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4-1.
POWER SWITCH
(Figure
4-1)
Placing
the POWER Switch
in
the ON
position
will
energize
thr
welding
power
source
fan and control
circuitry
and
place
the
welding
power
source
in
a
ready-to-weld
status.
Placing
the
POWER Switch
in
the OFF
position
will shut the
welding
power
source
down.
Even
though
the POWER Switch is in the
OFF
posi
ion and the
welding
power
source
is
apparently
elec
trically
shut
down,
electrical
input
power
is
still
present
on
all
circuitry
up
to
the
POWER Switch
and
primary
contactor.
To
completely
cut-off
all electrical
input
power
to
the
welding
power
source,
it will be
necessary
to
place
the line
disconnect switch
in the
OFF
position
or
remove
the line fuses.
4-2.
VOLTAGE CONTROL
(Figure
4-1)
The VOLTAGE
CONTROL,
located
on
the front
panel,
pro
vides
a
means
of
selecting
the
voltage
desired within the load
voltage slope
connection range
being
used.
Rotating
the
con
trol in
a
clockwise direction
will increase the load
voltage.
Whenever
a
Remote
Contactor Control
is
to
be
used,
make
connections
to
she
CONTACTOR
CONTROL
Receptacle
)RC3)
on
the
welding
power
source
as
instructed
in
item
3~5.
In order for
a
Remote Contactor Control Station
to
operate
the
contactor
in
the
welding
power source, the
Remote Con
tactor
Control
must
be able
to
supply
115 volts
ac
60 Hz
power
to
the
CONTACTOR CONTROL
Receptacle whenever,
weld
output
is desired.
Also,
whenever
suspension
of
weld
output
is
desired,
the Remote Station
must
be able
to
cut-off
the
115 volts
ac
supply
to
the
receptacle (RC3).
Another
prerequisite
for
remote
control of the
contactor
is
to
have
the
CONTACTOR CONTROL Switch
on
the
welding
power
source
in
the REMOTE
position.
If this switch it left in he
STANDARD
position,
the
contactor
will
energize
as soon
as
the
POWER Switch is
positioned
to
ON.
The CONTACTOR CONTROL
Circuitry
(and
115 VAC Re.
ceptaclea)
it
protected
by
a
15 ampere fuse
)F2)
which is
located behind the
right
front side
panel.
If this fuse should
open,
the
contactor
coil
would
de-energize
(if
the
CON
TACTOR CONTROL Switch
were
in the
STANDARD
posi
don)
and all weld
output
would be
suspended. Alto,
if this
fuse should open,
it
will be noted that 115 volts
ac
would
not
be available
at
the
115
VAC
Receptacles.
IMPORT
When
replacing
fuse
F2,
ensure
that
the fuse
being
used
as
a
replacement
is
one
of proper size and
rating.
A fuse of
larger rating
will
permit overloading
of
the
115
volts
circuitry
and
thereby
cause
damage
to
the
welding
power
source.
The
scale
surrounding
the
VOLTAGE CONTROL
is cali
brated in
percentage
and should
not
be misconstrued
as
an
amperage
or
voltage reading.
It
is
recommended
that
the
meters
be read whenever it is necessary
to
know the amper
age and
voltage
output.
4-3.
REMOTE VOLTAGE CONTROL RECEPTACLE &
SWITCH
(Figure
4-1)
If
a
Remote
Voltage
Control is
to
be
used,
make Connections
from rhe Remote
Voltage
Control
to
the
VOLTAGE CON
TROL
Receptacle
as
instructed in item
3-6.
When
remote
control of the
voltage
is
desired,
it is essential
that the
VOLTAGE CONTROL Switch be
placed
in
the RE
MOTE
position. Likewise,
if
a
Remote
Voltage
Control
it
not
to
be
utilized,
the
switch
must
be
in
the
STANDARD
position.
When
in
the
STANDARD
position only
the
VOLT
AGE CONTROL
on
the
front
panel
will control the
voltage.
The 30
volts control
circuitry
in the
welding
power
source
is
protected by
a
circuit breaker
(CR2)
which is located
on
the
right
side
of
the
front
panel.
If this circuit breaker
opens,
the weld output goes
to
minimum output and remains
there, regardless
of the
position
of any of the
welding
power
source
controls.
When
this
occurs,
neither the VOLTAGE
CONTROL,
or
Remote
Voltage
Control will
have
any
effect
on
~ne
weld
output.
Manually
reset
the
circuit
breaker
before
attempting
to
resume
operation.
This
welding
power
source
is
equipped
with
an
overload
Circuit Breaker
(CR1)
which
will
suspend
all weld
output
in the
event
an
excessive overload is
placed
on
the
welding
power
source.
The Circuit Breaker
circuitry
consists of
two
current
trans
formers
)CT1
&
CT2(
which
are
located
on
the
primary
side
of
the
main
transformer
(Ti)
and
two
sets
of
contacts
which
are
wired in series with
the
contactor
coil. Should
an
over
load
occur,
the
current
sensing
transformers would detect the
overload and
cause
the
Circuit Breaker
to
trip.
When the
breaker
trips,
the
two sets
of
contacts
in
series
with the Con.
tactor
coil
will
open
and
thereby
cause
the
Contactor
to
de-energize
and
suspend
all weld output. To
place
the
weld
ing
power
source
in
a
ready-to-weld
status
again,
it will be
necessary
to
manually place
the Circuit Breaker
atms on
the
front
panel
in
the ON
position.
46.
METERS
(Figure
4-1)
This
welding
power
source
is
equipped
with
a
dc
ammeter
and
a
dc voltmeter. These
meters
are
internally
connected
to
the
welding
power
source
weld
output terminals, The volt.
meter
will indicate
the
dc
voltage
at
the
secondary terminals,
but
will
not
necessarily
indicate
the actual
voltage
at
the
welding
arc.
If the
welding
cables
are
excessively long,
or
have poor,
loose
connections,
the
difference
between actual
arc
voltage
and
the
voltage
at
the
welding
power
source
secondary
terminals
may
be
considerable. The
ammeter
will
indicate
the
weld
current
output
of
the
welding
power
source.
4-7.
DUTY CYCLE
(Figure
4-2)
.
c~
-
.
-
~
I
I
U
NOTE
I
I
The
contacts
of the
VOLTAGE CONTROLareof the
continuous type,
thereby
making
it
possible
to
ad(ust
this
control
while
welding.
4-5.
CIRCUIT
BREAKER
OVERLOAD
PROTECTION
(Figure
4-1)
4-4.
CONTACTOR
CONTROL
RECEPTACLE
&
SWITCH
(Figure
4-1)
~IIuflhIlL.]jU
I
I
Whenever
the
CONTACTOR CONTROL Switch is
in
the
STANDARD
position, open.circuit voltage
will be
present
at
the
secondary
terminals
as
long
as
the
POWER Switch is
positioned
to
ON.
1000
~a
900
E
ow
ja.
800
700
U
I
30
40
50
60
708090100
%DUTY CYCLE
DA.901
181-1
Figure
4-2.
Duty Cycle
Chart
OM-254
Page
11
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