source Wiring Diagram, 230/460 vac, 60 Hz and 220/400 vac, 50 Hz
16
Page 17
D-37049
17
NOTE: Recent modifications to the power source may not be reflected in this schematic. For
Figure 5-3. Power Source Schematic, 230/460/575 vac, 60 Hz
up-to-date information on your model, refer to the schematic on the inside cover of
the power source or contact the factory.
Page 18
D-37050
Figure 5-4. Power Source Wiring Diagram, 230/460/575 vac, 60 Hz
18
Page 19
SECTION 6
6.1 GENERAL
Always provide the series or serial number of the unit on which the parts will be used. The serial number is stamped
on the unit nameplate.
REPLACEMENT PARTS
19
Page 20
SECTION 6
REPLACEMENT PARTS
13
8
5
6
R
9
15
10
11
3
14, 16
1, 2
Figure 6-1. Power Source (Front View)
230/460 vac, 3 ph., 60 Hz
230/460/575 vac, 3 ph., 60 Hz
220/400 vac, 3 ph., 50 Hz, CE
QTY. ITEM CIRCUIT
NO. REQ. NO. DESCRIPTION SYMBOL
1 2 13733935 RECEPTACLE, CABLE OTB
2 2 13792513 CONNECTOR, QUICK (NOT SHOWN)
3 1 32279BK PANEL, FRONT, SCREENED
4 1 32280BK TOP PANEL ASSY., SCREENED
5 1 400073 METER, VOLT, 0-50
6 1 400074 METER, AMP, 0-400 AMPERE
8 1 480041 KNOB
9 2 950122 CIRCUIT BREAKER, 10 AMP CB1, CB2
10 1 952219 OUTLET, 110V J3
11 1 952209 RECEPTICAL ASSY., 19-PIN J1
12 1 4511387 PANEL, CONTROL, PWR-SUP 8830/35/50
13 1 540187 LABEL, CONTROL PANEL
14 1 36045TGY PANEL, LEFT SIDE
15 1 36052TGY PANEL, RIGHT SIDE
20
Page 21
SECTION 6
REPLACEMENT PARTS
26, 30, 31, 32, 33
36
27
28
35
29
21
25
22
34
2935
Figure 6-2. Power Source, Inside Front View
QTY. ITEM CIRCUIT
NO. REQ. NO. DESCRIPTION SYMBOL
21 1 36036BK BASE
22 1 36638 BUSBAR, BRIDGE
23 4 952218 FASTENER, EXPANSION, NYLON
24 1 17300016 RESISTOR, 300W, 16 ohm
25 1 36082 INDUCTOR ASSY. L1
26 1 36046TGY PANEL, TOP COVER
27 1 952073 TERMINAL BLOCK TB2
28 1 36629 SHUNT SH
29 2 672348 CAPACITOR, 0.01µf, 1KV C7, C8
30 1 2091514 LABEL, WARNING
31 1 99512240 LABEL, CAUTION LIFT
32 1 954008 DECAL, DANGER HIGH VOLTAGE
33
* 1 954720 LABEL, SCHEMATIC, 230/460 V, 60 Hz & 220/400 V, 50 Hz
1 954721 LABEL, SCHEMATIC, 230/460/575 V
34 3 36650 SCR ASS'Y (includes Heatsinks, 2 SCR's - 952142) SCR1-6
35 2 950711 SWITCH, THERMAL TS1, TS2
36 2 99512558 BRACKET, RESISTOR
* Located on underside of Top Cover.
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Page 22
SECTION 6
48
51
47
52
REPLACEMENT PARTS
43, 44
42
41
53, 54
55, 56
Figure 6-3. Power Source
(Right Side View)
QTY. ITEM CIRCUIT
NO. REQ. NO. DESCRIPTION SYMBOL
41 4 36048BK LEG, A-FRAME
42 1 2062334 MOTOR, FAN M1
43 1 36091 BOARD, INPUT TERM, 230/460 V TB1
1 32236 BOARD, INPUT TERM, 220/400 V TB1
1 36110 BOARD, INPUT TERM, 230/460/575 V TB1
44 6 672065 STRAP, TERMINAL, 230/460 V & 220/440 v
9 672065 STRAP, TERMINAL, 230/460/575 V
45 1 36065 BUSBAR, CAPACITOR, POS.
46 1 36064 BUSBAR, CAPACITOR, NEG.
47 12 13732230 CAPACITOR, 10000 LMFD 50WV C11-22
48 1 38135 PCB POWER/CONTROL TAFA PCB1
51 4 950708 BOARD SUPPORT CIRCUIT LOCKING
52 2 36174 BRACKET, HEATSINK
53 1 36080 TRANSFORMR ASSY., MAIN, 230/460 V T1
1 36520 TRANSFORMR ASSY., MAIN, 220/400 V, 50 Hz T1
1 36087 TRANSFORMR ASSY., MAIN, 575 V T1
54 1 2062211 THERMOSTAT 180°C (included with all T1 Transformers) TS3
22
Page 23
SECTION 6
REPLACEMENT PARTS
62
63
74
75
64
72
73
65
66
61
68, 69
70
67
Figure 6-4. Power Source
(Inside Top View)
QTY. ITEM CIRCUIT
NO. REQ. NO. DESCRIPTION SYMBOL
61 1 36107 SWITCH, POWER DISCONNECT S1
62 6 13735018 CORE, TOROID, .5ID X .203OD L2-7
63 6 672348 CAPACITOR, 0.01µf, 1 KV C1-6
64 1 36049BK BAIL, LIFTING
65 1 36043BK BRACKET, FAN
66 1 13735508 SHROUD, FAN
67 1 36173 BLADE, FAN
68 1 36044BK PANEL, REAR, GRAY
69 1 954521 LABEL, RATING, 230/460V, 60 HZ
1 954535 LABEL, RATING, 230/460/575V
1 954636 LABEL, RATING, 220/400V, 50 HZ
70 1 13732733 DECAL, COPPER ONLY
72 1 647361 TERMINAL, LUG, GROUND GND1
73 1 38100** FILTER NETWORK FN1
**Used only on 220/400V power sources with CE labels.
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F-15-434 11/97
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