FORM:1OM-312A-6/69 MODEL 250 AC/DC (900941) 250P AC/DC — (900 950) 250 AC/DC-HF (901 122) 250P AC/DC-HF (901 129) INSTALLATION OPERATION AND MAINTENANCE MANUAL miller WELDERS, miller ELECTRIC MFG. CO., Appleton, Wisconsin € ADDITIONAL COPY NWSA CODE NO. 4579‘=== SECTION 1- SAFETY RULES FOR OPERATION OF ARC WELDING MACHINE =—= 11. GENERAL GA, These rales apply to ac and de welding generators, ac transformer and ac/de welding machines, and fe transformer rectifier welding machines. DB, In arc-welding operations, were electrically en~ ergized parts are exposed, observe the following safely rales to insure maximum personal safety land protect nearby persons, Dc, Failure to observe these safety precautions may expose not only you, but fellow workers as well, to serious injuries,” Once those rules are learned and kept in mind, proceed with maximumassurance, WELDING MACHINE 1.2. WELDING CABLES DON'T overload cables. OA, Never use welding cables at currents in excess of thotr rated capacity, It will cause overheating anc rapid deterloratios of the Insulation, It is alsc uneconomical, DON'T use wornor poorly connestedcables, GB, Inspect the cables frequently, Immediately repair al breaks tn the insulation with rubber and friction tapes, Tighten all cable connections and adequately, insulste any Joints where a connector may have at exposed condictive part, In addition to the potentie. hazard to. life, a hazard occurs when exposed sections of cable come in contact with grounded metallic objects, causing an arc, Unprotected eyes may be injared and flee may result if combustible materials such as oll or grease are in the vicinity. The efficiency and quality of welding will be im= proved by ellmination of these dangerous grounds, land by Keeping connections tight. 1.3, ELECTRODE HOLDER: DON'T use electrode holders with defective jaws. GIA, Keep the jaws of the electrode holder tight and the gripping Surfaces in good condition toprovide clase Contact with the electrodes, Defective jaws will permit the electrode to wohble, making control of the welding operations difficult, DON'T use electrode holder with loosecablecon~ nections, CIB, Keep the connections of the electrode Iead to the holder tight at all times, SC, Use only fully insulated electrode holders (and with ‘out protruding serewheads,) ID, Never touch two electrode holders from two separate Welding machines at the same time, 1.4. CODE CONFORMANCE ‘The mackine and its equipment must be installed and maintained in accordance with the National Electrical Code and local requirements, 1.5. PARALLEL CONNECTIONS BA, See diagrams in the instruction manual applying to the welding machine used, POWER DISCONNECT SWITCH If the welding machine does not include » power Aiscomect switch, install oneat or near the machine, 1.7. POLARITY SWITCH DON'T operate the polarity switch under load, GA, The polarity switch (when supplied) is provided for changing the electrode lead from positive (reverse polarity) to negative (straight polarity). Never move it while Under the load of a welding current, Gperate this switch only while the machine 1s ‘dling and the welding etreutt isopen, The potential dangers of opening the circuit while carrying high current are: Ci(2) Ap are will farm between the contact surfaces of the switeh and severely burn them, (2) The person tarowing the switch may recetve a severe bun from this arolog 1.8, RANGE SWITCH DON'T operate the range switch under load, TA, The range switch (when supplied) is provided for obtaining required current settings, It must never be operated while the machine is under the load of welding current. Operate the range switch only ‘while the machine 18 Liling and the welding cizeutt {5 open, The potental danger of switching the circuit while carrying high current is the formation of an fare between the contact surface which will severely turn them, Repeated occurrences of this arcing will eventually prevent operation of the contacts, 1.9. EXHAUST GASES DON'T use gas engine units in confined sprees without venting the exhaust gases, A, If gasoline or other fuel driven welding machines are operated indoors, provide means to pipe the exhaust gases to the outside air to avoid carbon monoxide poisoning, TOM-312A Page 11.10, POWER CIRCUIT GROUND. DON'T use welding machine without grounding frame or case. GA, Ground the ground cable of every power clreult to Page 2 prevent accidental shock by stray current, The potential danger is that development of astray cur~ Fen may give 2 fatal shock should # person, for ‘example, place one hand on the welding machine an the olser on the switen box, or other grounded equipment, Do not ground 10 pipelines carrying gases or flammable Iiquids and conduits carrying Electrical concuctors, Be sure conductors can safely carry the ground current, Whea con- necting the welding machine, properly ground the machine frame or case, WELDING OPERATIONS CONTAINERS WHICH HELD COMBUSTIBLES DON'T weld on containers which have held com= psstible or flammable materials or materials whieh, when heated, give off flammable or toxic vapors without proper cleaning, purging, or Inerting, Welding on containers which have held lammableor combustible materials may be extremely danger~ ‘us, To prevent afire or explosionof the container, follow the recommendations of the American Weld- ing Society’ Pamphlet 46,0 "Welding or Cutting Con tainers Which Have Held Combustibtes*, DON'T depend on your eyes o nose to deelde if it is safe to weld on a closed container. Find out what was in the container or use an explostineter. Avery small amount of residual flammable gas or liquid can cause a serious explosion, NEVER use oxygen to ventilate a container, . When you know the container held a gas or liquid which will rendily dissolve in water: (CQ) Flush out with water several times and then fall with water as far as work permits, posi~ tioning container to permit introduction of a8 mich water as possible, ap. DE, 12, 113, aa. as, 2X2) Refore welding be sure there Is a vent or opening to provide fur release ofalr pressure. When you know the contuinor held a gus of liquid wnieb Will not readily dissolve in water, Si) Clean out thoroughly with steam or a cleans~ ‘ng agent and purge all air oF inortwith w gus such as carbon dioxide oF nitrogen before re~ pairing, Carbon dioxide is heavier thanatrand Will tend to remain in the container ifthe open= ing 1s at the top. Use steam to clean out light material. Use a strong caustic soda solution to clean out heavy olls or grease. Be cure to purge all air or inert with a gas, such as nitrogen or earhon dioxide, no matter how well you have cleaned, There may still, be traces of oll, grease, or other reudi oxidizable materisl under the seams, [Be careful when cleaning with steamor caustic soda wear goggles and gloves. ay 43) oy DON'T clean wheretherets poor ventilation, Ventilation is necessary to carry avay harmful or explosive vapors, DON'T clean where there are open flames, When scraping or hammering to remove heavy sludge or seale, use « spark resistive tool and keep 4 wot to avold sparks, Keep your head and arms as far away from your work as possible. HOLLOW casTinGs DON'T weld on hollow (cored) castings that bave rot been properly vented, The casting may explode, EXPLOSION HAZARDS NEVER weld in or near explosive atmospheres, Such atmospheres can be created by flammable gas leaks or by vapors from flammable liquids (gueoline, aloohot, eto.) or by combustible dusts, VENTILATION DON'T weld in confined spaces without adequate ventilation, \When welding in confined spaces, provide ventilation tn accordance with United States of America Stand~ ard 249.1, 1967, Always provide adequate ventila~ tion hy blowers, air Lines, or other acceptable means, Never! use compressed oxygen, The depletion of the oxygen supply, the heat of welding, and the fumes given off may cause severe digo comfort o a serious illness. When toxic fumes from lead or cadmium bearing. materials or any other suhstances are present in harmful concentrations, always use an air supplied respirator,18, aa, 116, na, a7, oA, OB, ae, aa, 119, SOLVENTS, Do not weld where chlorinated hydrocarbon vapors from degreasing, cleaning, or spraying may Teachor be drawn into air surrounding the weldingoperation, ‘The heat of the are can decompose solvent vapors 19 form phosgene, a highly toxic gas and other irritating decomposition products. Do not Weld where ultraviolet lighi from the electric are can penetrate air containing even minute amounts of vapors from solvents such as trictlo— roethylene or perchloroethylene, Ultraviolet light Gan decompose the vapors to form phosgene, a highly toxic gas, and other irritating products, FIRE HAZARDS DON'T weld near flammable or combustible materials. Fires ean be caused by the aro, by contact with the healed metal, by slag, or sparks, Keep com- uslibles at least 35 feet from the are or suitably protected, If welding must be done in a particular area, move the combustibles away. If they cannot bbe moved, cover themeompletely with fire resistive sereens, Cover cracks or openings in floors or walls; sweep floor free of combustibles and wet down, if wood, being sure welder wears insulation shoe ‘coverings, Avoid welding on partition walls in contact with combustibles, Heated metal on the other side of partition walt being welded upon can ‘ignite combustibles In contact with the partition. Where other than a minor fire might develop, have a fire wateher stand by with suitable fire extin= guishing equipment for at Teast one-half hour after the welding is completed, ELECTRICAL SHOCK-VOLTAGE OPEN power eizeuits before checking machines, Before working on the wiring, ewitches, controls, cte,, open the power line disconnect switch. In fnost welding shops the power supply used for fare welding machines is 230 or 460 volts, Open Cireutt voltages are usually less than 100 volts and welding or are voltage drops are still lower, How~ ‘ever, ail of these voltages arecapuble of developing, S harms on fatal current to the body DON'T toueh electrically “hot” parts, Never touch any exposed or non-insulated part of the cables, cable connectors, clamps, electrode holders, electrodes, oF the power supply equipment to prevent harmful Or fatal electric shook or buras, ELECTRICAL SHOCK-DAMPNESS NEVER work in ¢ damp area without suitable in Salation against shock, Keep hands, feet, and clothing dry at all times, ‘To prevent harmful body shocks, keep hands, feet and clothing dry. Never stand oF lie in puddles of Water, damp ground, or against grounded motal when welding without suitable insulation against shock, Always find a dry board or rubber mat to stand on when water, moisture, or perspiration cannot be avoided. Dampness between the body and an en- ergized or grounded metallic part lowers the resistance to the passage of current to the body Which may produoe a harmful or fatal shock, Salt im perspiration or sea water dangerously lowers, contact resistances, STARTING UNDER LOAD DON'T leave an uninsulated electrodeholder,ora 1.20. 121 ive" electrode on the table top oF Incontact wich fa grounded metallic surface, When it is not in use, never place an electrode holder in contact with the table topor other metallic surface in contact with welding ground. Provide fan insulated hook of holder for the electrode holder. ‘A potential danger 4s that 2 holder in contact with the ground cireuit provides a dead short circuit on the welding machine, Tf the machine should be Started up, this short circuit would cause an ex- cessive load on the michine and may damage the Insulation, FACE PROTECTION DON'T use cracked or defective helmets or shields. Keep the helmet, hand shields, or face shield tn good condition, Iferacks occur in thofibre material, Feplace the shield, since the loukage of arc rays may cause serious burns. EYE PROTECTION NEVER under any circumstances, took at an ‘electric are without eye protection. Make sure that flash goggles are used under the welding helmet at all times, particularly while gas shielded-are weldi aa. ae, Tn some type of are welding, such as gasshielded~ ‘are welding,sltra-violet and infrared radiation from the are ts particularly intense and requires constant attention to avoid are flashes to the welder when Striking an ae and to avold exposure to other welders. NEVER strike an arc without ascertaining that nearby persone ether have the necessary pro feotive equipment or are looking in the opposite direction, For welding operations in open areas, provide portable, non-reflecting sereens to shield persons nearby from the Fays of the arc, Bye burns from the are, though nol generally permanent injuries, are exceedingly painful, Such burns frequently Foforred 0 28 "flashes", feel like hot sand in the eye. For eye burns consult your first aid station for doctor, TOM-2124 Page 2op, NEVER use cracked, ill-fitting, or defective plates, ‘The filter glass plate provided in the helmets and shields must be of reputable manufacture conform- ing to the latest USA Standard 22.1, Replace racked ov (Nefitting filler plates pramptly. NEVER use filter plates withouta protecting cover glass, Keep a clean cover glass in front of tho filter plate for the protection thereof, Frequent renewal Of these cover glasses is necessary, since they become covered with spatter, reducing vision, 1.22, CLOTHING OB, oe, 1.28 aa, Page 4 NEVER use poor, inadequate, or worn-out cloth ing, Wear heavy shoes, tightly laced, Keep clothing dry, Proper and dry, ollafree clothing is essential for the welder's protection, Clothing mast not only keep off the spatter and molten particles, but must also abstruct the rays of the arc and, when nec essary, insulate the body from harmful electrical currents, Wear leather or asbestos gloves at all times to protect the hands and wrists, Dark colored shirts fare preferred to light ones’ because light ones reflect aro rays to exposed parts of the body. a the case of gas shielded-are welding, light colors are more reflective and may eause eye burns due to the intense ultra-violet rays given off hy the process, Avoid cotton fabrics when gas shlelded- fare welding. An are burn oa the skin resembles a sunbarn, ‘except that it Is ususlly more severe, Clothing ca he made flame resistant by trestment with a solution of 9/4 pound of sodium stannate in 1 gal~ lon of water, then wring out and dipped ina solution of 1/4 pound ammonium sulphate per gal~ Ion of water, Don't wash clothing so prepared in water, bat dry clean, When ‘welding operations are to be performed in vertical and overhead positions, leather sleevelets, aprons, and in some cases leggings and ear plugs ‘Should be used to prevent severe burns from spatter and molten metal, HOT METAL BURNS NEVER pick up hot objects, Never. plok up pleces of metal which have just been welded or heated, or tho stub ends of electrodes which have been discarded, GRINDING AND CHIPPING Whenever it (s necessary to grind or chip metal, wear protective goggles specifically designed for this purpose, Serious eye injuries may result from failure fo wear protective goggles. 1.25, ob, ne, ap, oR, ar, aw, . Wadipter is Fequired between NEVER do any enipping oF griaulleg without pro- teetive goggles, ‘COMPRESSED GAS CYLINDERS EVER strike an arc on compressed gas eylin« ders, Avold aveidental contact ofthe electrodes, electrode holder, o other electrically energized parts witha compressed gas cylinder or any other pressure Vessel, Serious accidents oF fires may result, Use L.0.C, oylinders, They are manufactured and maintained {n aecordance with 1,C.C, requtrernents land are safe so long as they are properly handled, Don't drop cylinders. Identify gas content by the name marked on the cylinder. If the cylinder is unmarked, do not use it, Rebirn it to the supplier, Do not rély on color este, Never use a oylinder or its contents for other than intended purposes, Keep oll and grease away fromoxygeneylinders and eylinder valves. Keep cylinders away from exposure to sparks, hot Slag, open flame and all possible sources " of ignition or excessive heat, ie careful that cylinders are not placed so as to hecome a part of an electrical circuit, Avoid third rails, wires and electrio welding circuits, When transporting eylinders by crane, use cradle, platform or other suitable support. Never lit tho eylindowe by slings, by the caps ox by electric magnets. Never use cylinders as supporte or rollers, Never try to mix any gases in 8 cylinder. Never try to refill a cylinder, Mark empty cylinders "Empty" or "SIT", Send “Emptys" back to. the supplier Keep "Emptys" end "Fulls™ separate, Never tamper with or alter cylinder numbers or ‘other markings, This 1s not only foolish but may bbe illegal, Do not tamper with or change fittings on eylinders, promptly. If valves cannot be opened by hand, d> not use hammer or wrench, Notify supplier. Protect cylinder valves from bumps, falls, falling objects, aad from weather, Keep them covered with cylinder caps when moving cylinders. Keep valves cloted on empty eylinders, | See that your cylinders are clea of passageways land active work areas and that they are secured against falling, inder and reg= ulator, always use a standard adapter, Those ay toe obtained from your supplier, Whore right and left hand threads are used on adapter, use two Wrenches to insure leak proof connections. Do not store cylinders In unventilsted24, GENERAL ‘This manual has been prepared espectally for use in familigrizing personnel with the design, ‘installation, operation and maintenance of the welding machine, In some cases, the contents of this pablication are generalized. ’ All information presented herein should be given careful con~ Sideration t assure optimam performance and sevice of the equipment. ‘Questions or problems relating to this equip~ ment will reeelve prompt attention by contacting the nearest welding representative. 2.2. RECEIVING-HANDLING To prepare the welding machine for installation, sevoral items should be checked, Clean all pac ing material from around the unit and carefully Inspect for damage that may have been caused by shipping, Any claims for loss or damage that may have oecured in transit must be filed by the buyer with the earrior, Copy of bill of lading and freight DIIL will be furnished on request If occasion to file claim arises, Be sure 0 read all the instructions before at~ ‘tempting to operate the welding machine. When requesting information concerning the welding machine, be sure to furnish stock, serial and model numbers. 23, DESCRIPTION ‘This model welding machine 1 an ac and de type, and can he used for welding johs ealling for felthér ue or de current, Its design consists of a movable shunt, which is located between the primary and secondary'coils for fast continuous current con~ trol within the selected range, Two ranges are | ee 24, 1 Meseirod 1 raaauancy a SECTION 2 - INTRODUCTION ——— available for ae welding and two ranges for de welding. ‘High open elreuit voltage means maximum are stability and ease in are starting, A weld stabilizer in the de eircult improves de welding char- acteristics, Foreededratt cooling ensures keeping all com- ponents well below critical operating temperatures providing daty cycle rating 1s not exceeded, Primary and secondary colls are dipped in in~ sulating varnish and baked, which provide maxi= mum resistance to moisture damage and increased dtelectric strength, It is housed in a heavy gauge steel case, protected by a rust preventive coating ‘and baked ¢namel. ‘Placing the POWER switch in the ON position, supplies proper operating voltage to the fan motor and the power transformer and in tarn to the Secondary output terminals or through the rectifier and weld stabilizer to the secondary outpat ter- rinals. SAFETY Before attempting to make primary or second- ary connections, change parts or miske repairs, be sure the welding machino is completely dis~ connected fom the main power line. Caution should be exercised in taking voltage measurements when troubleshooting the unit, Al- ways avold contact hetwoen any part of the hum body and any current carrying part of the welding muehino, Before the welding machine is put intooperation, read the complete safely section at the frontof this manual, This Will help avoid any possible injury due to ‘misuse or Improper welding applications, cv HIGH ial input POWER Power Rance. POLARITY Main PoweR sire XPM sure ries RECTIFIER £2 TJ aioe erequeney savers owy Figure 2.1. Block Diagram T ATES AT HATED TOR | wetome | ove ia [sarees | Naas | 8 Big Hi rec eimom ae TOM-312A Page 5ee SECTION 3 - INSTALLATION —— 341. LOCATION (Figure 3-1) "Four mounling holes sre provided tn the welding machine base for machines where mounting is re quired, Figure 3-1 gives overall dimensions andthe ‘base mounting hole layout for installation that may require this information, ‘good installation is essential ifthewelding ma~ chine is to provide satisfactory and dependable service, Proper component operating temperatures are maintained by the air stream produced by the welding machine fan unit, Therefore, the welding machine should he located eo that the air passage {nto the front and bottom of the welding machine 1s, not restricted. The back of the welding machine should be away from the wall (12 inches minimum, distance) so that the air passage from the fan will not be blocked. "Tae location should he such that a minimum amount of dirt or dust will be drawn Into the alr stream, Preventive maintenance will consist of re~ moving the machine wrapper and blowing out the dust ‘accumulation inside the welding machine, Por this reason it is desirable to locate the unit 60 that the wrapper can be removed Without much restriction, Figure 31. Dimensional Drawing & Base Mounting Hole Layout 22, Page § PRIMARY CONNECTIONS ‘Those ac/do welding michine are a single phase anit and must be connected to a single phase power line or any one phase of athree phase system of the proper voltage, A throe phase system ordinarily consists of three wires and any to of the three ‘wires constitute one phase, Consult the local power and light company if there is any question about type of the system used locally or the proper connection to obtain single phase power service to tho welding machine, Locate and open the small access door below the fan on the rear panel of the welding machine, The primary input voltage connection terminal board is behind thisuecess door, The welding machine should be operated from a separately fused or circuit breaker protected circuit, The maximum capacity of the welding machine is affected hy the line voltage land if the elzeuif is overloaded, The performance of ‘the Welding machine will be impaired, TABLE 34 Install a cable of two primary leads plus one ground wire (see Table $-1 for proper wire size) {nto the rear of the welding muchine, near the hhottom through the outlet hole provided for this purpose, Tals opening will take standard conduit, fittings and the service wires from the line dis~ connect switch to the welding machine should be heavy rubber covered cable or run in solid or flexible conduit, Connect the two primary power input leads to the two brass studs labeled 1, or LINE, -—> Allel AIA © Alla © 230 v. 460 Vv. Figure 3.2. Primary Voltage Jumper Links “*#°1**2 Connect a ground load from the stud tabolod GRD to a sultable ground such as the groundon the mata disconect switch ora water pipe, driven ground rod, eto, Use whatever grounding moans ts acceptable to ocal electrical inspection authorities, ‘The stud labeled GRD is connectod to the welding machine chassis and is for grounding purposes only, Make sure ground cable connected to the Ground ‘Connection on the machine ts connected to a suitable ground such a8 a Water plpe, ground rod, et'200-208/230/460 VOLTS '200-208/230/460 With PFC go0-230.vouts "| 220 vous ssovous so0-m20voU's ano vous eovours ol ls "230/380 /460 VOLTS j Loe novos ™'sovous **"* asovous yovours he rr) coe [aes = ae Je 8 Jb 2 7250/380/500 VOLTS With PF. vir) ) aso vous "apo vours soovours 230 vours ano vours se0vous tease [ea [ae ties Fn nt a (| "3307 460/575 VOUS 790/460/575 VOLTS With PRC fe ssovours S75 yours cr asovours srsvous 730/460 VOLTS "230/460 VOLTS Wi ee oo, tauunase} —Upanaagaa) (enpgaa lad aa Figure 3:3. Primary Voltage Connections And Link Arrangement 10M-312A Page 7These wolding machines are designed to operate on either 230 volts or 460 volts single phaso, 50/00 Hz ac power line, Facilities for operation on other primary voltages, if ordered, are in- corporated at the factory. ‘To connect the welding machine properly for the voltage available, position the copper links, located immodiately above the primary Input studs labeled Lor LINE as tllustrated ‘in Figure 8-2 or the Voltage Link Arrangement (See Figure 3-3), Welding machines arealvays shipped, unless otherwise ordered, with the connections in the highest line voltage position for which the particular michine was built, ‘Whenever only one jumper link connection is, necessary for the proper input voltage such as 460 volts, connect both jumper Hinks across thesame two terminals, ‘This will prevent losing the second jumper link, ‘Recheck sil cables and inks for tightness and.cor- rect comections. 33, SECONDARY WELDING CONNECTIONS It is recommended that thowolding cables be kept as short as possible, placed close together and be of adequate current carrying capacity, The resist= ance of the welding cables. and connections cause fa oltage drop which is added to the voltage of the aro, Excessive cable resistance may result in overloading as well as reducing the maxtmum ear~ rent output of which the welding machine is capsble. ‘The proper operation of any are welding machine is toa great extent dependent on the use of welding cables and connections that are In good condition and of adequate size, An insulated holder must he used to ensure welders safety. It is important, especially whore high frequency ts used, that the ligsor frayed portions of the weld~ ‘ing eable do not touch or come too close to the cace of the welding machine, In certain instances where electrode holder adapters areused, itmay be hecessary to insulate or block away from'the ease, When welding with ac or de, if thewelding cables are coiled up they will generate a magnetic field that will seriously affect the operattonofthe welding machine, Always lay the welding cables out. Also, the welding cables should not be taped together when, using high frequency, but placed 3/4 to Linch apart fon a sultable Uoerl such asa 2x 41x 40r 1x6 fand fastened with plastic clamps or slips. Do not lise metal clamps as they will fend to serve as an antenna and radiate high frequency, Ifavailable, the luse of vinyl covered cables Ie recommendedas this material has better high frequency shielding char- acteristics than rubber covered cable. Select the proper size Welding cable from Table A. JACK PLUG INSTALLATION (Figure 34) (Models ‘without HF only) “Two twistlock Jack plugs are furnished on models without high frequency, Models with high frequency fare furnished with regular studa and nuts for Secondary connections, » Follow instructions carc~ fully for proper installation of the twistlock jack plugs to the welding cables, See Table 3-2 for proper welding cable size, “Standard jack plugs furnished with this unit will accommodate cable sizes ranging from 6 to 1. 1, Remove 3/4 inch of insulation from one ond of the welding cable. 2, Clamp the welding cable in a vise with the upinsulated end protruding upward out of the vise approximately 1-8/4 inches. 5, Place the steel tie wire approximately 1/4 inch (8) from the end of the insulation, 4, Make a half turn around the cabie bringing the looped ends of the tie wire together. Insert a rod of approximately 3/8 itch diameter through the two looped ends of the tle wire, 6, Twist the tie wire (B) until the entire tie wire is twisted and Is tight around the insulation of the welding cable. 7. Clip off the looped ends of the tie wire, 8, Bend the twisted tle wire over ulong theside (C) of the uninsulated portion of the welding cable. 9, Drive out the fiber pinholding thesiber insulator in place on the twistlock jack plug, 10, Remove the fiber insulator from the jack plug. 11, Loosen the set screw holding the copper foiland metal strip in place, _o. 0 thm c Ufa D on ranues2 Eo aes Pa a a BLP Laie BPR IB IE Sli oL ok Bl BB Sh Densier OF NOT Oven 200 CIRCULAR MILS.FER Ar e. WELD CABLE INBULATION waht A VOLTAGE RATING TO wth UAV HAVE HIGHER OPEN CIRCUIT VOLTAGE Page 8 Figure 34. Jack Plug Installation 12, Wrap the copper foil tightly around the unin= sulated end of the welding cable and twisted tie wire (D). 18, Place the metal strip next to the copper foll (B), 14, Place the twistlock Jack plug on the end of the welding oable and silde it over the copper foil and the metal strip.Adjust the twistlock Jack plug so that when the bet screw is tightened, it will clamp the welding cable between the metal strip and thesideof the jack plug, 16, ‘Tighten the set screw. AT, Replace the fiber insulator and fiber pin (F). 18, Remove the welding cable from the vise andre~ peat the above steps for the other welding cable, 34, ELECTRODE HOLDER AND WORK CLAMP INSTALL- ATION Comect a work clamp to the opposite end of one of the welding cables to which the jack plug or lug. was installed, ‘Connect an electrode holder to the opposite end of the other welding cable to which the jack plug for hig was installed, An ineulated holder must be tused to ensure welders safety. The method af con= necting the cables to the work clamp and electrode holder will depend on the manufacturers instruction ‘munsul for instructions, 35. GAS CONNECTIONS (Models with High Frequiney nly ‘The gas valve ¢ located on tho right side of the front control panel near the secondary electrode receptacle, Connect the gas line to the gas valve connection labeled IN, The gas comnections have a ight hand, 5/8-18 fomale thread, Make sure the Girection of gas flow through the valve is as in dicated on the front panel, Connect the torch jus hose t0 the gas valve laneled OUT. ‘Tne gas flow must be controlled accurately with the ald of a regulator anda flow meter, No specific recommendations for rates of flow can be given as this depends entirely on the specific welding con~ ditions. Correct argon flow is usually between 8 fand $8 cable feet of gas per hour. The helium flow (s between 18 and3B cubictect per hoar, When designing, fixturing and setting up welding pro codures, remomber the specific gravity of argon is heavier than air, 1,38,andhelium|s lighter than air, 1138, air being 1. More specific information con- ‘Germing the process to satisfy the welding needs can be obtained from the manufacturer of the electrode holder equipment. 36, PARALLEL CONNECTION OF TWO OR MORE WELD- ING MACHINES (Figure 35) Connect cables of sultable size from each welding machine to the same phase in the main lino dis~ connect switeh, This arrangement will enable all machines to be comected on the power lines simultaneously when the line disconncot switch is placed in the ON position, In fusing the primary tizcuit, follow National Electrical Code speoifi~ cations, When connecting two machines in parallel, {do not exceed double the recommended fuse size for fone machine, For three machines, do not ex ‘eeed three times the recommended fuse size for fone machine, wic. Primary cables from the primary torminals to the eommon switch should be the same length andsize, Figure 3.5. Parallel Connections It ts desirable that the junction of theprimary cables be made at the line disconnect switch rather than at the machine terminals, “Malice sure that all machines connected in parallel have the same phase relationship, This can be checked as follows: (1) Temporarily connect all ELECTRODE terminals together with No. 14 or larger wire. (2) Place the Polarity Switch in the ‘AC position and the Range Switch in the AC,HI pposttion on all machines, (8) Energize all machines Connected in parallel, (4) with a voltmeter, check the voltage across the WORK receptacle of one ma= ‘chine ana the WORK receptacles of theother machine for machines, If the voltage is approximately zero, the phase relationship of all machines ts correct, If, however, the voltage is approximately 130 volts (double oper oirouit voltage) the phase relationship 3e incorrect, Reverse the primary vonmections uit fone machine at a time until zero voltage between all WORK receptacles is acquired, Remove the temporary jumper wires connected to the BLEC= TRODE receptacles. ‘When making secondary (welding) connections, the welding cables should be the same length and size, It is desirable that the junction point of the lectrode cables be near the eledtrode holder andthe junction point of the work cables be near or at the work. i SECTION 4 - OPERATION ———— Never, under any circumstances, operate the weld ‘ing machine wits the cover removed, Inaddition to a safety hazard, improper cooling may result in ‘Gamage to the welding transformer and the welding. machine components, Warranty is void if welding machine is operated with sides open. DUTY CYCLE (Figure 4-1) Welding machines are rated on @ percent duty coyele based on 10 minute intervals, For example: ‘40 percent duty cycle simply means that she weld- ing current is on for 4 minutes, off 6 minutes, on again for 4 minates, off 6 minutes and soon, It must be kept In mind that time intervals other than 10 minutes will yield different test rating results. As the output is rediced or tnereased, the duty foyole will increase or decrease, TOM-312A Page 9i i : 0 «2 25.20 40 Go 6070 A700 100 woury eveue Figure 4-1. Duty Cycle Chart VOLT-AMPERE CURVES (Figure 4.2) ‘The volt-ampere curves show the output voltage ayallable atany given output current within the limits ‘of the minimum and maximum Fine Current Adjust- ment Control setting, Load voltage ts prodeter- mined to a large degree by arc characteristics. With the uee of the volt-ampero curves, it (5 possible to determine the amperage required for a particular load voltage. With reference to the volt-ampere curves, the ‘curves show the maximum and minima settings of the Fine Current Adjustment Control only, Curves, for other settings will fall hetween the maximam and ‘minimum curves shown, Figure 4.2, Volt-Ampere Curves 43, WELDING CURRENT SELECTION (Figure 43) ‘The Range Switch, located on the right side of the front control panel, has three positions for selection ‘of welding current, AC HIGH, AC/DC LOW ana DC HIGH, Place the switch in the position necessary to satisfy the particular welding application. If the required current Is in both ranges, use the lower range, as this will provide better’ current control. Page 10 Never, under any circumstances, operate the Cur- rent Range Switch under load, ‘Areing caused by opening the circuit carrying high current will severely burn the contact surfaces, This uuroing of the contact surfaces will decrease the maxiroum ‘urrent carrying capacity of the switch and possibly fuuse the switch to become inoperative, 4.4, POLARITY SELECTION (Figure 43) The Polarity Switch located on the left side of the front control panel has three positions for a choice of three Welding currents, dc straight polarity, de reverse, and ac. Tae Polarity Switch must he positioned in ac~ cordance with the setting of the Current Range Switch, When the Current Range Switeh is tn the AC, HIGH or LOW position, the Polarity Switch must bbe ‘in the AC position, When the Current Range Switch is in the DC, HIGH or LOW position, the Polarity Switeh can either be in the STRAIGHT or REVERSE polairty position, in a ew || car Le wa, le ote ee searemmey anton ‘Start Contra! S™ Tee Ha Ree = ney asa hase Fine Current gone a on Pas eam, Figure 43. Control Panel View OF Welding Machine45, FINE CURRENT ADJUSTMENT CONTROL (Figure 43) 46, 47. Seleot the exact desired welding current withir the range hy rotating the Fine Current Adjustment Control on the front of thewolding machine, A cur- Font indicator, above the Fine Current Adjustment Control, shows the current in accordance with the ‘current’ range in use, The upper two seales show the HIGH and LOW ac ranges and the lower two sonles the HIGH and LOW de ranges. HIGH FREQUENCY CONTROL RECEPTACLE AND SIITCH (Models with High Frequency Only) (Figure A bwo pole twistlock receptacle is provided on the front control panel and ts labeled High Frequency Start Control, A remote switen comected to the receptacle and to the electrode holder will provide control of the high frequency. The remote switch fs furnished as standard equipment with the welding ‘machine. ‘The high frequency assembly has a dual function: to enable starting tho are (in Gas Tungsten Azz Welding) without touching the electrode to the wore and to stabilize the are during the welding operatior. "The high frequency switch has three positions: START, CONTINUOUS and OFF, Position the swites in accordance with the requirements for the par- ticular welding job, Th the START position, higt frequency will be introduced intotheweldingeircult only when starting to weld, This position is usually used for Gas Tungsten DC Are Welding. In the Continuous position, usually used for Gas Tungsten ae. Aro Welding, high frequency will be introduce! into the welding’ clreult during the entire welding ‘operation, The High Frequency Switch on the frort ‘control panel. should be placed in the OFF position When the welding machine is used for Snieled Metal- ‘Aro (Stick Electrode) Welding. POST FLOW VALVE TIMER (Models with High Fro ‘quency Only) (Figure 4:3) ‘The post flow gas valve timer is located near the top of the front control panel, The post flow gas 48. 49, ‘valve timer controls the length of time the gas will continae ta flow after thearcbas been broken. ‘This timer should be set go that the gas flow coninses for fa suffictent Tength of time to allow the tungsten to cool to a point where it will no longer be con tarinated when exposed to the atr, This time set~ ting ts usually 10 seconds for euch 100 amperes of welding current being used, The tungsten must cool bright and ehiny, any blucing or blackening of the tangsten indicates « lack of gas coverage and will Introduce tungsten contamination into the weld. ‘This lack of gas coverage may be caused by a short cooling time, wrong gas cup, loose connection, rafty conditions, ete, ON-OFF POWER SWITCH (Figure 4-3) Placing the Power ON-OFF Switeh in the ON position will make the welding machine ready for operation. Place the Power ON-OFP Switch in the OFF position when the welding job is completed, SHIELDED METAL-ARC (STICK ELECTRODE) WELD: ING (Figure 4-4) 1, If the gas supply 1s comnected to the gas valve on the Welding machine be sure to turn off the shielding gas supply, GIF models only) 2, Remove High Prequency Start Control switch from the High Frequency Start Control Recep- tacle, (HP models only) 3, Insert the lug from the Work welding cable to the WORK terminal, Connect the other end of the work eable fo the workpiece, On models without, H.F., receptacles are used in place of studs for seoondary connections. 4, Insert the lug from the clectrodeholder cable} to the ELECTRODE terminal, 5. Place the Line Disconnect Switeh in the ON position, 6, Place the Power ON-OFF Switch in the ON position, Figure 4-4, Shielded Mets Are (Stick Electrode) Connections TOM-B12A Pogo 11430. Page 12 iGH FREQUENCY. ‘START CONTROL 7, Place the Polarity Switch tp the position tocor- respond with the position of the Current Range Switeh, When the Current Range Switeh i in either AC, HIGH or LOW position, place the Polarity Switch In the AC position,” When the Current Range Switch is placed tn tie DC, HIGH or LOW position, the Polarity Switch must be placed in either the DC Heverse or DC Straight position, 8, Adjust the Current Range Switch to the desired current range, Either DC HIGH or LOW or AC BaGH ov LOW, 9. Turn the Fine Current Adjustment Controt until the current indicator registers the desired weld- ing current. 10. Place an electrode of proper type and stze into the electrode holder and commence welding, 11, Resadjust the Fine Current Adjustenent Control and the Current Range and Polarity Switches, itneoessary, 12, After the Welding Job 1s completed, break the Welding aro and place the Power ON-OF F Switch 1n the OFF position, GAS TUNGSTEN-ARC (TIG) WELDING (Models with High Frequency and Gas Control Only! (Figure 4-5) 1, Make: shielding gas connections as described in paragraph 8-5. 2, Using a 10 foot length of No, 1 welding cable, attach a lug to this cable and insert to the Work terminal, Ifa longer cable is required, double the cable size, Connect the other end of this cable to the workpiece, 3. Refer to the process manual for connecting the Gas Tungsten Are (TIG) Torch, shielding gas and control eables, GAs-rower ‘ConnecTion igure 4-5. Gas Tungsten-Are Connections 4, Comect the plug of the furnished remote switen to the High Frequency Start Control Heoep~ tacte, Place the Polarity Switch in one of the three positions to match the welding application, Metal fo bo Wolded is usually the determining factor in selecting the proper current, 6, Adjust the Current Range Switch to the desired current rango. Be sure tho setting of this switen imatches the sotting of the Polarity Switehas far as ac or de are concerned, 7, Adjust tho Fine Current Adjuctment Control for the approxtmate current within the current range ‘of the Current Range setting. The upper two Scales show the HIGH and LOW AC ranges and the lower two scales show the HIGH and Low Dc ranges, 8, Plige the High Frequency Switeh in the STAR’ position for de welding and in the CONTINUOU: position for ac welding, Adjust the Post Flow Gas Valve Timer for ap- proximately 10 seconds for each 100 amperes of welding current, 10, Plgee the ON-OFF Power Switch in the ON) position, The ges timer will go through one foyele and shut Off, Bring the electrode close to the workplace, 11, Energize and hold the High Frequency Start Con- trol Switch until an are ts established, 12, Resadjust any of the controls, ifnecessary,untit propor welding operation i dhtained, 18, Alter the wolding job ts completed, break the Welding are and shielding gas will flow for the preset limo setting on the Post Flow Gas Timer, 8ae SECTION 5 - SEQUENCE OF OPERATION ‘Be gure the branch elrcult, main disconnect switch ‘or circuit fuses are removed before attempting any inspection oF work on the inside of the welding machine, Placing tie POWER switch on the welding ‘machine In the OFF position, docs not remove voltage from the power terminals inside of the machine, ———~—S 51, POWER FACTOR CORRECTION CAPACITORS. ‘The power factor correction capacitors wre built into the welding machine as standard equipment on models with power fa0tor correctiononly, These capacitors should require no maintenance’ or at~ tention and should poseess an infinitelifo,unless the power line is subjected to high voltage surges. If « capacitor should fail, ttean readily be recognized by the bulged case and’oll spillage and can be easily replaced, 52, TRANSFORMER ‘Occasional blowing out the dust and dirt from around the transformer is recommended. This should be done periodically depending upon the Tocation of the unit and Une amount of dust and dixt in the atmosphere. A clean dry alr stream should be used for this cleaning operation, 53. MOVABLE SHUNT Approximately once a year, it may be necessar/ to lubricate the LEAD SCREW, GUIDES, and SHUNT SLIDE.Apply light ooat of faitly high tomperatars grease, taking onre to avotd gotting grease on any ther part of the welding machine, Use SOCONY BEB high temperature grease or equivalent, 54, SHUNT GUIDE ADJUSTMENT ‘Tals adjustment is incorporated Into the welding ‘machine to compensate for vibration noises shoul they arise. The adjustment is composed of two tabs welded to the main transformer eoreanda set screv of bolt threaded into each tab, The set screws o> ots in turn apply a slight pressure against the Shunt guide or epacer, depending upon the amount the serews are turned is, Tats adjustment holds the movable shunt firmly in the guides, If a Vibration problem should develop during pro- longed use of the welding machine, follow the in- striction listed below for correction, 41. Remove all tneoming line power from the welding machine by turning the Line Disconnect Switch OFF or pulling the line fuses. 2, Open hott sides of the welding machine case land locate the two tabs, ‘There is one welded to ach elde of the main transformer core between the upper and lower coils, 3, Loosen the lock nuts on these screws, 4) Tighten each screw the same amount until the Hand. Wheel on the front of the welding machin: offers a slight pressure when it is turned to in« ‘enease or decrease, 5, Tighten the Tock nats oneach screw andel sides, 6. Operate the welding machine under welding con- titions. Hf a noticeable vibration is still present, repeat the preceding steps, the 55, FANMOTOR All models ave equipped with an exhaust fan ani 57. 58. rely on forced draft for adequate cooling for high duty oyeles and overloads, The fan motor is mant- Jnolured with Ilfetime lubrioated sealed ball bearing fand no attention should he required. HIGH VOLTAGE CAPACITORS (Models with High Fre: ‘quency Are Stabilizer Only) ‘These parts should require no attention and are rarely source of trouble, A defective capacitor, however, 1s evideat usually by the appearance of melted Sealing material at the bottomof the housing oF evidence of oil leakage in certain cases. Any looal radio repair shop can readily determine the condition of the capacitors, (If oneofthe high volt- fage capacitors should fail, operation may be con~ Hmed with one canscitor ‘until a new one can be secared,) In order to prevent excessive overload on the remaining single capacitor, the spark gap point setting ehould be reduced to about .00 SPARKC GAPS (Models with High Frequeney Are Stab ilizer Onty) ‘The spark gaps canbe readily inspected by opening the access door on top of the welding machinc, “The spark gape are normally sot at ,008" apart at the factory, It will be necessary to periodically readjust these after extended poration, Usually in~ spection and adjustment every three or four months Will suffice. "Readjustment is also indicated when intormittent operation of tao gaps ts noted, Usually this oceure when the setting has increased to .019" or greater. SPARK GAP ADJUSTMENT (Models with High Fre- ‘quency Are Stabilizer Only) Generally speaking, the high frequency output varies directly (up to & certain point) with the spark Sap spacing. Ip extreme eases where the greatest mount of high frequency 1s needed it may be neces= sary to adjust the spark gap seitingto 010" or even 013", This naturally also Increases the high irequenoy radiation and itis suggested that the mint= smum gap setting (.004" to .008") consistent with good welding operation be used, c i ¢ Figure 5:1, Spark Gap Adjustment IOM-S12A Page 18eT) Widening the spark gaps through normal operation may, if not corrected, increases the loading of the high’ vollage capacttors discussed In a previous, section, and thus contribute tothetr premature fatl= ture, Cleaning or dressing the points of the spark gaps is not recommended as the material at the points is tangsten and it is impossible to file, The ‘entire point should be replaced when the tungsten section has completely disappeared, cy ‘To Adjust Spark Gaps Proceed As Follows: 1, Loosen sorew A on hoth sides. 21 Place feeler gauge of proper thickness between, gaps C, 8, Apply Slight pressure against spark gap B so fester gauge te neld firmly tn gop, 4, Tighten serews A, 59. BY-PASS PANEL (Models with High Frequency Are ‘Stabilizer Only) ‘The purpose of the by-pass panel is to reduce the high frequency feedhack Into the transformer of the welding machine, A defective capacitor in this circuit would re- duce the high frequency output and might be evident by loss of oll from the metalease, If in doubt as to the condition of the capacitors, have them checked tat « radio repatr shop, The resistors would show evidence of being cracked if they are defective, Failure ofthis cireuitis rareandwouldhe suspected only ae a last resort, SECTION 6 - TROUBLESHOOTING ——es INTRODUCTION ‘The data collected here, discusses some of the common probleme which ogeur in this Welding ma~ chine, 4 little thought will probably solve the problem involved through the information provided, ‘The assumption of his data is that a proper welding condition has been achleved and has been used until trouble developed, In all cases of equip= ‘ment malfunction, the manufactarers recommen= flations should be’strictly adhered to and followed. If sfter performing the following procedures the trouble Is still not remedied, itis recommended that a servicomnan be called . At is recommended iat the electrical schematic be used for reference during the troubleshooting. TROUBLE: High oF low outyat, POSSIBLE CAUSE: 1, Jumper links on primary board connected for to- correct primury voltage, 3, TROUBLE: Erratic weld ourrent, POSSIBLE CAUSE: 1, Incorrect Polarity on de, 2) Loose welding comections. 3, Bad or damp electrodes. F, TROUBLE: Fan does not nan, POSSIBLE CAUSE: 1. Line fuses blown. 2) Bower ewiteh defective, 3, Fan motor defective, G, TROUBLE Wandering Are=Poor control of direction of are, POSSIBLE CAUSE: 1, Use of tungsten considerably larger than re= commended. ©, TROUBLE: Fan runs normal, Machine doco not operate on acy POSSIBLE CAUSE: 1, Current Range Switch in the DC HIGH position. 2) Polarity Switen in olther the DC STR or REY position, 8, Welding’ cables not mnleing proper connections, 3, TROUBLE: Fan runs normal, Machine does not operate on dc, POSSIBLE CAUSE: 1, Current Range Switch in the AC HIGH positior, 2! Polarity Switch in the AC position, BL Welding cables not’ malking proper connections, igh Frequency difficulty in eatablishing the POSSIBLE CAUSE: 1, Spark gap spacing incorrect, 2) Tungsten larger than recommended for weld cur~ rent. involved, Dissipation ofhigh frequency fromelectrodeholder lead, E, TROUBLE: Fan runs slow, POSSIBLE CAUSE: 1, Jumper links on primary hoard connected for in~ correct primary voltage, TROUBLE: Tungsten electrode oxidizing and not remaining bright after conclusion of weld, POSSIBLE CAUSE: 1, Water leak in electrode holder, 2 Loose gas fittings on regulator gas line, ‘will siphon oxygen into the weld zone, sufficient gas flow. rafts blowing gas’ shield away from tungsten, 5, Dirty filler rod or material, 8, Gas shutting off too quickly after end of weld, Tats 3, Page 14e Ee 250 AMPERE LiMiTED INPUT AC/DC WELOING MACHINE i ” POWER FACTOR CORRECTION (’P" MODELS ONLY) ‘Circuit Drawing bsteseisesleasioa ELECTRODE WORK Figure 6-1. Circuit Diagram For Models Without High Frequency 1OM-312A Page 18SECTION 7 - OPTIONAL EQUIPMENT een NO. 18 RUNNING GEAR A four 8 inch diamater steel wheel running gear with towing handle, Tals running gear comes in two Sections end holts to the welding machine base, Front ection with towing handle swivels on a stationary bas? for maximum maneuverability. NO, 28 RUNNING GEAR Stme as No, 1B Running Gear except wheels have a soltd rubber tire, No, 1BCR Same as No, 1B, tut with provision for carrying two gas cylinders, No, 280R, ‘Same as No, 28, but with provisisions for carrying two gas cylinders, Figure 7-1. No, 28 Running Gear TOM-812A Page 17FORM PL-312A-4/69 MODEL 250 AC/DC (900 941) 250P AC/DC (900 950) 250 AC/DC-HF (901 122) 250P AC/DC-HF (901 129) Effective with serial No. R397162 PARTS LIST miller ELECTRIC MFG. CO., Appleton, Wisconsin ADDITIONAL COPYFigure A ~ Main Assembly PL312A-4/69 Page 1Effective with sertal No, R397162 Item Dis, Factory No. Migs. Part No. Description Figure A Main Assembly T ‘Oia 80S WRAPPER, 1 014 084 WRAPPER |? : Haat 2 015 366 BRACKET, mig HP, : ror a 025 709 CHOKE. ASSEMSLY (consisting of) : iat 038090. PANEL, mtg -w/terminals ....0 101s. 101 R5 080615 | RESISTOR, 100 ohm 2 watt 12222021200 aa cs 604208 ScAPAcrTOR,IMFD ....2 0222202001 iat 010014 CLAMP, mtg’- capacitor 22222202021 aiaeaa 4 020628 PANEL ASSEMBLY, HLF, (Figs) 1101221 1 oa 5 015268 BRACKET, mtg~#.F, Panel li, ae 14 6 015 408 BRACKET, mig- foot pressure 6.101221 Seas 7 010.020 FOOT, pressure ~ shunt block is pee aati w teeta 8 026.627 SFAL, rubber... 7 Poroad 9 016 647 PANEL ASSEMBLY, control (Pig. G) oe 10 SRL (037.482 RECTIFIER ASSEMBLY (Fig. C) ee un 014202 BAFFLE, alr ~ rectifier . . aoa 2 016 756 PANEL ASSEMBLY, rear (Fig. D)” beet: 2 016 799 PANEL. ASSEMBLY, rear (Fig, D) ea: 13 TEL 038.932 PANEL ASSEMBLY’ primary (Pig. E111 eet 13 TEL 7038931 PANEL ASSeMaLY, primary (Pig, E) <2. eee: 13 TEL 038.934 PANEL ASSEMBLY, primary (Pig. E) 21 ee 14 C1031 614 CAPACITOR, 90 méa 440 volts ..s.. 10 2 a 15 014198 BASE ASSEDIBLY .... oe ae 15 019 823 -RASE ASSEMBLY (rifective with Serial No. ABSO38) vee ee ecec cece eeeeeee aon 15 014 199 BASE ASSEMBLY’ (17111 eee a 45 019 824 BASE ASSEMBLY (Rifective with Serial No, UAB5638) oe eee eee ee eee ee ee eee eee aon we osego7 STABILIZER, TITTIES seeeee Hae a 915722 GROMMET . : Sates oro. 18 030035 SCREW, cap ~ fox hd $/edd x 2-1/28 21221 ouette eae aw 601873 NUT, hex 3/8-21 roles asa Hea sie 20 TL 036.395 TRANSFORMER ASSEMBLY’ (consisting of) ¢ rou 21 TL (#038 886 ©, CORE ASSEMBLY Pasjcoaties ee 23° TL #033873 COLT, primary - secondary 12272271221 2 2 25 TL «#4033874 © COLL; secondary » Peace 28 20 TL 036.306 TRANSFORMEE ASSEMBLY (ess + eee 21 TL «M036 885, CORE ASSEMBLY... 20. tee 22 TL #4099205 | COIL, primary - secondary i, a rou 24 TL $098.186 | COLL, primary - secondary LM: ee aa 25 TL "#083874. | COM. Secondary 2s... 0+ sce sc see Boo 26 010 615 SPRING, extension siete a eae 2 010887 PULLEY ASSENBLY, indiéator wire (con sisting oD) aoe eae o1oeis . PULLEY | Pais iseee eur? 010.617 | BUSHING * oe gee aes 014205 | BRACKET, mig ~ roaoaiog 602.258" WASHER, fiat 3/16" SAE, zee ta 602 205 | WASHER, lock ~ isl tooth N sea eae 602 084 | SCREW, Prd hd 10-39 x 5/8" ie Seee gee aaa 501 862 | NUT, ex 10-3 eee eev ease ecese eee eee acer raed 28 016645 PARI. ASSEMBLY, front (Fig. B) 11. ace 28 016697 PANEL ASSEMBLY, front (Fig. B) aoe 28 019 198 PANEL ASSEMBLY, front (Fig. 3) Effective with serial No, 29810 ve cess see 14 039.628 PLUG ASSEMBLY, jack... 1.215 22 019.838 STRIP, copper vee. essc cc see 2 2 ors. WIRE, ‘He... 60ST ITE 2 8 Recommended Spare Purts ‘#Replace al. Factory or Authorized Service Station Optional Parte 'BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS, PL.312A-4/69 Page 2Figure B — Panel Assembly, FrontQuantity tem Di, Now _ Ng, Desorption Figure Panel Asay, ont See Fig. A Page? em 28) 7 Sr NAMEPLATE (order by BOOETGTSEEAT HODOTT, 7 2 019855 BROAL, Har, smiten, ee rae 3 01a 888 DECAL! HR, reseptacle ce ea ot 014625 PANEL. front "== ae 2 O14 584 PANELS front 2222 : 1 o 17 893 PANEL! front (tiocdve wits seict'No, Ssh)" 1 1 85 RCL 000 602 © -RECEPTAGLE, ooniol WE vss s es ; eee Se TDi ‘a1 RELAY, time deny s+ . : ee a" fig 206 BRACKET, mig tinne delay rely’ > : 22 8 st LL 610_SWITCH, toggle SPDT center off 5. : aH S St tL G1? SWITCH, pamer «60 amp arst : . oid SoS) orig SWiTeH'AsSeaLY, polarity (Fig, Bi) : sree grey 6) $3 OLL 15 SWITCH ASSEMULY, Farge (Fig. 2) 5 : aa @ 3g ofl SHUNT ASSEMBLY (Fig 59) : fee & G01 862 NUT, hex 10-82 : 202 3 e G02 205. Wastten, lock - int oath No, 30 : 22 2 os S02 938 | WASHER fat aie" SAEs + : ccd 66 10 616 PULLEY : 20203 & 85 620 PANEL asSEifaL, sadondiey (hig. BS) | : 2 3 1099 628 RECEPTACLE, wvistloce = secondary : 2 68 cst “as601 SOLENOID, gua consisting o)s sees scsccoss . oa +093 08) COIL, 118 ites z : ea 08 exo ase HITUIRG tot ot A, BAB” 1017 : 23 % 010 617 BUSHING, brass ++ : : 292 3 a O19 722 BRAKE, friction : toi 4 B 018 788 HANDWHELL Aah onaig 6 ae aeea 3 019727, HANDWHEEL ....., 1 a as i Sioeso pix ron i/ext" 2! tora 8 ibe03 Leon : faced 601941 | SCREW, cap ~ hex hd 1/4-20 . a a a 02 208 | WastiEh, Jock» int tooth 1/4 eerie 602241 WASHER! fist a/4" SAE, ; ere 601 867, NUT, hex 1/4-20 .. ee eee . i + a ‘*Recommentied Spare Parts BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS, PL.9128-4/69 Page 4Item Dia, Factory No, __Mkgs, Part No, Deseription Quantity FigureB1 O11 716 Switch Assembly, Polarity (See Fig. B Page 4 Item 60) Aon oT ‘Of 83 BRACKET, mig - suppor’ - T 92 O11 840 BRACKET'ASSEMELY, mtg (consisting ee 1 93 010671 SPRING «2. eee lessee eee eee 2 94 011841 HANDLE ASSbAiBEY 22202020021 4 35 011640 PLATE ASSEMBLY (consisting of) | 1 100.628, GUIDE, rotor sv... ee eee eat 3 100622 SHIM, Fotor guide 2222S 2 011968 | BOARD ,. ge eae 1 oisés «TROTOR 2 2222TLIIEIIL 1 O11 644 CONTACT, eoppe? * stationary” * + 2 2 011.643 | CONTACT’ ASSEMBLY, moveable (consisting of) 2112222. 3 011 074 | SPRING, pressure - front of board .... oe 1 011.953] CONTACT, copper ...eeeeeeeecesee 2 011075 |! SPRING, pressure - réar'of board’ 1121 1 0119651 BAR, jumper... 7 3 100621 | BAR, shorting |2.2..2 1 7 2 96 oig6o3 kwon’... IITIIIT 7 1 a 014203 BAR, support 122222205 pee ieeece ed 1 Figure B1 ~ Switch Assembly, Polarity BE SURE TO PROVIDE MODEL, AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS, Page 5Hem Dia, Factory No. Mkgs. Part No. Description quantity FigureB2 «011 715 Switch Assembly, Range (See Fig. B Page 4 Item 61) node Tor THs GO PLATE SSEMBCY (Sonata OD «vee 7 T 100 623, GUIDE, rotor... 0. +eeeeresceceedeneneneee 5 100 622 | SHIM, Fotor guide TTI 3 011965 1BOARD .... yee. csicseecessesee eee 1 om 968] ROTOR eee lan are an 1 011644 | CONTACT, copper ~ stationary’ 2221 2TTL III 6 011 643 || CONTACT'ASSENBLY, moveahle (consisting cpeareee 2 911074 1, SPRING, pressure ~ front of board... ital 1 011.953) T CONTACT, copper sss se sree seeee 2 011075 | | SPRING, pressure = Pear of board’ 1211 1 102 O11 841 HANDLE ASSEMBLY 2.0... 0..00 lp ssesces 1 03 011.840 BRACKET ASSEMBLY, mtg ‘ening of). +00. 1 04 10671, SPRING ..... 0. peeaheeeate ee 1 105 914.203 BAR, support’ | eerie 1 108 O11 839 BRACKET, ing > biped ieeceneaiaie te 1 107 019 603 KNOB eepnronrrornn 1 Figure B2 ~ Switeh Assembly, Range BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS, PL3120.6/69 Page 6tom Dis, Factory No, Migs, Part No, Description Quantity Figure B3 036 071 Shunt Assernbly (See Fig. B Page 4 Item 62) umes ai DIO G2 ROD, gilde.-.. +2. cscs vet yar sess seeseeeeeeeee z 12 602.045 SCREW, machine ~Tit ha 10-s2'x 6-1/2" brass ; | 4 123 014207 BRACKET, mtg = pulley ..ee.eeeseeeeeesee a 14 010617 BUSHING, brass... aie 1 125 010618 PULLEY... 4s. 2 2020s et 2 126 010628 WIRE, tndteator’ 222.212) pe 1 7 010.005 BLOCK, spacer ~ shunt! Sere 2 ue 010959 SLIDE, shunt .......0, eetaieeeal 2 129 010677 BLOCK, rear = shunt 2.222222 .TTIIIITIT 1 130 010620 BALL, Steel vo. ....sstrsseresseecee 1 036.072 BLOCK ASSEMBLY, shunt (consisting of)" a im 010110 BLOCK, insulation - rear... ...2e4000 a 132 026.630 INSULATION, tube - nylon’. 22.1. ilvtassecsceses 4 133 036 047 | BLOCK, laminste? 20.222 2DIEIGIIDITE 1 134 010107 | BLOGK'ASSEMIBLY, i oases 1 135, 010661 PIN, roll 1/8 x5/8". ees eaecescecececrenes 2 16 024785 COLLAR, locking... 222. 1 107 010072 WASHER, ollite... 2.2 TISIIIIIIIIII 1 138 010624 BLOCK, front - aluminum 22.222 1 139 024776 SCREW, lead, ale aie cee scree alee rales 1 Figure B3 ~ Shunt Assembly *Recommended Spare Parts BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS, Page 7Item Dia, Factory No, kgs, Part No, Deseripticn Quantity FigureB4 (038630 Panel Assembly, Socondary (Soe Fig. & Page 4 Item 67) sleds Tas GOL 639 NUT, hex = brass 1/919 «sc cccsecesesescsseseseseee 3 ur 601 40 NUT, hex - brass 1/2-13 jam ee eaaeaees 2 148 038.982 STUD, brass 1/2-18 x 2-5/8"... eee ives 1 9 010912 PIN, tol 1/85 oe ce eesecesescccecscesccecroes i 150 033603 PANEL 2 TTIITL peraiees i 181 602 247 WASHER, flat 1/2 S\A.ie, °° 22 oaiiees 1 182 602 217 WASHER, lock ~ ext tooth 1/2" fecdes a b Figure B4 — Penel Assembly, Secondary BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS, PL312A-4/69 PageBE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS, Item Dia, Factory No, _Mkgs. Part No, Description Quant Figure c 037.482 Rectifir Assembly (See Fig. A Page 2 Item 10) sai Meste Ter ‘EI 705 CAPACITOR ASSEMBLY (consisting of) T 162 RE 030726, RESISTOR, 1K ohm Swattsssvesssesees 1 163 CB 031.688. | CAPACITOR, .5 mfd 200 vie 1272222121 1 164 G10 01 CLAMP os eee ec eeecacceceeerces 1 165 Di 097.308 DIODE, mREE-9390 TI 4 168 981 688 © CAPACITOR ASSEMBLY 122222222 12111 2 167 031689 CAPACITOR ASSEMBLY 111. ......005 2 Figure © — Rectifier AssemblyItem Dia, Factory Without] No, _Bikgs. Part No, Deseription WP, Pag Figure D Panel Assembly, Fear (See Fig. A Page 2 Item 12} eh i7i —FAt_082 80S MOTOR, fan (Comsisting Os vsssseseeee ee : 1 024601, BEARING Gieaiieeteee aes 2 ie 014631 WIND TUNNEL ASseMaLy 1222 .220TTTII i 173 032612 BLADE, fan 60 cycle ......s.ssc seers i 473 4092614 BLADE! fan 50 cycle | Petuieetale i m4 014623 PANEL, rear ee. . 0 Brana a ama 014 086 © PANEL, rear 11221 i a Optional Equipment *Recommentied Spare Parts Figure D ~ Panel Assombly, Rear BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS, PL312A.4/69 Pago 10Quantity Item Dia, Factory ee with No._Mkgs. Part No. Description ls. Eat Eat Figure E Panel Assembly, Primary (See Fig. A Page 2 Item 13) ane a} ier 601 835 NUT, RExJO-B2 BASS weve es ei 182 602 203. WASHER, lock - split 3/36". 7 2222222212 4 8 163 010913 WASHER, flat - brass 3/16" 1D" 222222221 8 2 18s 028 631 INSULATION eee eet 46 185 038.618 LINK, jumper 12220 2T SII 2 2 186 038 662 PANEL, mtg ~ components v.21. Lt 11 387 038 887 SCREW, hex collar ~ brass 10-89 1-8/8" 111! 46 388 601 836 NUT, hex brass 1/420... sess eaes 44 89 038 888 SCREW, hox collar = brass i/4220 x i-1/2 eee: 190 013.657 LABEL, line - gra. eae 201 as 010915 WASHER, flat - brass 1/4" ID LILI. t tl 2 2 12 602.207 WASHIER, look ~ split 1/4” anes 2 2 Figure E — Pansl Assembly, Primary BE SURE TO PROVIDE MODEL AND SERIAL NUMBEE WHEN ORDERING REPLACEMENT PARTS, Page 11Item Dia, Factory No, _Mkgs. Part No, Description Quantity Figure F 020628 Panel Assembly, High Frequency (Seo Fig. A Page 2 Item 4) soi 301 ‘O10 855 SHIRAP, bus = copper 5-0/8" long... - +--+ T 202 010 883 STRAP, bus ~ copper 8" long... = 1 203 36 91 STUD, brass 9/628 x 2-1/8". T IL 2 204 601 838 NUT, hox ~ brass 9/8-16 jams ++ 8 205 R2_—030603._- RESISTOR, 10K ot m 10 watt fixed” + 1 208 014159 BRACKET, mig ~ capacitor . a 1 207 C3031 601 CAPACITOR, 10 mft 600 voits de ¢ 1112 a 208 R2_-_030602 RESISTOR, 10 ohm 100 watt fixed v.12. a 209 C2 "031602 CAPACITOR, .002 mfd 6000 volts de +++ a 210 T2036 865 TRANSFORMER, 115 volts nigh voltage « - a 2 010 884 © STRAP, bus - copper 6-3/4" long... ss i 212 038 887 SCREW, hex collar ~ brass 10-32 x 1-3/8" 2 213 TS 083.601 COTL, coupling ey. seer eeeeeeeeeeeee 1 216 O16 601 PANEL, mtg - components, 21.022 TLII 0 2 215 © G 020623: SPARK GAP ASSEMBLY (Fig. Fi)" 212202021 a ‘Recommended Spare Parts BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS, Figure F ~ Panel Assembly, High Frequency PL.312A.8/69 Page 12Item Dia, Factory No, Mkgs. Part No, Description Quantity Figure F1 020623 ‘Spark Gap Assembly (See Fig, F Page 12 Item 215) ios Bi B62 023 SCREW, cap - socket hd 10-244 5/8" wvssvcseee « 222 604772 WASHER, flat No, 88,A.E. .......:sc0s0scs0ee 4 233 010 888 © CONNECTOR, holders... ssricsssccsceeeees 1 228 020622 HOLDER, polit... . Heeales seis 4 225 020 603 POINT, set of four 7 Eocene? 1 set 226 010.913 WASHER, flat ~ brass 3/16" 1D" | Settee 8 237 020621 BASE. see eevee eee ees rate eee 1 228 602 204 WASHER, jock “external tooth No.0 222222 ITIIIIIIITS 8 229 802 101 SCREW, tad hd 10-24 x 6/8". onesie 8 Figure F1 — Spork Gap Assembly *Recommended Spare Parte BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS, Page 13.Item Dia, Factory No, _Mlgs, Part No, Description Quantity Figure G (016647 Panel Assombly, Control (Seo Fig, A Page 2 tem 9) oo 288 O93 HSE DECAT, terminal WEES. ©s sess esse eeee T 237 13 568 LABEL, CR2 Palenaielpe stag ele ea 1 238 01g 67 LABEL, ORI 222.0 1 238 038.881 PANEL, mtg ~ components, 222.2 TL TInt 1 240 SK2 087 446. RECTIFIER, signal... eres alee tet 1 241 RI 030.601_-RESISTOR, 1K ohm 25 wait s ale 1 242 RL 034601 RELAY, 24 wlts do... : 2 243 CR2 034619 RELAY, 24 voltsac 1.0. ss tree L 244 TE2 038782 BLOCK, terminal 10 post’ || 1 BE SURE TO PROVIDE MODET. AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS, Figure G — Panel Assembly, Controt PL12A-4/69 Page 14NUMERICAL P&RT NUMBER INDEX Factory Page Item Factory Page Item Factory Page Item Factory Page Them Part No, No, __ No, Part No, No. No. Part No, No. No. PartNo, No. No. 010 0087 rr 019 8554 8 025 7092 3 38 630 4 67 mood 28 0 th 013.856 14236 ose e211 186 ° 164 013857 «11190 oss 782 14 ad 10020 2 7 01g 8654 53 9266272 8 3682 14239 100352 38 oisssr 14288 926.6307 132 038687 18 «187 & o10072 7 187 o1saes id 87 o266s1 11184 no 2B o1o107 7 138 oagess 12189) 101107 ist 038 881 2203 10296 4 3 o14 oss 2 1 oso6or 14241 033.9322 w o10 5212 * 014085 104 930602 12208 035 934 2 1B p10 6152 26 014159 12206 030608 12-205 038.9828 48 oss 2 oid 1982 16 030615 2 * de 6b | o14is9 2 18 030726 8 152 7 1s oid 2022 rr 039.6024 ower 014203 «5 & OTB osgezs 4 ve 18 6 108 osi6or 42207 033.6292 7 124 o1a2058 2 * 931602 «12209 106207 130 014 2064 st ogi 614 2 “4 0106247 133 o1g207 7 123 oa 68s 9 163 30021 5 . 0106287 126 oid 53a 54 031 6389 166 iooe22 b& ft o10@29 7 x21 o14623 10 17d oaiess 9 1st 6 ‘ 010.6504 4 014625 4 co 0317089 161 a ed 010.6617 138 o146s) 10172 6 . os7l 5& 93% | 14503 2 1 6 104 032 603 300173 06777 1s ps2612 100173, soless 11 18h on0883 12202 015 2662 2 0s2 614 1078 sol eas 11188 oxo 82122 01s 2682 5 601638 12204 o10 88512201 015.4062 6 601 e398 146 ono es7 2 2 015 7222 " sg 0504 . 801 8408 at uo sss 1s 223 03g.185 2 22 601862 2&4 0 Fh 010912 8 43 03a 1862 24 4 63 010913 «118 tase | o1seor 12 a4 a3 601 32213, so1s67 4 * 13 226 016 6452 28 oaga7s 2 23 sor e732 aw o1oo1s 119 oie 6472 3 osge7s 2 25 sol sal 4 * 0109597 Bs 016 6972 28 016 7582 2 018 7992 2 sozo2s 13 an oom 66 te 602 0487 122 6 : 03460. 14 4 502 094 2 * ono 5& 7& 0178334 54 os¢e19 1d 4 602101 13229 6 * 0347014 36 502208 11 182, o161o 4 58 602 208 13 ae o1ei7 4 50 o19 1952 28 602205 28 +8 wii ess 8 toL eos 4,75, oss 6014 68 4 et on ego 5 95 58 96k go2207 11192 O16 56 58 6 107 602 2084 * 6 * 0197224 n 0360477 133 602 2178 182 ogss 56 t8 197274 38 oago7l 4 602238 28 0 Fh 6 * 019 284 RB 0360727 4 65 ons 4 61 o19 #282 15 036.9952 coz 214 . onze 4 60 o19 6242 1b 036 396 2 602 2478 asi oss 5& se | oisess 2 * 036 807 2 6 106 axe 86512 oso 5G Ok 036.8862 04208 2 * 6 103 020608 13225, 604772 18a oe. 5&@ 348 | o2062 13227 6 102 020622 «18-34 037305 9 165 oioss 58 #8 020623 12215 037 4822 10 6 * 0206282 4 037 445 14240 0119655 * 11968 BR tk 6 * oer ip * os8 090 2 . ous 5a 0247787 139 0385038 150 6 * 0247857 136 ose 61s 11188, ‘Part Not Called Out By Item Number Page 17