TAFA 9300 Transformer-Rectifier Power Source
Contents
1. EAS tre NE XL X2 A ALTERNATE A 3 p 10 23 BK 40 2 d 279 2 n x TRANSFORMER E 2 5 A x 9d a amp a 5 x Xi 8 5 WRING TO Al A CONTROL 22 8 X3 19 BK D X4 B 21 BK o 30 a o9 yy ost 12 a lt Pe 240 5 7 oF 2 4 4 4 q A ao x x 7T i 12 8K 3d 2 13 o BK 2 8 8 ELM 16 14 1 3 15 24 18 9 42 9 lt 5 3 13 BK 28 43 BK 43 BK PRIMARY LEADS 1C TO 7 5 55 ps m 5 T2 TO CHANGE OVER BOARD 16 33 5 n p a R3 E 18 COM H 2 2 4310k I 200v 39 8K _ 16 29 230v SODVE 395 460 CHANGEOVER BOARD ON POWER TRANSFORMER R4 b 20 Bk 43 BK 43 BK GROUND SCREW UNE 35 BK 30 CONTROL BOARD 32 CHANGE RECORD FINISH CODE PER 800001 Ne DATE NONE ES FRE ADOT WE LE TS EE UNLESS OTHERMISE SPECITIED OWENSIONS ARE Os ALLE TERS TOLERANCES BELOW APPLY EXCEPT FOR SAARC EPEE VENDOR DESIGNED PARTS AND TEMS PRODUDED TO2. 85012652 6 15 00 181 14 UNLESS OTHERWISE SPECTED YEWA TE WE moves mag ENDAR PMS MD TENS 2 oo PEER Meis DIAGRAM SCHEMATI E DIAGRAM SCHEMATIC poor Dj TAFA 9300 EUROPEAN LE C MODEL atom wena m ar 20 02 00 2 04mm RGS 6 3 97 FULL 005 ae A REDE Tur wir DG NUI SCALE DRAWING h 6 9 97 FOUDRE 6 owe wo SHEET 2 Folie D thease 5 830138 T 8 T 5 T T 5 T gt T 1 FIG 1 UNKS FOR 200v UNE FIG 2 LINKS FOR 230V UNE FIG 5 LINKS FOR 400V LINE FIG 4 UNKS FOR 460V LIN CONTROL TRANSFORMER ON YOKE CONTROL TRANSFORMER ON YOKE INPUT CABLE DIAGRAM CONTROL TRANSFORMER ON YOKE CONTROL TRANSFORMER ON YOKE UNKS FOR 575V LINE SEE NOTE 2 INSTRUCTIONS FOR SETTING VOLTAGE CHANCEQVER PANEL AND CONN CTING POWER UNE ALSQ SEE INFORMATION IN INSTUCTION MANUAL INPUT CABLE 1 CHECK NAMEPLATE OF WELDER 10 CERTAIN IT IS DESICNED 10 ACCOMMODATE DESIRED UNE VOLTAGE 2 MOVE LEAD 35 BLACK ON CONTROL TRANSFORMER AS SHOWN ACCORDING TO THE LINE VOLTAGE 3 CHECK THE LOCAL CODES FOR PROPER LINE MRE SIZE 10 USED WELDER KEQUIKEMENTS SHOWN NAMEPLAIE OF THE WELDER IF CODES ARE NOT ESTABLSHED FOR AREA USE THE CHART
3. 9300 Transformer Rectifier Power Source For the Following Spec e 100006 001 200 230 400 460 575 V 50 60 Hz 5 MANUAL Number 193111 023 Revised February 14 2000 TAFA INCORPORATED CONCORD NEW HAMPSHIRE 03301 U S A DECLARATION OF CONFORMANCE THERMAL ARC 2200 Corporate Drive Troy Ohio USA 45373 1085 Declare under our sole responsibility that the following product s TAFA 9300 to which this declaration relates is are in conformity with the following standard s or other normative document s 1 EMC Directive 89 336 EEC of 3 May 1989 as amended by 92 31 EEC of 28 April 1992 and 93 68 EEC of 22 July 1993 by meeting the provisions of EN50199 EMC Product Standard for Arc Welding Equipment 2 Low Voltage Directive 73 23 EEC of 19 February 1973 as amended by 93 68 EEC of 22 July 1993 by meeting the provisions EN60974 1 Safety requirements for arc welding equipment Part 1 Welding Power Sources IEC 974 1 1989 and the Draft Revision IEC 974 1 of October 1996 23 April 1999 Wayne Beisner Director of Engineering Welding Equipment 193111 023 Table of Contents INTRODUCTION How To Use This Manual 1 1 Equipment Identification 1 1 Receipt Of Equipment dove Wem Rem Yee wv 1 1 Meanings Of Markings And Graphical Symbols 1 1 ARC SPRAYING SAFETY INSTRUCTIONS AND WARN
4. 3 1 193111 023 DESCRIPTION OF EQUIPMENT TAFA 9300 ITEM 100006 1 Rated Output Amperage 350 A Rated Output Voltage 34 V Rated Duty Cycle 100 Maximum Open Circuit Voltage 35 V Rated Input Voltage 200 230 400 460 575 V Operating Input Voltage Range 200 180 to 220 V 230 207 to 253V 400 360 to 440 V 460 415 to 506 V 575 517 5 to 632 5 V Rated Input Amperage 50 44 25 22 18 at 350 amp rating Input kW 15 7 KW at 350 amp rating Input Frequency 50 60 Hz Input Phase Three Phase Table 3 1 Machine Specifications for 100006 1 6 6 P Ba NE BABE iT SE ii 58 __ d Py E TN 9 16 1 8 40mm 7 35 22 44 787mm 565mm TAFA 9300 Weight 368 ibs 167 kg Figure 3 2 Dimensions and Weight Information 3 2 July 30 1997 193111 023 DESCRIPTION OF EQUIPMENT E E 50 100 150 200 250 500 350 VOLTS N AMPS DC INPUT 230 VOLTS 3 PHASE 60 HZ Figure 3 3 Volt Amp Curve July 30 1997 3 3 TRANSFORMER TERMINAL 193111 023 DESCRIPTION OF EQUIPMENT TERMINAL STRIP OVERLOAD THERMOSTAT MAIN POWER INPUT CONTACTOR TE ENT CONTROL PC CONTROL BOARD OUTPUT SCR SCR1 SCR3 T2 OUTPUT RECTIFIER CR1 CR4
5. STRIP TB1 1 2 CIRCUIT BREAKER 115 VOLTS TERMINAL STRIP TB1 12 amp 13 STABILIZER FILTER L1 L2 C1 C6 Functional Block Diagram for TAFA 9300 July 30 1997 TB1 3 TB1 10 193111 023 INSTALLATION INSTALLATION Location For best operating characteristics and longest unit life take care in selecting an installation site Avoid locations exposed to high humidity dust high am bient temperature or corrosive fumes Moisture can condense on electrical components causing corro sion or shorting of circuits Dirt on components helps retain this moisture Adequate air circulation is needed at all times in order to assure proper operation Provide a mini mum of 12 inches 305 mm of free air space at both front and rear of the unit Make sure that the ventila tor openings are not obstructed Grounding The frame of this power source should be grounded for personnel safety Where grounding is mandatory under state or local codes it is the re sponsibility of the user to comply with all applicable 20 30 ibs 9 1 13 6 kg Soil Treating Material copper sulphate magnesium sulphate or rock sait in circular trench and covered with earth Grounding Conductor lt het ey Approx Ft 305 18 Inches 457 mm Approx Ground er a Figure 4 1 Outside Ground asten Grounding Conductor to the
6. times when making original installation See Figure 4 1 Treating An Inside Ground Reduce the diameter of the hole to 6 inches 152 mm pour soil treating material in and around the rod Add enough water to dissolve 8 pounds 4 0 kg of soil treating material Flood the hole every 6 months and replace the soil treating material when it is all dissolved See Figure 4 2 Connection To Line Voltage Refer to Table 4 1 for wire sizes required CAUTION Conductor size shall be se lected to meet NEC CE Code and local codes and shall be modified as required for line voltage drop and ambient tem perature This power source operates on a three phase AC input See nameplate of the machine to determine required input voltage and frequency Make certain that the power source is connected for the power supply voltage available The input power cables should be connected to the power supply through a fused disconnect switch furnished by the cus tomer Refer to the identification nameplate to de termine the rating of the machine then consult the local power company for wire and fuse size code If no code exists use the size of wire fuses listed in Table 4 1 Ground Line Input Wire Size Wire Size Voltage AWG AWG Lag Fuse Rating es 9300 9300 200 8 8 60 230 8 8 60 400 12 12 30 460 12 12 30 575 12 12 30 Input conductor sizes are based on allowable amp
7. THE INSTALLATION SECTION OF THE MANUAL 4 CONNECT THE THREE PHASE POWER UNE TO THE LINE CONTACTOR LOCATED ON THE BASE CAUTION HE CERTAIN INPUT CIRCUIT IS OPEN BEFORE HANDLING LINE 5 CONNECT THE POWER SYSTEM GROUND 10 THE SCREW ON THE BASE NOTES 1 FOR PRIMARY AND SECONDARY CONNECTION DIAGRAM AND SCHEMATIC SEE 204093 FOR THE 350 2 INPUT CABLE CONNECTIONS ARE TYPICAL 10 ALL FIGURES SHOWN 2 Es EEE E Q 3 ANY CHANGES 10 THIS DRAWING MUST BE REFLECTED ON DRAWNG 204491 m Fase CODE PER 80020 Tu i a RES GND SCREW ON BASE 204084 12 8 97 La 4 r3 PARS VOLL CONTROL TRANSFORMER ON YOKE m s um iion M E Bay 8 06 1 NONE mi ait diem 55 1 4 92 T 204094 Eee CAE ER ER E NOXIA 5 T E T 3 1
8. The fan motor incorporates sleeve bearings You can expect the life of this motor to exceed 50 000 hours without relubrication Periodically cleaning the motor and lubricating the bearings will extend the life of the motor The following table will furnish a recommended guide as to the frequency of this lubrication if desired TYPE OF DUTY LUBRICATION INTERVAL Light up to 6 hrs day Every 12 mo Moderate 7 to 15 hrs day Every 6 Heavy 16 24 hrs day Every 3 mo NOTE Apply 1 12 drops of 20Wnon deter gent oil at each end of bearing Inspection and Cleaning For uninterrupted satisfactory service from this power source it is necessary to keep the machine clean dry and well ventilated At least every three months or more often as necessary wipe and blow out all dirt from the machine s internal components with air pressure of not over 25 psi 172 kPa Be sure to wipe the fan blades clean Check and tighten all electrical connections as necessary to eliminate unnecessary losses and to avoid subsequent trouble from overheating or open circuits Check for broken wiring or damaged insu lation on wiring WARNING Disconnect line voit age from the unit before at tempting any servicing inside unit Turn off fused disconnect switch that supplies power to power source and remove its fuses CAUTION The flow of air through the power source is carefully directe
9. 12 K TO CONTROL A BOARD 1 13 POSINVE CR4 R2 8 c 6 CONTROL p o NEGATIVE B ca 8 200 230 200 230 200 400 400 460 375 BOARD 10 TBi 9 o NOT USED lt 2 EE CONTROL BOARD x2 1 lt 1 1 1 1 2 4 D EU 3 c NOT USED 4 5 24 VAC 051 1 7 lt 8 lt lt 10 lt 1 3 lt 94 1 2 11 lt J2 1 LQ 1 5 2 2 1 6 o lt 12 3 lt 1 7 14 POTENTIOMETER 42 6 A J3 1 J3 POWER 5 ON OFF sem LED E 7221109 5083 TB1 3 POWER SOURCE lt 13 3 J3 9 X 4 f 3 46 TB1 5 5 REMOTE SNS lt 2 6 13 6 158 TEST 1 7 lt 7 81 8 VOLTMETER TB1 9 TB1 10 VOLT AMPMETER TB1 11 ARC ESTABUSH UU CHANGE RECORD 1 12 ORE ep T eene a TB1 13 115 VOLTS AC
10. N utilisez que des bouteilles de gaz protecteur des d tendeurs des boyauxs et des raccords con us pour chaque application sp cifique ces quipements et les pi ces connexes doivent tre maintenus en bon tat Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation Lisez et respectez les consignes relatives aux bouteilles de gaz comprim et aux quipements connexes ainsi que la publica tion P 1 de la CGA identifi e dans la liste de documents ci dessous LES MOTEURS PEUVENT ETRE DANGEREUX Utilisez l quipement l ext rieur dans des aires ouvertes et bien ventil es Si vous utilisez ces quipements dans un endroit confin les fum es d chappement doivent tre envoy es l ext rieur loin des prises d air du b timent d tincelles ou d une flamme nue Si c est possible laissez le moteur refroidir avant de faire le plein de carburant ou d en v rifier le niveau au d but du soudage Ne faites pas le plein de carburant ras bord pr voyez de l espace pour son expansion Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur 8 V 96 2 3 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC instruction 830002 DES PIECES EN MOUVEMEN
11. Precautionary Static Base Plate Mtg Caster Caster Brace Support Axle Rear Axle Steel Washer FL ST 3 4 Wheel Pin Cotter 1 16 x 1 1 2 Panel Side Left Capacitor Electrolytic Clamp Cap Mtg Bar Bus Choke Filter Assembly Input Contactor Line Transformer Power Assembly 193111 023 PARTS LIST Qty per Assy ss BK KR OD NN A gt N Naana RON A gt HS HP ABD gt DY 193111 023 PARTS LIST Parts List for Figure 7 1 Quantity Item Part Description Qty Spares No Number per Class 1 Class 2 39 204090 1 Board Voltage Control 1 40 204091 Bracket Mounting 1 41 CW 811 Link Voltage Changeover 9 42 830130 1 Transformer Control 1 43 W 11166 11 Fuse 1 2 A 1 44 204077 Choke Filter 1 45 204066 Panel Rear 1 46 203785 Bracket Mounting 2 47 409870 Washer Insulating 8 48 409869 Bushing Insulating 8 49 404044 7 Thermostat Overload 1 50 204375 Suppressor Surge Assembly 1 51 405140 1 Clamp Mounting 3 52 203776 1 Bar Bus 3 53 405139 Rectifier Silicon Controlled 3 54 16DA 954 12 Pin Spring 3 55 203779 Heat Sink Top 1 56 8RT 609 Fan 1 57 830121 Bracket Mtg Motor 1 58 12TW 595 1 Motor Fan 1 59 402833 3 Diode Silicon Neg Base 1 60 W 10933 3 Diode Silicon Neg Base 3 61 830120 Heat Sink 1 62 201751 1 Bra
12. Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 May 11 1998 2 3 ARC SPRAYING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001A This page intentionally left blank 2 4 May 11 1998 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC Instruction 830002 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC MISE EN GARDE LE SOUDAGE A L ARC EST DANGEREUX PROTEGEZ VOUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT NE LAISSEZ PAS LES ENFANTS S APPROCHER NI LES PORTEURS DE STIMULATEUR CARDIAQUE A MOINS QU ILS N AIENT CONSULTE UN MEDECIN CONSERVEZ CES INSTRUCTIONS LISEZ LE MANUEL D OPERATION OU LES INSTRUCTIONS AVANT D INSTALLER UTILISER OU ENTRETENIR CET EQUIPEMENT Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de m me que des dommages au reste du mat riel et la propri t si l utilisateur n adh re pas strictement toutes les regles de s curit et ne prend pas les pr cautions n cessaires En soudage et coupage des pratiques s curitaires se sont d velopp es suite l exp rience pass e Ces pratiques doivent tre apprises par tude ou entrainement avant d utiliser l equipement Toute personne n ayant pas suivi un entrainement intensif en soudage et coupage ne devrait pas tenter de souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que
13. any cylinder Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve 1 Protect compressed gas cylinders from excessive heat me Keep protective cap in place over valve except when cylinder is chanical shocks and arcs in use or connected for use 2 Install and secure cylinders in an upright position by chaining Read and follow instructions on compressed gas cylinders them to a stationary support or equipment cylinder rack to associated equipment and CGA publication P 1 listed in Safety prevent falling or tipping Standards A WARNING ENGINE EXHAUST GASES can kill Use equipment outside in open well ventilated areas 2 Kf used in a closed area vent engine exhaust outside and away from any building air intakes Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding proc ess be sure to treat them carefully Engines produce harmful exhaust gases ENGINE FUEL can cause fire or Do not add fuel while smoking or if unit is near any sparks or explosion open flames Allow engine to coo before fueling If possible check and add fuel to cold engine before beginning job Do not overfill tank allow room for fuel to expand Do not spill fuel if
14. be set at 4 mark This corresponds to the VE3000 VE2500 section on the gauge label Examples Top edges lined up 488 Excessive force Loosen both nuts and start over 1 4 turn at a time NEVER adjust until points coin force by backing cide off the nuts Fric tion will produce a false reading Always start from Step 1 Correct rated force Less than rated force Tighten nuts alternately Figure 6 2 July 30 1997 6 1 193111 023 TROUBLESHOOTING To Calibrate Force Gauge gauge is suspected of being out of calibration due to wear or damage check it on a flat surface as shown below True flat surface or straight edge If the calibration edges do not line up calibrate the gauge by filing the bottom contact points Figure 6 3 Testing Procedures Printed Circuit Board See Figure 6 4 Test point 3 3 is the common ground and the negative probe should be connected to this point unless otherwise specified All test readings are based on the line voltage supply being within speci fications that is not exceeding 1096 of nominal line voltage For example on a 460 volt 3 phase line the line voltage must not exceed 506 volts or be less than 414 volts Adjustments Preset at factory The following describes the factory adjustments It is not intended that the adjustments be made in the field Refer to Figure 6 4 fo
15. d autres s adressent aux groupes lectrog nes La norme 249 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce document ainsi que d autres guides que vous devriez conna tre avant d utiliser cet quipement sont pr sent s la fin de ces instructions de s curit SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE REPARATION D ENTRETIEN ET D ESSAI 6 Arr tez tout quipement apr s usage Coupez l alimentation de l quipement s il est hors d usage ou inutilis 7 N utilisez que des porte lectrodes bien isol s Ne jamais plon ger les porte lectrodes dans l eau pour les refroidir Ne jamais les laisser trainer parterre ou sur les pi ces souder Ne touchez pas aux porte lectrodes raccord s deux sources de courant en m me temps Ne jamais toucher quelqu un d autre avec l lectrode ou le porte lectrode 8 N utilisez pas de c bles lectriques us s endommag s mal piss s ou de section trop petite N enroulez pas de c bles lectriques autour de votre corps N utilisez qu une bonne prise de masse pour la mise la terre de la pi ce souder Ne touchez pas l lectrode lorsqu en contact avec le circuit de soudage terre 12 N utilisez que des quipements en bon tat R parez ou rem placez aussit t les pi ces endommag es 13 Dans des espaces confin s ou mouill s n utilisez
16. escape before completely removing cap pressure 2 2 May 11 1998 ARC SPRAYING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001A NOTE Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields The following is a quotation from the General Conclusions Section ofthe U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper 63 Washington DC U S Government Printing Office May 1989 there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields can interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around the body About Pacemakers 4 Keep welding
17. or watching Eye protection filter shade selector for welding FUMES AND GASES can be hazardous to your health Arc spraying produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breath the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases WELDING can cause fire or explosion Sparks and spatter fly off from the arc spray The flying sparks and hot metal spatter hot workpiece and hot equipment can cause fires and burns Protect yourself and others from flying sparks and hot metal Do not spray where flying sparks can strike flammable material May 11 1998 Properly install and ground this equipment according to its Owner s Manual and national state and local codes Turn off all equipment when not in use Disconnect power to equipment if it will be left unattended or out of service Donotuse worn damaged undersized or poorly spliced cables Do not wrap cables around your body Useonly well maintained equipment Repair or replace damaged parts at once Wear a safety harness to prevent falling if working above floor level Keep all panels and covers securely in place Wear approved safety glasses Side shields recommended Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Wear protecti
18. pas de source L ELECTROCUTION PEUT ETRE MORTELLE Une d charge lectrique peut tuer ou br ler grave ment L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le circuit d alimenta tion et les circuits internes de l quipement sont aussi sous tension d s la mise en marche soudage automatique ou semi automatique avec fil ce dernier le rouleau ou la bobine de fil le logement des galets d entrainement et toutes les pi ces m talliques en contact avec le fil de soudage 9 sont sous tension Un quipement inad quatement 10 install ou inad quatement mis la terre est dangereux 1 Ne touchez pas des pi ces sous tension 11 2 Portez des gants et des v tements isolants secs et non trou s 3 Isolez vous la pi ce souder et la mise la terre au moyen de tapis isolants ou autres 4 D connectez la prise d alimentation de l quipement ou arr tez 1 le moteur avant de l installer ou d en faire l entretien Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de Fali mentation afin d viter une mise en marche accidentelle Veuillez installer cet quipement et le mettre la terre selon le manuel d utilisation et les codes nationaux provinciaux et locaux applicables LE RAYONNEMENT DE L ARC PEUT BRULER LES YEUX ET LA PEAU LE BRUIT PEUT ENDOMMAGER L OUIE L arc de soudage produit une chaleur et des rayons ultraviolets i
19. power source and cables as far away from body as practical 5 Connect work clamp to workpiece as close to the weld as possible The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete information PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Heaith Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis High way Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Pro tection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding
20. Assurez vous que l air est dangereuses respirer propre la respiration 6 Ne soudez pas proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc 1 Eloignez la t te des fum es pour viter de les respirer peuvent r agir avec des vapeurs et former des gaz hautement 2 l int rieur assurez vous que l aire de soudage est bien ven toxiques et irritants til e ou que les fum es et les vapeurs sont aspir es l arc 7 Ne soudez des 161 5 galvanis es ou plaqu es au plomb ou au 3 Sila ventilation est inadequate portez un respirateur adduc cadmium que siles zones souder ont t gratt es fond que tion d air approuv Si l espace est bien ventil si n cessaire portez un respirateur 4 Lisez les fiches signal tiques et les consignes du fabricant adduction d air Car ces rev tements et tout m tal qui con relatives aux m taux aux produits consummables aux rev te tient ces l ments peuvent d gager des fum es toxiques au ments et aux produits nettoyants moment du soudage 2 2 8 V 96 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC instruction 830002 LE SOUDAGE PEUT CAUSER UN IN CENDIE OU UNE EXPLOSION L arc produit des tincellies et des projections Les particules volantes le m tal chaud les projections de soudure et l quipement surchauff peuvent causer un incendie et des br lures Le contact accidente
21. INGS 2 DESCRIPTION OF EQUIPMENT 3 Controls and Outlets MO man MARNE EAE ER es 3 1 INSTALLATION 4 LOCATION o REESE E eI GS HE ne quies 4 1 GroundlDgio d eoo BP uela e nerd SS d zr sew 4 1 Connection To Line Voltage 4 2 Input Connections To Power Source 4 3 MAINTENANCE 5 Exchange Service Policy 5 1 Replacing SCRS ooo oe esee repu Sed ne ae et 5 1 P bricatiofi 9 de Mee ct pe ne 5 1 Inspection and Cleaning 5 1 TROUBLESHOOTING 6 Detailed Troubleshooting Instructions 6 1 PARTS LIST 7 Equipment Identification 7 1 How 1o Use This Parts List 3 am es yao ok ro o Lok dut ve 7 1 How To Select Recommended Spares 7 1 DIAGRAMS December 10 1997 Revised 193111 023 INTRODUCTION INTRODUCTION How To Use This Manual This Manual usually applies to just the underlined specification or part numbers listed on the cover If none are underlined they are cov ered by this manual To ensure safe operation read the entire manual including the chapter on Safety Instructions and Warnings Throughout this manual the words WARNING CAUTION and NOTE may ap
22. RECOCHITD STAMDARIS TRE ausa DIAGRAM CONNECTION 1 ESPN eee NE Lip 9300 EUROPEAN LE C MODEL 041 DES RAT Enr pid 00 Amm RGS BAJ 5 3 97 FULL A 90 4 00 aoga owm penaa simi DG NOT SCALE DRAWING 6 8 97 4 at Maman on sm om SHEET i OF 2 ered thereon the cie and contra papery of TA Hee Harp 0980 Dis coving obe dares to 1 850138 3 T 2 T 1 12 1 M 1 19 LEGEND B FAN MOTOR 1 6 CAPACITOR 57 000 MFD 35V DC 67 11 GAPACITOR 047 MFD 400V 12 CAPACITOR 01 MFD 400V DC CIRCUIT BREAKER 10 CRI 3 DIODE NEG BASE 160 AMP DIODE NEG BASE 150 AMP DSi LIGHT EMITTING DIODE YELLOW OVER TEMPERATURE WARNING LIGHT F1 FUSE CONTACTOR 3 A RECEPTACLE 10 PIN CONTROL BOARD J2 RECEPTACLE 6 PIN CONTROL J3 RECEPTACLE 11 PIN CONTROL BOARD K1 CONTACTOR INPUT u CHOKE 12 INPUT RI SHUNT 400 AMP 50MV R2 5 RESISTOR 10 OHM 100w R6 8 RESISTOR 50 OHM 5W R9 11 RESISTOR 680 OHM 3 25W st THERMOSTAT SCRI 3 RECTIFIER SILICON CONTROLLED n TRANSFORMER POWER T2 TRANSFORMER CONTROL TB TERMINAL BLOCK 14 10 n TB1
23. SPECIFICATION NUMBER 100006 001 July 30 1997 7 1 193111 023 PARTS LIST Figure 7 1 7 2 February 14 2000 Revised Quantity Recomm Item Part Spares No Number Class 1 Class 2 100006 1 1 204078 2 830132 3 830133 4 830131 1 5 405072 1 6 405734 7 368705 8 8 204087 9 204079 10 W 10080 2 11 203756 1 12 203909B 2 13 404460 1 14 490545 15 402037 9 16 401937 8 17 404400 18 203627 7 19 AAW 1199 20 16DA 3493 21 405154 6 22 204036 23 204068 24 203047 5 25 403702 1 26 204076 27 203052 28 201607 12 29 No Number 30 405054 4 31 No Number 32 830134 33 405278 13 34 361052 10 35 204092 36 203885 37 830726 1 38 204154 February 14 2000 Revised These parts are shown in relationship to their location in the machine but they are all part of Carryall 910230B 10 Parts List for Figure 7 1 Description Power Source Assembly Spacer Panel Top Panel Side Right Panel Front Control Diode Light Emitting Clip Retaining Capacitor W Leads and Term Cable Assembly Catch Spring Connector Straight Bracket Mounting Board P C Control Assembly Support P C Board Spacer Grommet Rubber Strip Terminal 14 Station Nameplate Terminal Strip Circuit Breaker Pushbutton Bracket Mounting Resistor Washer Insulator Resistor Fixed 100 W Label
24. T PEU 3 Seules des personnes qualifi es doivent d monter des protec VENT CAUSER DES BLESSURES teurs ou des capots pour faire l entretien ou le d pannage n cessaire Pour emp cher un d marrage accidentel pendant l entretien d branchez le c ble d accumulateur la borne n gative 5 N approchez pas les mains ou les cheveux de pi ces en mou vement elles peuvent aussi accrocher des v tements amples et des outils 1 Assurez vous que les portes les panneaux les capots et les 6 R installez les capots ou les protecteurs et fermez les portes protecteurs soient bien ferm s apr s des travaux d entretien et avant de faire d marrer le 2 Avant d installer ou de connecter un syst me arr tez le moteur moteur Des pi ces en mouvement tels des ventilateurs des 4 rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples DES ETINCELLES PEUVENT FAIRE EX Portez toujours un cran facial en travaillant sur un accumu PLOSER UN ACCUMULATEUR lateur L ELECTROLYTE D UN ACCUMU 2 Arr tez le moteur avant de connecter ou de d connecter des LATEUR PEUT BRULER LA PEAU ET c bles d accumulateur LES YEUX 3 N utilisez que des outils anti tincelles pour travailler sur un accumulateur 4 N utilisez pas une source courant de soudage pour charger Les accumulateurs contiennent de l lectrolyte un accumulateur ou survolter momentan ment un
25. T POINTS POT VOLTAGE REMARKS 1 TP2 30 10 Checks positive supply voltage Checks R60 fuse to power suppl 2 __ 1 s 15 75 Checks voltage regulator TP4 Adjusts phase balance of all TP5 R12 Same as TP4 three phases 6 R13 4 TP8 TP3 400 Amps 5V Checks shunt amplifier x 10 Table 6 1 July 30 1997 6 3 193111 023 TROUBLESHOOTING This page intentionally left blank 6 4 July 30 1997 193111 023 PARTS LIST PARTS LIST Equipment Identification Allidentification numbers as described in the Intro duction chapter must be furnished when ordering parts or making inquiries This information is usually found on the nameplate attached to the equipment Be sure to include any dash numbers following the Specification or Assembly numbers How To Use This Parts List The Parts List is a combination of an illustration Figure Number and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts All parts ofthe equipment are listed except for commer cially available hardware bulk items such as wire cable sleeving tubing etc and permanently at tached items which are soldered riveted or welded to another part The part descriptions may be in dented to show part relationships To determine the part number description quan tity or application of an item simply locate the i
26. acities of insulated copper conductors with not more than three conductors in a raceway or cable Table 4 1 Recommended Wire and Fuse Sizes 4 2 July 30 1997 193111 023 INSTALLATION Input Connections To Power Source WARNING The fused discon nect switch Open or place in the OFF position and remove the fuses To avoid an accident make the electric power con nections to the power source first then to the fused discon nect switch This will prevent an accidental application of power while the machine is being con nected 1 A line wall disconnect switch with fuses or circuit breakers should be provided at the main power panel see Figure 4 3 The primary power input must have four insulated copper conductors three power leads and one ground wire The wires may be heavy rubber covered cable or may be run in a solid or flexible conduit Do not connect the input conductors until step 3 2 For access to input terminal board remove the screws which secure the right side panel of the power supply The input terminal board Figure 4 3 is clearly marked to show the available primary voltage connections which may be used Set the voltage links on this board to match your actual incoming voltage As shipped from the factory the input terminal board voltage links are set up for the highest line voltage 3 Thread the input conductor cables from the wall disconnect switch through the hole in the
27. cket Mounting Motor 1 63 No Number Nut 1 2 13 Hex Flanged ST 2 64 5CW 974 Bar Bus 2 65 5CW 975 Bushing Insulator 2 66 5CW 976A Washer Insulating 4 67 No Number Washer Flat ST 1 2 3 68 No Number Washer LK Std 1 2 5 69 No Number Screw 1 2 13 x 1 3 4 HHC ST 2 70 351505 Screw 1 2 13 x 1 3 4 ST Drilled for Item 72 1 71 No Number Washer LK Std 46 1 72 No Number Screw 6 32 x 3 8 Rd Hd MH ST 1 73 CW 1142A Shunt 50 400 Amp 1 405548 Label Frame Ground 1 408891 Label Ground 1 74 No Number Screw 1 2 13 x 1 HHC ST 1 75 204491 Label Voltage Changeover 1 76 830175 Shield Heat 1 Not Illustrated 7 4 February 14 2000 Revised 193111 023 DIAGRAMS DIAGRAMS e Note the model and specification number shown on the equipment nameplate Locate these numbers in the model and specification number columns below e Use only those diagrams and instructions that are applicable VOLTAGE MODEL SPECIFICATION CONNECTION SCHEMATIC CHANGEOVER NUMBER NUMBER DIAGRAM DIAGRAM DIAGRAM TAFA 9300 100006 1 830138 830138 204094 Sheet 1 Sheet 2 July 30 1997 PRIMARY LEADS 1A 7A amp 18 TO 78 TO CHANGE OVER BOARD L CONTROL BOARD
28. d by baffles Never operate the power source with any of the side or top panels re moved or open as serious damage to the rectifiers might result July 30 1997 5 1 193111 023 MAINTENANCE This page intentionally left blank 5 2 July 30 1997 193111 023 TROUBLESHOOTING TROUBLESHOOTING Detailed Troubleshooting Instructions Mounting Procedure for SCRs 1 Thoroughly clean heat sink surface to eliminate any dirt or contamination 2 Apply a thin coat of Alcoa 2 compound to cleaned surface Alcoa 2 is available from Prestolite Power Corporation part number 903870 3 Positively locate the SCR in place in the heat sink A small spring pin in the extruded heat sink will locate the SCR 4 Place the clamp in position with the bolts through the holes in the heat sink and proceed in following manner 5 Tighten the nuts evenly until finger tight Force Gage shown in position 903878 Clamp 405140 Heat Sink Heat Sink Figure 6 1 6 Tighten each bolt in 1 4 turn increments using correct size hex key 7 Placethe Force Indicator Gauge 903878 firmly against the springs as shown Be sure both ends and the center are in firm contact with the springs The gauge notch location will indicate the spring deflec tion or force Correct mounting force is indicated as shown below 8 Spring deflection over 2 1 4 inches of spring is 037 002 for all clamps 9 All clamps to
29. e au outes conditions Brasage fort au chalumeau toutes conditions 3 ou 4 Oxycoupage mince moins de 1 po 25 mm 2ou3 moyen de 1 6 po 25 150 mm 4005 plus 6 po 150 mm 5ou6 Soudage aux gaz mince moins de 1 8 po 3 mm 4005 de 1 8 1 2 po 3 12 5 ou 6 pais plus de 1 2 po 12 mm 60u8 Soudage l arc avec moins de 5 32 po 4 mm 10 electrode enrob es SMAW de 5 32 1 4 po 4 6 4 mm 12 plus de 1 4 po 6 4 mm 14 Soudage l arc sous gaz avec fil plein GMAW m taux non ferreux toutes conditions 11 m taux ferreux toutes conditions 12 Soudage l arc sous gaz avec lectrode de tungst ne GTAW toutes conditions 12 Soudage l hydrog ne atomique AHW toutes conditions 12 Soudage l arc avec lectrode de carbone CAW toutes conditions 12 Soudage l arc Plasma PAW toutes dimensions 12 Gougeage Air Arc avec lectrode de carbone mince 12 pais 14 Coupage l arc Plasma PAC mince moins de 300 amp res 9 moyen de 300 400 12 pais plus de 400 amp res 14 LES VAPEURS ET LES FUMEES SONT 5 Ne travaillez dans un espace confin que s il est bien ventil DANGEREUSES POUR LA SANTE sinon portez un respirateur adduction d air Les gaz protec teurs de soudage peuvent d placer de l air et ainsi Le soudage d gage des vapeurs et des fum es causer des malaises ou la mort
30. faire le plein Le piquage et le meulage produisent des particules m talliques M fiez vous des projections brulantes de soudage suscep tibles de p n trer dans des aires adjacentes par de petites ouvertures ou fissures M fiez vous des incendies et gardez un extincteur port e de la main N oubliez pas qu une soudure r alis e sur un plafond un plancher une cloison ou une paroi peut enflammer l autre c t Ne soudez pas un r cipient ferm tel un r servoir ou un baril Connectez le c ble de soudage le plus pr s possible dela zone de soudage pour emp cher le courant de suivre un long par cours inconnu et pr venir ainsi les risques d lectrocution et d incendie Ne d gelez pas les tuyaux avec un source de courant Otezl lectrode du porte lectrode ou coupez le fil au tube con tact lorsqu inutilis apr s le soudage Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque volantes En refroidissant la soudure peut projeter du clats de laitier Portez des v tements appropri s pour prot ger la peau Emp chez tout contact entre une bouteille et une lectrode de Ne faites pas le plein en fumant ou proche d une source Portez un cran facial ou des lunettes protectrices approuv es Des crans lat raux sont recommand s soudage
31. fuel is spilled clean up before starting engine Engine fuel is highly flammable 1 Stop engine before checking or adding fuel MOVING PARTS can cause injury Have only qualified people remove guards or covers for main tenance and troubleshooting as necessary Moving parts such as fans rotors and belts can cut To prevent accidental starting during servicing disconnect fingers and hands and catch loose clothing negative battery cable from battery 1 Keep all doors panels covers and guards closed and securely bai hands hair loose clothing and tools away from moving in place 2 Stop engine before installing or connecting unit Reinstall panels or guards and close doors when servicing is finished and before starting engine SPARKS can cause BATTERY GASES Always wear a face shield when working on a battery TO EXPLODE BATTERY ACID can burn Stop engine before disconnecting or connecting battery cables eyes and skin Do not allow tools to cause sparks when working on a battery Batteries contain acid and generate explosive Do not use welder to charge batteries or jump start vehicles gases Observe correct polarity and on batteries STEAM AND PRESSURIZED HOT Do not remove radiator cap when engine is hot Allow engine to COOLANT can burn face eyes and cool skin Wear gloves and put a rag over cap area when removing cap The coolant in the radiator can be very hot and under Allow pressure to
32. iami FL 33128 1430 Broadway New York NY 10018 National Electrical Code norme 70 NFPA National Fire Protection Cutting and Welding Processes norme 51B NFPA National Fire Association Batterymarch Park Quincy MA 02269 Protection Association Batterymarch Park Quincy MA 02269 2 4 8 V 96 193111 023 DESCRIPTION OF EQUIPMENT DESCRIPTION OF EQUIPMENT This unit is a constant voltage transformer rectifier type DC power source that provides volt ampere characteristic curves that are basically flat Controls and Outlets 1 Circuit Breaker 10 amps Protects the 115 V AC control circuitry 2 Negative Terminal Serves as a connec tion point for the lead to the spray gun 3 Positive Terminal Serves as a connec tion point for the lead to the spray gun The unit is equipped with a terminal strip for con nection the the spray console 18 1 V POWER 9 11 2 ON OFF 2 1 3 1 POWER SOURCE ON OFF 2 TB 5 REMOTE 181 6 f POTENTIOMEIER VOLIMETER 181 9 VOLT AMPMEER 181 10 AMPMEIER g o 1 12 NEUTRAL 13 S NEUTRAL 13 VOLTS AC 14 S GROUND 14 5 Nc 16 n TERMINAL STRIP TB1 amp sa IO em 4 J Figure 3 1 Control Panel July 30 1997
33. l de l lectrode ou du fil lectrode avec un objet m tallique peut provoquer des tincelles un chauffement ou un incendie 1 Prot gez vous ainsi que les autres contre les tincelles et du m tal chaud 2 Ne soudez pas dans un endroit o des particules volantes ou des projections peuvent atteindre des mat riaux inflammables 3 Enlevez toutes mati res inflammables dans un rayon de 10 7 m tres autour de l arc ou couvrez les soigneusement avec des b ches approuv es LES ETINCELLES ET LES PROJEC TIONS BRULANTES PEUVENT CAUSER DES BLESSURES LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommag es peuvent exploser Comme les bouteilles font nor malement partie du proc d de soudage traitez les avec soin Prot gez les bouteilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage Enchainez verticalement les bouteilles un support ou un cadre fixe pour les emp cher de tomber ou d tre renvers es Eloignez les bouteilles de tout circuit lectrique ou de tout soudage MISE EN GARDE LES GAZ D ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs LE CARBURANT PEUR CAUSER UN IN CENDIE OU UNE EXPLOSION Le carburant est hautement inflammable 1 Arr tez le moteur avant de v rifier le niveau de carburant ou de
34. n error Move the equipment to the installation site before uncrating the unit Use care to avoid damaging the equipment when using bars hammers etc to un crate the unit Additional copies of this manual may be pur chased by contacting TAFA at the address given above Include the Owner s Manual number and equipment identification numbers Meanings Of Markings And Graphical Symbols LY Output Control Increase Decrease P Circuit Input Voltage Switch olo Wire Feed 115V AC 10 AMPS Receptacle Rating For Auxiliary Power 193111 023 INTRODUCTION This page intentionally left blank 1 2 July 30 1997 ARC SPRAYING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001A ARC SPRAYING SAFETY INSTRUCTIONS AND WARNINGS 4 WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR DO NOT LOSE THESE INSTRUCTIONS READ OPERATING INSTRUC TION MANUAL BEFORE INSTALLING OPERATING OR SERVICING THIS EQUIPMENT Welding products and welding processes can cause serious injury or death or damage to other equipment or property if the operator does not strictly observe safety rules and take precautionary actions Safe practices have developed from past experience in the use of welding and cutting These practices must be learned thr
35. ntenses susceptibles de br ler les yeux et la peau Le bruit caus par certains proc d s peut endommager l ou e Portez une casque de soudeur avec filtre oculaire de nuance appropri e consultez la norme ANSI Z49 indiqu e ci apr s de courant alternatif moins qu il soit muni d un r ducteur de tension Utilisez plut t une source de courant continu Portez un harnais de s curit si vous travaillez en hauteur Fermez solidement tous les panneaux et les capots pour vous prot ger le visage et les yeux lorsque vous soudez ou que vous observez l ex cution d une soudure Portez des lunettes de s curit approuv es Des crans lat raux sont recommand s Entourez l aire de soudage de rideaux ou de cloisons pour prot ger les autres des coups d arc ou de l blouissement avertissez les observateurs de ne pas regarder l arc Portez des v tements en mat riaux ignifuges et durables laine et cuir et des chaussures de s curit Portezun casque antibruit ou des bouchons d oreille approuv s lorsque le niveau de bruit est lev 8 V 96 2 1 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC Instruction 830002 SELECTION DES NUANCES DE FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE selon AWS 8 2 73 Op ration Dimension d lectrode ou Nuance de de Epaisseur de m tal ou de filtre Coupage ou soudage Intensit de courant oculaire rasage tendr
36. ood electrical contact is made between conductor and frame Connect the other end of the grounding conductor to the system ground If for any reason an input cable which does not include a grounding conductor is used the equip ment may be grounded with a separate conductor if permitted under applicable code or by special permission of the jurisdictional body responsible for enforcement of the code Minimum size and color coding requirements must be in accordance with any applicable state or local code or the National Electrical Code If metallic armored cable or conduit is used the metal sheathing or conduit must be effectively grounded as required by state or local code or the National Electrical Code system ground is not available the power source must be connected to a driven ground rod see Figures 4 1 and 4 2 or to a water pipe that enters the ground not more than 10 feet 3 048 mm from the machine Refer to the Wire and Fuse Size Chart Table 4 1 for selection ofthe proper ground ing conductor NOTE The grounding conductor must be as shortas possible in orderto produce the most efficient installation Treating An Outside Ground The soil treating materials are placed in a circular trench around the rod but not in direct contact The crystals are gradu ally dissolved by surface waters and the solution is carried into the most useful area of earth surround ing the electrode rod Flood the trench several
37. ough study and training before using this equipment Anyone not having extensive training in welding and cutting practices should not attempt to weld Certain of the practices apply to equipment connected to power lines other practices apply to engine driven equipment Safe practices are outlined in the American National Standard 249 1 entitled SAFETY IN WELDING AND CUTTING This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions HAVE ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Disconnect input power or stop engine before installing or serv icing this equipment Lock input power disconnect switch open or remove line fuses so power cannot be turned on accidentally ARC RAYS can burn eyes and skin NOISE can damage hearing Arc rays from the spraying process produce intense heat and strong ultraviolet rays that can burn eyes and skin Noise from some processes can damage hearing 1 Wear a welding helmet fitted with a proper shade of filter see ANSI Z49 1 listed in Safety Standards to protect your face and eyes when thermal spraying
38. pear Pay particular attention to the information provided under these headings These special annotations are easily rec ognized as follows WARNING gives information re garding possible personal in jury Warnings will be enclosed in a box such as this CAUTION refers to possible equipment damage Cautions will be shown in bold type NOTE offers helpful information concern ing certain operating procedures Notes will be shown in italics Equipment Identification The units identification number specification or part number model and serial number usually appear on a nameplate attached to the control panel In some cases the nameplate may be at tached to the rear panel Equipment which does not have a control panel such as gun and cable assem blies are identified only by the specification or part number printed on the shipping container Record these numbers for future reference December 10 1997 Revised Receipt Of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping If there is any damage notify the carrier immedi ately to file a claim Furnish complete information concerning damage claims or shipping errors to TAFA Order Department 146 Pembroke Road Concord New Hampshire 03301 Include all equip ment identification numbers as described above along with a full description of the parts i
39. r reference to P C Board 203909 1 1 Balance Adjustment for Conduction Angle of SCRs The potentiometers R 12 R 13 are used to adjust the balance 2 Arc Establish J 2 plug pins 1 and 6 Pin 6 is common ground Pin 1 will have 15 volts when the output amps is 50 amps R68 adjusts this or more and pin 1 will drop to O volts when with 20 amps or less 6 2 July 30 1997 193111 023 TROUBLESHOOTING el LE 1068295021 O Mg Wel H Buo 11 O HP E QU JO TN 4 ua n Bosco C sanno 95 71 R68 x JO es VU T9 Figure 6 4 ADJUSTING TEST TES
40. rear panel see Figure 4 3 Connect the conductors to termi nals on the input contactor Connect the ground wire to the grounding stud provided on the base near the contactor WARNING is of the utmost importance that the chassis be connected to an approved elec trical ground to prevent acci dental shocking Take care not to connect the ground wire to any of the primary leads 4 Recheck all connections to make sure that they are tight well insulated and that the proper connec tion has been made July 30 1997 4 3 193111 023 INSTALLATION Place links in proper position based on input voltage value INPUT LINE CONTACTOR MOUNTED ON BASE 5 INPUT CABLE CONNECTIONS GROUND CONNECTION ON BASE SHOWN CONNECTED FOR 200V CONTROL TRANSFORMER MOUNTS ON POWER TRANSFORMER YOKE Figure 4 3 Input Voltage Connection amp Changeover 4 4 July 30 1997 193111 023 MAINTENANCE MAINTENANCE Exchange Service Policy See Solid State Electrical Control Module Ex change Service Policy included in this manual Replacing SCRs The provisions of the Exchange Module included in this manual are extended to cover the complete SCR assembly Replacing an SCR is a critical task but it can be accomplished in the field by following the instructions in the Detailed Troubleshooting In structions section located in the Troubleshooting chapter of this manual Lubrication
41. rod with an approved ground clamp Not less than 8 Ft 2438 mm rules and regulations Where no state or local codes exist it is recommended that the National Electrical Code be followed Refer to Table 4 1 for wire sizes The requirements and recommendations for grounding apply to rubber tire mounted equipment In addition to the usual function of protecting per sonnel against the hazard of electrical shock due to fault in the equipment grounding serves to dis charge the static electrical charges which tend to build up on the surfaces of mounted equipment These static charges sometimes cause painful shock to personnel and in some instances lead to the erroneous conclusion that an electrical fault exists in the equipment Use an input power cable assembly which in cludes a grounding conductor to connect this equipment to the input power supply When in cluded in the cable assembly the grounding con ductor will be green or green with a yellow stripe or bare Connect the grounding conductor to the Fasten Grounding Conductor Grounding to the rod with an approved Conductor ground clamp Removable Cover Floor Not less than B Ft 2438 mm 5 e Soil SS Treating S ES Material D 6 Inches 152 mm Approx Figure 4 2 Inside Ground July 30 1997 4 1 193111 023 INSTALLATION equipment grounding terminal if provided and if not to the equipment frame taking care to see that g
42. tem in question from the illustration and refer to that item number in the corresponding Parts List An Application Code is used to distinguish parts that are applicable only to certain Specifications and or Assemblies This code is found in the right most column of the Parts List If an item in the Parts List applies to all Specifications or Assemblies the word ALL will be in the Application Code column Refer to the following list to determine the appro priate Application Codes for the Specifications or Assemblies covered by this manual If only the assembly or specification number is listed the use of an Application Code does not apply to this manual How To Select Recommended Spares The first two columns of the Parts List are used to show the recommended quantity of parts which are typically required for spares or replacement purposes The quantities under Class 1 are for parts that are consumed or that may need replace ment in two years or less depending on operating hours Class 2 quantities are for parts that may need replacement under unusual service condi tions or additional operating hours These are sug gested quantities based on expected usage or the minimum package quantity Class 1 spares are repeated under Class 2 but the quantities may be larger to allow for additional operating hours Con tact your equipment dealer for assistance in estab lishing the spare parts program best suited for your needs
43. v hicule acide et d gagent des vapeurs explosives 5 Utilisez la polarit correcte et de l accumulateur LA VAPEUR ET LE LIQUIDE DE RE N tez pas le bouchon de radiateur tant que le moteur n est pas FROIDISSEMENT BRULANT SOUS refroidi PRESSION PEUVENT BRULER LA Mettez des gants et posez un torchon sur le bouchon pour ter PEAU ET LES YEUX Laissez la pression s chapper avant d ter compl tement le bouchon Le liquide de refroidissement d un radiateur peut tre br lant et sous pression PRINCIPALES NORMES DE SECURITE Safety in Welding and Cutting norme ANSI 749 1 American Weld Safe Handling of Compressed Gases in Cylinders document P 1 ing Society 550 N W LeJeune Rd Miami FL 33128 Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Safety and Health Standards OSHA 29 CFR 1910 Superintendent of Documents U S Government Printing Office Washington D C Code for Safety in Welding and Cutting norme CSA W117 2 Asso 20402 ciation canadienne de normalisation Standards Sales 276 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances Safe Practices for Occupation and Educational Eye and Face Pro norme AWS F4 1 American Welding Society 550 N W LeJeune Rd tection norme ANSI Z87 1 American National Standards Institute M
44. ve clothing made from durable flame resistant material wool and leather and foot protection Use approved ear plugs or ear muffs if noise level is high If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manu facturers instruction for metals consumables coatings and cleaners Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Shielding gases used for spraying can displace air causing injury or death Be sure the breathing air is safe Remove all flammables within 35 ft 10 7 m of the spray arc If this is not possible tightly cover them with approved covers Be alert that sparks and hot materials from arc spray can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap 2 1 ARC SPRAYING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001A FLYING SPARKS AND HOT METAL can Wear approved face shield or safety goggles Side shields cause injury recommended Chipping and grinding cause flying metal Wear proper body protection to protect skin CYLINDERS can explode if damaged Keep cylinders away from any welding or other electrical cir cuits Never allow a welding electrode to touch
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