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the
wire
feeder
electrical
input
power
leads for the purpose
of
shutting
the wire
feeder
down in the
event
that
one
or
more
of the thermostats in the
welding
power
source
should
open
and shut
the
welding
power
source
down. Failure
to
connect
the wire feeder
to
the
contacts
of CR2 would result
in the
wire feeder
continuing
to
feed wire
even
though
weld
current
is not present.
Make the connections
to
the
welding
power
source
as
follows:
1.
Remove the
right
side
panel.
Terminal
strip
iT is located
in the upper
rear corner
of the
right
side of the
welding
power
source.
2.
Locate
the
7/8
hole in the
rear
panel
of the
welding
power
source
and
route
leads
from
the
wire
feeder
through
the
hole
to
terminal
striA
iT.
3.
Connect wire feeder
input
power leads
to
terminals 13
and 14 of terminal
strip
iT.
4.
Replace
right
side
panel.
3- 8. 115 VOLTS AC RECEPTACLE
(Figure
3-4)
The
three-pole,
twistlock
receptacle
on
the front
panel
of
the
welding
power
source
is intended
to
provide
115
volts,
60
Hertz
electrical
power
for
operation
of
accessory
equipment.
To
secure
the
corresponding three-pole
plug
in this
recep
tacle,
insert the
plug
into the
receptacle
and
rotate
the
plug
clockwise.
IMPORTANT
The 115 VOLTS AC
receptacle
is
protected by
fuse
F2 which is located
on
the front
panel.
If it should
become
necessary
to
replace
the
fuse,
ensure
that
a
fuse of the
same
rating
is used for
a
replacement.
A
fuse of
a
larger rating
will
permit overloading
of the
115
volts
circuitry
and
thereby
cause
damage
to
the
weldingpowersource.
3-9. OVERLOAD PROTECTION
The SCR
circuitry
is
protected by
a
miniature fuse Fl
lo
cated
on
the front
panel
of the
welding
power
source
(see
Figure
3-4).
If fuse Fl should open, the weld
output
would
cease.
There
are
thermostats
located
in
the
main
rectifier
and
transformer.
In the
event water
flow stops while
the unit is in
use
and the main rectifier
and/or
transformer becomes
too
warm, the
thermostat(s)
will
open
and
suspend
all output. If
this occurs, initiate
water
flow and allow
the unit
a
cooling
period
before
attempting
to
resume
operation.
The POWER
circuit breaker
CR1 will
open
to
interrupt
in
coming
power
if
the
input
power is
too
high.
The circuit
breaker
must
be
manually
reset.
1.
Make
electrical
input
and weld output connections
as
outlined in Section 3-2 and
3-3.
2.
Make
water
connections
as
required
and
turn water
flow
on.
3.
Select
desired
dc
open
circuit
voltage
as
outlined
in
Section 3-4.
4.
Make
connections
to
CONTACTOR CONTROL
recep
tacles.
5.
Place POWER
circuit breaker in
ON
position.
6.
Close the Contactor Control
to
apply
115 volts
ac
to
the
welding
power
source
voltage
control circuit.
3-10. DUTY CYCLE
(Figure
3-5)
The
duty cycle
of
a
welding
power
source
is the percentage
of
a
ten
minute
period
that
a
welding
power
source can
safely
be
operated
at
a
given
output. This
welding
power
source
is
rated
at
100 percent
duty cycle.
This
means
that the
welding
power
source
can
be
safely operated
at
rated
load
con
tinuously. Figure
3-5 enables the operator
to
determine the
safe output of
the
welding
power
source
at
various
duty
cycles.
800
3-11. VOLT-AMPERE CURVE
(Figure
3-6)
The
volt-ampere
curves,
Figure 3-6,
show the output
voltage
available
at
each
given
output
current.
40
Prior
to
welding,
it is
imperative
ti
t
proper
protective1
clothing (welding
coat
and
gloves)
and
eye
protection
(glasses
and/or
welding helmet)
be put
on.
Failure
to
comply
may
result
in
serious and
even
permanent
bodily damage.
7.
Commence
welding.
4-2. SHUTTING DOWN
1.
Open
the
Contactor Control
to
remove
115 volts
ac
from
the
welding
power
source
voltage
control circuit.
2.
Allow the
welding
power
source
to
idle with the
water
flowing
for
a
cooling period.
3.
Turn off
water
flow.
4.
Place the POWER circuit breaker
in
the OFF
position.
w
UI
0.
4
a
z
0
UI
700
600
500
50
60
70
80
90
100
%
DUTY CYCLE
8-049 263
Figure
3-5.
Duty
Cycle
Chart
35
r
30
-1
0
20
0
4-1. GAS METAL-ARC WELDING
(GMAW)
SECTION
4
-
SEQUENCE
OF OPERATION
100
200
300
400
500
600
700
DC
AMPERES
Figure
3-6.
Volt-Ampere
Curve
B-049
264
Page
8
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