Table of Contents
Advertisement
Open
the
right
rear
side door
to
obtain
access
to
the
primary
contactor.
Connect the three
input
conductors
directly
to
the
line
terminals
of
the
primary
contactor
and
connect
the
ground
conductor
to
the terminal labeled
GROUND.
See
Fig
ure
3-2 for
input
conductor connections. The
remaining
end
of the
ground
conductor should be connected
to
a
proper
grnund.
Use whatever
grounding
method that is
acceptable
to
the local electrical
inspection authority.
The
terminal
labeled
GROUND
is connected
to
the
welding
power
source
chassis and
is
for
grounding
purposes
only.
Do
not
connect
a
conductor from the
terminal
labeled
GROUND
to
any
one
of the
line
terminals
on
the
primary
contactor
as
this will result
in
an
electrically
hot
welding
power
source
chassis.
C.
Matching
The
Welding
Power Source To The Avail
able
Input
Voltage
The
input
voltage jumper
links
provided
on
the
primary
ter
minal board
permit
the
welding
power
source
to
be
operated
from
various line
voltages.
The various
voltages
from which
this unit
may
be
operated
are
stated
on
the
nameplate
and
on
the
input voltage
label. See
Figure
3-2 for location of this
label. The
input voltage jumper
links
are
positioned
for the
highest
of the
voltages
stated
on
the
nameplate.
If the weld
ing
power
source
is
to
be
operated
from
a
line
voltage
which
is
lower
than
the
highest voltage
for which
the unit
was
designed,
the
jumper
links will
have
to
be moved
to
the
proper
positions
before
operating
the unit.
Figure
3-3 shows
the various
positions
of the
jumper
links
on
the standard
welding
power
source.
If the
input voltages
on
the
name
plate
differ from those
shown in
Figure 3-3,
the
input voltage
jumper
links
must
be
positioned
as
shown
on
the
input voltage
label.
NOTE
If
only
one
jumper
link
is
required
on
each of the
grouped
terminals,
it
is
recommended
that the unused
jumper
links be
placed
across
the terminals which
are
to
be used. This will
prevent
losing
the
jumper
links
which
are
not
required
for this connection.
3-3.
SECONDARY CONNECTIONS
(Figure
4-1)
The
POSITIVE
and
NEGATIVE
secondary
terminals
are
located behind the lower front
access
panel.
The
access
panel
which
covers
the
secondary
terminals is secured
by
two
fas
teners.
To open the
access
panel,
rotate
the fasteners
counler
clockwise
one
full
turn.
Likewise,
so
close the
panel,
rotate
the
fasteners clockwise
one
full
turn.
A.
Welding
Cables
It is recommended that the
welding
cables be
kept
as
short
as
possible, placed
close
together,
and be of
adequate
current
carrying capacity.
The resistance of the
welding
cables
and
connections
cause
a
voltage
drop
which is added
to
the volt
age
of
the
arc.
Excessive cable resistance
may
result in
over
loading
as
well
as
reducing
the maximum
current
output of
which
the
welding
power
source
is
capable.
The proper opera
tion
of any
arc
welding
power
source
is
to
a
great
extent
dependent
on
the
use
of
welding
cables and connections
that
are
in
good
condition and of
adequate
size.
Use Table
3-2
as
a
guide
for
selecting
the
correct
welding
cable size
for
the
anticipated
maximum weld
current
that will
be used. Table 3-2 takes into
account
the total cable
length
for the weld circuit. This
means
the
length
of the
Electrode
cable
that
connects
the
wire feeder
to
the
welding
power
source
and the Work
or
ground
cable between
the
welding
power
source
and the work
piece.
For
example:
if the Elec
trode cable is 75 feet
long
and the work
or
ground
cable is 25
feet
long,
select the size cable from
Table 3-2
that is
recom
mended for 100 feet. In
a
situation where
a
maximum weld
current
of 150 amperes is
anticipated,
No. 2 weld cable is
recommended for both the Electrode and Work cables.
WE LOIN C
*TDTA
LLEN
C
TI-I
OF
CABLE ICOPPE RI
IN
WELD CIA
CIJIT
AMPERES
SO
too
150
200
250
300
350
400
100
4
4
2
2
2
1
1/0
1/0
150
2
2
2
1
1/0
2/0
3/0
3/0
200
1
1
1
1/0
2/0
3/0
4/0
4/0
250
1/0
1/0
1/0
2/0
3/0
4/0
4/0
2-2/0
300
2/0
2/0
2/0
3/0
4/0
4/0
2-2/0
2-3/0
350
3/0
3/0
2/0
4/0
4/0
2-2/0
2-3/0
2-3/0
400
3/0
3/0
3/0
4/0
2-2/0
2-3/0
3-2/0
2-4/0
500
4/0
4/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
3-3/0
600
2-2/0
2-2/0
2-2/0
2-3/0
3-2/0
2-4/0
3-3/0
3-4/0
700
2-3/0
2-3/0
2-3/0
2-4/0
3-3/0
3-4/0
4.4/0
4-4/0
800
2-3/0
2-3/0
2-3/0
2-4/0
3-3/0
3-4/0
4-4/0
4-4/0
A-002
623
NOTE:
A.
50
FEET
OR
LESS.
B
CABLE
SIZE
IS
BASED
ON DIRECT
CURRENT IDCI.
100% DUTY CYCLE
AND
EITHER
A
4
VOLTS OR
LESS
DROP
OR
A
CURRENT DENSITY
OF NOT OVER 300
CIRCULAR MILS
PER
AMP.
C.
WELD
CABLE
INSULATION
WITH
A
VOLTAGE
RATING TO WITHSTAND THE
OPEN-CIRCUIT VOLT
AGE
IOCVI
OF
THE
WELDING
POWER
SOURCE
MUST
BE
USED. WHILE MOST WELDING POWER
SOURCES
HAVE
AN
OPEN-CIRCUIT VOLTAGE
OF
LESS
THAN
100
VOLTS. SOME
WELDING
POWER
SOURCES OF
SPECIAL
DESIGN
MAY HAVE
HIGHER OPEN-CIRCUIT
VOLTAGE.
3-4.
115 VOLTS AC RECEPTACLE
(Figure
4-1)
Two
receptacles,
both labeled 115
VAC,
are
provided
on
the
front
panel.
The
duplex
115 VAC
receptacle fRC4)
is in
tended
to
be used for
operating
accessory
equipment.
The
three-pole
twistlock. 115
VAC
receptacle (RC2)
is intended
to
be used for
supplying operating
power
to
a
control/feeder.
To
secure
the
corresponding three-pole plug
into this recep
tacle,
rotate
the
plug
as
far
as
it
will
turn
in
a
clockwise
direction.
3-5.
CONTACTOR
CONTROL CONNECTIONS
(Figure
4-1)
The
CONTACTOR CONTROL
Receptacle IRC3) provides
a
junction
point
for
connecting
a
Remote Contactor Control
device
to
the
contactor
control
circuitry
in
the
welding
power
source.
To
connect
the Remote
Contactor Control
to
the
CONTAC
TOR CONTROL
Receptacle,
insert the
two-pole plug
from
the
Remote Contactor Control device
into the
CONTACTOR
CONTROL Receptacle
and
rotate
the
plug
as
far
as
it
will
Line
Table 3-2.
Secondary
Cable Sizes
Figure
3-2.
Input
Conductor Connections
Te-gol 181-2
I
I
I
I
230 VOLTS
460 VOLTS
Figure
3-3.
Input Voltage Jumper
Link
Arrangement
OM-254
Page
9
Advertisement
Table of Contents
