Miller INTELLIMATIC S-52M Owner's manual

INTELLIMATIC S-52M
Miller
Brand
Miller
Model
INTELLIMATIC S-52M
Category
Welding System
Type
Owner's manual

This manual is also suitable for

January
1984
FORM:~
OM-1547
tî‚”e
MANUAL
Effective
With
Serial
No.
J0669606
MODEL
INTELLIMATICrM
S52M
INTELLIMATICTM
S54M
INTELLIMATICTM
PROCESS
SELECTOR
CONTROL
I11IHER
~
S
î‚‘~.
~
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON,
WI
54912
USA
OWN
ERî‚’S
PAINTEt)
IN
U.S.A.
q~p
î‚‘L-
q~p
~
LIMITED
WARRANTY
EFFECTIVE:
JUNE
1.
1979
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY-Subject
to
the
terms
and
conditions
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
submitted
by
the
original
user
within
the
foregoing
periods.
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
furnished
by
Miller
is
free
from
defect
in
workmanship
and
In
the
case
of
Millerî‚’s
breach
of
warranty
or
any
other
duty
material
as
of
the
time
and
place
of
delivery
by
Miller.
No
war-
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
ranty
is
made
by
Miller
with
respect
to
engines,
trade
ac-
therefore
shall
be,
at
Millerî‚’s
option
(1)
repair
or
(2)
replacement
cessories
or
othe~
items
mar~ufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(31
engines,
trade
acce~sories
and
other
items
are
sold
subject
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of
thî‚’~ir
respective
manufacturers,
if
any
.
All
Miller
service
station
or
(41
payment
of
or
credit
for
the
purchase
~î‚‘
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
(less
reasonable
depreciation
based
upon
actual
usel
upon
date
of
original
purchase.
return
of
the
goods
at
Customerî‚’s
risk
and
expense.
Upon
receipt
I
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
clai-
~
Except
as
specified
below,
Millerî‚’s
warranty
does
not
appl~
mant
on
the
warranty
cI~im
procedures
to
be
followed.
to
components
having
normal
useful
life
of
less
than
one
Ill
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
MILLERMATIC
parts
that
come
in
contact
with
the
welding
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA-
?
wire
including
nozzles
and
nozzle
insulators
where
failure
does
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
not
result
from
defect
in
workmanship
or
material.
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,.
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
Miller
shall
be
required
to
honor
warranty
claims
on
war-
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
within
the
following
periods
from
the
date
of
delivery
of
Equip-
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
(î‚‘
ment
to
the
original
user:
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EX
CLUDED
AND
DISCLAIMED
BY
MILLER.
1.
Arc
welders,
power
sources
and
components
.
.
1
year
2.
Original
main
power
rectifiers
3
years
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
(labor
-
1
year
only)
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
3.
All
welding
guns
and
feeder/guns
90
days
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
4.
All
other
Millermatic
Feeders
1
year
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
5.
Replacement
or
repair
parts,
exclusive
of
labor
.
60
days
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
d
6.
Batteries
6
months
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLERî‚’
WARRANTIES
DO
NOT
EXTEND
provided
that
Miller
is
notified
in
writing
within
thirty
(30)
days
TO.
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
of
the
date
of
such
failure.
MILLERî‚’S
WARRANTIES
TO,
ANY
CONSUMER.
j?î‚’
jî‚’~î‚’
~
~
,~?î‚‘
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
-
SAFETY
RULES
FOR
OPERATION
OF
ARC
WELDING
POWER
SOURCE
1
-
1.
Introduction
1
1
-
2.
General
Precautions
1
1
-3.
ArcWelding
4
1
-
4.
Standards
Booklet
Index
6
SECTION
2
-
INTRODUCTION
2
-
1.
General
Information
And
Safety
7
2
-
2.
Receiving-Handling
7
2
-
3.
Description
8
SECTION
3
-
INSTALLATION
3-1.
Location
8
3
-
2.
Drive
Motor
8
3
-
3.
Shielding
Gas
Connections
8
3
-
4.
Water
Control
Kit
(Optional)
Connections
9
3
-
5.
Weld
Cable
Connection
9
3
-
6.
Optional
Process
Selector
Control
Installation
9
3
-7.
DriveRollAndWireGuidelnstallation
10
3
-
8.
Welding
Gun
Connections
12
3
-9.
Installation
Of
Spool-Type
Wire
12
3-10.
Installation
Of
Reel-Type
Wire
(Optional)
12
3-11.
Installation
Of
Wire
Reel
(Optional)
.12
3-12.
Adjusting
Hub
Tension
12
3-13.
Voltage
Sensing
Connections
12
3-14.
Internal
Program
Options
13
3-15.
Presetting
Internal
Program
Options
14
3-16.
Weld
Control
-
Welding
Power
Source
Interface
Connection
14
SECTION
4
-
TERMINOLOGY
SECTION
5
-
PRESETTING
SEMIAUTOMATIC
WELDING
PROGRAMS
SECTION
6
-
SEMIAUTOMATIC
WELDING:
KEY
SWITCH
IN
RUN
POSITION
6
-
1.
Dual
Scheduling
Via
The
Gun
Trigger
16
6
-
2.
Dual
Scheduling
Via
The
DSS-9M
17
SECTION
7
-
SEMIAUTOMATIC
WELDING:
KEY
SWITCH
IN
SET
POSITION
7
-
1.
Dual
Scheduling
Via
The
Gun
Trigger
20
7
-
2.
Dual
Scheduling
Via
The
DSS-9M
20
7
-
3.
Dual
Scheduling
Via
The
Program
Select
Pushbutton
21
7
-
4.
Timed
Welds
21
SECTION
8
-
PRESETTING
MANUAL
WELDING
&
CUTTiNG
PARAMETERS
8
-
1.
CP
Mode
Operation
22
8
-
2.
CC Mode
Operation
22
SECTION
9
-
MANUAL
WELDING
&
CUTTING:
KEY
SWITCH
IN
RUN
POSITION
9
-
1.
CP
Mode
Operation
23
9
-
2.
CC
Mode
Operation
23
Section
No.
Page
No.
SECTION
10
-
MANUAL
WELDING
8
CUTflNG:
KEY
SWITCH
IN
SET
POSITION
10-
1.
CPModeOperation
23
10
-
2.
CC
Mode
Operation
23
SECTION
11
-
MAINTENANCE
8
TROUBLESHOOTING
11.
-
1.
Diagnostic
Displays
24
11
-
2.
Inspection
And
Upkeep
24
11
-
3.
Microprocessor
Battery
24
11
-
4.
Clearing
The
Weld
Program
Memory
(RAM)
25
11
-
5.
Reinstallation
Of
Hub
Assembly
25
î‚—SECTION
1
-
SAFETY
RULES
FOR
OPERATION
OF
ARC
WELDING
POWER
SOURCE.
1-1.
INTRODUCTION
-
We
learn
by
experience.
Learning
safety
through
personal
experience,
like
a
child
touching
a
hot
stove
is
harmful,
wasteful,
and
un
wise.
Let
the
experience
of
others
teach
you.
Safe
practices
developed
from
experience
in
the
use
of
welding
and
cutting
are
described
in
this
manual.
Research,
development,
and
field
experience
have
evolved
reliable
equipment
and
safe
installation,
opera
tion,
and
servicing
practices.
Accidents
occur
when
equipment
is
improperly
used
or
maintained.
The
reason
for
the
safe
practices
may
not
always
be
given.
Some
are
based
on
common
sense,
others
may
require
technical
volumes
to
explain.
It
is
wiser
to
follow
the
rules.
Read
and
understand
these
safe
practices
before
at
tempting
to
install,
operate,
or
service
the
equipment.
Comply
with
these
procedures
as
applicable
to
the
par
ticular
equipment
used
and
their
instruction
manuals,
for
personal
safety
and
for
the
safety
of
others.
Failure
to
observe
these
safe
practices
may
cause
serious
injury
or
death.
When
safety
becomes
a
habit,
the
equipment
can
be
used
with
confidence.
These
safe
practices
are
divided
into
two
Sections:
1
-
General
Precautions,
common
to
arc
welding
and
cutting;
and
2
-
Arc
Welding
(and
Cutting)
(only).
Reference
standards:
Published
Standards
on
safety
are
also
available
for
additional
and
more
complete
pro
cedures
than
those
given
in
this
manual.
They
are
listed
in
the
Standards
Index
in
this
manual.
ANSI
Z49.1
is
the
most
complete.
The
National
Electrical
Code,
Occupational
Safety
and
Health
Administration,
local
industrial
codes,
and
local
inspection
requirements
also
provide
a
basis
for
equip
ment
installation,
use,
and
service.
1-2.
GENERAL
PRECAUTIONS
Different
arc
welding
processes,
electrode
alloys,
and
fluxes
can
produce
different
fumes,
gases,
and
radiation
levels.
In
addition
to
the
information
in
this
manual,
be
sure
to
consult
flux
and
elec
trode
manufacturers
for
specific
technical
data
and
precautionary
measures
concerning
their
material.
A.
Burn
Prevention
Wear
protective
clothing
gauntlet
gloves
designed
for
use
in
welding,
hat,
and
high
safety-toe
shoes.
Button
shirt
collar
and
pocket
flaps,
and
wear
cuffless
trousers
to
avoid
entry
of
sparks
and
slag.
Wear
helmet
with
safety
goggles
or
glasses
with
side
shields
underneath,
appropriate
filter
lenses
or
plates
(protected
by
clear
cover
glass).
This
is
a
MUST
for
welding
or
cutting,
(and
chipping)
to
protect
the
eyes
from
radiant
energy
and
flying
metal.
Replace
cover
glass
when
broken,
pitted,
or
spattered.
See
1
-3A.2.
Avoid
oily
or
greasy
clothing.
A
spark
may
ignite
them.
Hot
metal
such
as
electrode
stubs
and
workpieces
should
never
be
handled
without
gloves.
Medical
first
aid
and
eye
treatment.
First
aid
facilities
and
a
qualified
first
aid
person
should
be
available
for
each
shift
unless
medical
facilities
are
close
by
for
im
mediate
treatment
of
flash
burns
of
the
eyes
and
skin
burns.
Ear
plugs
should
be
worn
when
working
on
overhead
or
in
a
confined
space.
A
hard
hat
should
be
worn
when
others
work
overhead.
Flammable
hair
preparations
should
not
be
used
by
per
sons
intending
to
weld
or
cut.
B.
Toxic
Fume
Prevention
Severe
discomfort,
illness
or
death
can
result
from
fumes,
vapors,
heat,
or
oxygen
enrichment
or
depletion
that
welding
(or
cutting)
may
produce.
Prevent
them
with
adequate
ventilation
as
described
in
ANSI
Stan
dard
Z49.1
listed
1
in
Standards
index.
NEVER
ventilate
with
oxygen.
Lead
-,
cadmium
-,
zinc
-,
mercury
-,
and
beryllium
-
bearing
and
similar
materials,
when
welded
(or
cut)
may
produce
harmful
concentrations
of
toxic
fumes.
Ade
quate
local
exhaust
ventilation
must
be
used,
or
each
person
in
the
area
as
well
as
the
operator
must
wear
an
air-supplied
respirator.
For
beryllium,
both
must
be
us
ed.
Metals
coated
with
or
containing
materials
that
emit
toxic
fumes
should
not
be
heated
unless
coating
is
removed
from
the
work
surface,
the
area
is
well
ven
tilated,
or
the
operator
wears
an
air-supplied
respirator.
Work
in
a
confined
space
only
while
it
is
being
ven
tilated
and,
if
necessary,
while
wearing
an
air-supplied
respirator.
Gas
leaks
in
a
confined
space
should
be
avoided.
Leaked
gas
in
large
quantities
can
change
oxygen
con
centration
dangerously.
Do
not
bring
gas
cylinders
into
a
confined
space.
Leaving
confined
space,
shut
OFF
gas
supply
at
source
to
prevent
possible
accumulation
of
gases
in
the
space
if
downstream
valves
have
been
accidently
opened
or
left
open.
Check
to
be
sure
that
the
space
is
safe
before
re-entering
it.
Vapors
from
chlorinated
solvents
can
be
decomposed
by
the
heat
of
the
arc
(or
flame)
to
form
PHOSGENE,
a
OM-1547
Page
1
Coil
excess
hose
to
prevent
kinks
and
tangles.
ICC
or
DOT
marking
must
be
on
each
cylinder.
It
is
an
assurance
of
safety
when
the
cylinder
is
properly
handled.
Identifying
gas
content.
Use
only
cylinders
with
name
of
gas
marked
on
them;
do
not
rely
on
color
to
identify
gas
content.
Notify
supplier
if
unmarked.
NEVER
DEFACE
or
alter
name,
number,
or
other
markings
on
a
cylinder.
It
is
illegal
and
hazardous.
Empties:
Keep
valves
closed,
replace
caps
securely;
mark
MT;
keep
them
separate
from
FULLS
and
return
promptly.
Prohibited
use.
Never
use
a
cylinder
or
its
contents
for
other
than
its
intended
use,
NEVER
as
a
support
or
roller.
Locate
or
secure
cylinders
so
they
cannot
be
knocked
over.
Passageways
and
work
areas.
Keep
cylinders
clear
of
areas
where
they
may
be
struck.
Transporting
cylinders.
î‚‘Nith
a
crane,
use
a
secure
sup
port
such
as
a
platform
or
cradle.
Do
NOT
lift
cylinders
off
the
ground
by
their
valves
or
caps,
or
by
chains,
slings,
or
magnets.
Do
NOT
expose
cylinders
to
excessive
heat,
sparks,
slag,
and
flame,
etc.
that
may
cause
rupture.
Do
not
allow
contents
to
exceed
130î‚°F.
Cool
with
water
spray
where
such
exposure
exists.
Protect
cylinders
particularly
valves
from
bumps,
falls,
falling
objects,
and
weather.
Replace
caps
securely
when
moving
cylinders.
Stuck
valve.
Do
NOT
use
a
hammer
or
wrench
to
open
a
cylinder
valve
that
can
not
be
opened
by
hand.
Notify
your
supplier.
Mixing
gases.
Never
try
to
mix
any
gases
in
a
cylinder.
Never
refill
any
cylinder.
Cylinder
fittings
should
never
be
modified
or
exchang
ed.
Protect
hose
from
damage
by
sharp
edges,
and
by
sparks,
slag,
and
open
flame.
Examine
hose
regularly
for
leaks,
wear,
and
loose
con
nections.
Immerse
pressured
hose
in
water;
bubbles
in
dicate
leaks.
Repair
leaky
or
worn
hose
by
cutting
area
out
and
splic
ing
(1-2D3).
Do
NOT
use
tape.
4.
Proper
Connections
Clean
cylinder
valve
outlet
of
impurities
that
may
clog
orifices
and
damage
seats
before
connecting
regulator.
Except
for
hydrogen,
crack
valve
momentarily,
pointing
outlet
away
from
people
and
sources
of
ignition.
Wipe
with
a
clean
lintless
cloth.
Match
.regulator
to
cylinder.
Before
connecting,
check
that
the
regulator
label
and
cylinder
marking
agree,
and
that
the
regulator
inlet
and
cylinder
outlet
match.
NEVER
CONNECT
a
regulator
designed
for
a
particular
gas
or
gases
to
a
cylinder
containing
any
other
gas.
Tighten
connections.
When
assembling
threaded
con
nections,
clean
and
smooth
seats
where
necessary.
Tighten.
If
connection
leaks,
disassemble,
clean,
and
retighten
using
properly
fitting
wrench.
Adapters.
Use
a
CGA
adapter
(available
from
your
sup
plier)
between
cylinder
and
regulator,
if
one
is
required.
Use
two
wrenches
to
tighten
adapter
marked
RICIHT
and
LEFT
HAND
threads.
Regulator
outlet
(or
hose)
connections
may
be
iden
tified
by
right
hand
threads
for
oxygen
and
left
hand
threads
(with
grooved
hex
on
nut
or
shank)
for
fuel
gas.
5.
Pressurizing
Steps:
Drain
regulator
of residual
gas
through
suitable
vent
before
opening
cylinder
(or
manifold
valve)
by
turning
adjusting
screw
in
(clockwise).
Draining
prevents
ex
cessive
compression
heat
at
high
pressure
seat
by
allowing
seat
to
open
on
pressurization.
Leave
adjusting
screw
engaged
slightly
on
single-stage
regulators.
3.
Hose
Stand
to
side
of
regulator
while
opening
cylinder
valve.
Prohibited
use.
Never
use
hose
other
than
that
designed
for
the
specified
gas.
A
general
hose
identification
rule
î‚•
is:
red
for
fuel
gas,
green
for
oxygen,
and
black
for
inert
gases.
Use
ferrules
or
clamps
designed
for
the
hose
(not
or
dinary
wire
or
other
substitute)
as
a
binding
to
connect
hoses
to
fittings.
No
copper
tubing
splices.
Use
only
standard
brass
fit
tings
to
splice
hose.
Avoid
long
runs
to
prevent
kinks
and
abuse.
Suspend
hose
off
ground
to
keep
it
from
being
run
over,
stepped
on,
or
otherwise
damaged.
Open
cylinder
valve
slowly
so
that
regulator
pressure
in
creases
slowly.
When
gauge
is
pressurized
(gauge
reaches
regulator
maximum)
leave
cylinder
valve
in
following
position:
For
oxygen,
and
inert
gases,
open
fully
to
seal
stem
against
possible
leak.
For
fuel
gas,
open
to
less
than
one
turn
to
permit
quick
emergency
shutoff.
Use
pressure
charts
(available
from
your
supplier)
for
safe
and
efficient,
recommended
pressure
settings
on
regulators.
Check
for
leaks
on
first
pressurization
and
regularly
there-after.
Brush
with
soap
solution
(capful
of
Ivory
OM-1547
Page
3
Uquid~î‚’
or
equivalent
per
gallon
of
water).
Bubbles
in
dicate
leak,
Clean
off
soapy
water
after
test;
dried
soap
is
combustible.
E.
User
Responsibilities
Remove
leaky
or
defective
equipment
from
service
im
mediately
for
repair.
See
User
Responsibility
statement
in
equipment
manual.
F.
Leaving
Equipment
Unattended
Close
gas
supply
at
source
and
drain
gas.
G.
Rope
Staging-Support
Rope
staging-support
should
not
be
used
for
welding
or
cutting
operation;
rope
may
burn.
1-3.
ARC
WELDING
-
Comply
with
precautions
in
1-1,
1
-2,
and
this
section.
Arc
Welding,
properly
done,
is
a
safe
process,
but
a
careless
operator
invites
trouble.
The
equipment
carries
high
currents
at
significant
voltages.
The
arc
is
very
bright
and
hot.
Sparks
fly,
fumes
rise,
ultraviolet
and
infrared
energy
radiates,
weldments
are
hot,
and
compressed
gases
may
be
us
ed.
The
wise
operator
avoids
unnecessary
risks
and
pro
tects
himself
and
others
from
accidents.
Precautions
are
described
here
and
in
standards
referenced
in
index.
A.
Burn
Protection
Comply
with
precautions
in
1-2.
The
welding
arc
is
intense
and
visibly
bright.
Its
radia
tion
can
damage
eyes,
penetrate
lightweight
clothing,
reflect
from
light-colored
surfaces,
and
burn
the
skin
and
eyes.
Skin
burns
resemble
acute
sunburn,
those
from
gas-shielded
arcs
are
more
severe
and
painful.
DONî‚’T
GET
BURNED;
COMPLY
WITH
PRECAU
TI
ON
S.
1.
Protective
Clothing
Wear
long-sleeve
clothing
(particularly
for
gas-shielded
arc)
in
addition
to
gloves,
hat,
and
shoes
(1-2A).
As
necessary,
use
additional
protective
clothing
such
as
leather
jacket
or
sleeves,
flame-proof
apron,
and
fire-
resistant
leggings.
Avoid
outergarments
of
untreated
cotton.
Bare
skin
protection.
Wear
dark,
substantial
clothing.
Button
collar
to
protect
chest
and
neck
and
button
pockets
to
prevent
entry
of
sparks.
2.
Eye
and
Head
Protection
Protect
eyes
from
exposure
to
arc.
NEVER
look
at
an
electric
arc
without
protection.
Welding
helmet
or
shield
containing
a
filter
plate
shade
no.
12
or
denser
must
be
used
when
welding.
Place
over
face
before
striking
arc.
*Trademark
of
Proctor
&
Gamble.
OM-1547
Page4
Protect
filter
plate
with
a
clear
cover
plate.
Cracked
or
broken
helmet
or
shield
should
NOT
be
worn;
radiation
can
pass
through
to
cause
burns.
Cracked,
broken,
or
loose
filter
plates
must
be
replaced
IMMEDIATELY.
Replace
clear
cover
plate
when
broken,
pitted,
or
spattered.
Flash
goggles
with
side
shields
MUST
be
worn
under
the
helmet
to
give
some
protection
to
the
eyes
should
the
helmet
not
be
lowered
over
the face
before
an
arc
is
struck.
Looking
at
an
arc
momentarily
with
unprotected
eyes
(particularly
a
high
intensity
gas-shielded
arc)
can
cause
a
retinal
burn
that
may
leave
a
permanent
dark
area
in
the
field
of
vision.
3.
Protection
of
Nearby
Personnel
Enclosed
welding
area.
For
production
welding,
a
separate
room
or
enclosed
bay
is
best.
In
open
areas,
surround
the
operation
with
low-reflective,
non-
combustible
screens
or
panels.
Allow
for
free
air
circula
tion,
particularly
at
floor
level.
Viewing
the
weld.
Provide
face
shields
for
all
persons
who
will
be
looking
directly
at
the
weld.
Others
working
in
area.
See
that
all
persons
are
wearing
flash
goggles.
Before
starting
to
weld,
make
sure
that
screen
flaps
or
bay
doors
are
closed.
B.
Toxic
Fume
Prevention
Comply
with
precautions
in
1-2B.
Generator
engine
exhaust
must
be
vented
to
the
outside
air.
Carbon
monoxide
can
kill.
C.
Fire
and
Explosion
Prevention
Comply
with
precautions
in
1-2C.
Equipmentî‚’s
rated
capacity.
Do
not
overload
arc
welding
equipment.
It
may
overheat
cables
and
cause
a
fire.
Loose
cable
connections
may
overheat
or
flash
and
cause
a
fire.
Never
strike
an
arc
on
a
cylinder
or
other
pressure
vessel.
It
creates
a
brittle
area
that
can
cause
a
violent
rupture
or
lead
to
such
a
rupture
later
under
rough
handling.
D.
Compressed
Gas
Equipment
Comply
with
precautions
in
1-2D.
E.
Shock
Prevention
2.
Electrode
Holders
Exposed
hot
conductors
or
other
bare
metal
in
the
welding
Circuit,
or
in
ungrounded,
electrically-HOT
equipment
can
fatally
shock
a
person
whose
body
becomes
a
conductcr.
DO
NOT
STAND,
SIT,
LIE,
LEAN
ON,
OR
TOUCH
a
wet
surface
when
welding,
without
suitable
protection.
To
protect
against
shock:
Keep
body
and
clothing
dry.
Never
work
in
damp
area
without
adequate
insulation
against
electrical
shock.
Stay
on
a
dry
duckboard,
or
rubber
mat
when
damp-
î‚•
ness
or
sweat
can
not
be
avoided.
Sweat,
sea
water,
or
moisture
between
body
and
an
electrically
HOT
part
-
or
grounded
metal
-
reduces
the
body
surface
electrical
resistance,
enabling
dangerous
and
possibly
lethal
currents
to
flow
through
the
body.
1.
Grounding
the
Equipment
When
arc
welding
equipment
is
grounded
according
to
the
National
Electrical
Code,
and
the
work
is
grounded
according
to
ANSI
Z49.V1
~î‚‘Safety
In
Welding
And
Cut
ting,î‚”
a
voltage
may
exist
between
the
electrode
and
any
conducting
object.
Examples
of
conducting
objects
include,
but
are
not
limited
to,
buildings,
electrical
tools,
work
benches,
welding
power
source
cases,
workpieces,
etc.
Never
touch
the
electrode
and
any
metal
object
unless
the
welding
power
source
is
off.
When
installing,
connect
the
frames
of
each
unit
such
as
welding
power
source,
control,
work
table,
and
water
circulator
to
the
building
ground.
Conductors
must
be
adequate
to
carry
ground
Currents
safely.
Equipment
made
electrically
HOT
by
stray
current
may
shock,
possibly
fatally.
Do
NOT
GROUND
to
electrical
conduit,
or
to
a
pipe
carrying
ANY
gas
or
a
flammable
li
quid
such
as
oil
or
fuel.
Three.phase
connection.
Check
phase
requirements
of
equipment
~before
installing.
If
only
3-phase
power
is
available,
connect
single-phase
equipment
to
only
two
wires
of
the
3-phase
line.
Do
NOT
connect
the
equip
ment
ground
ead
to
the
third
(live)
wire,
or
the
equip
ment
will
become
electrically
HOT
-
a
dangerous
condi
tion
that
can
shock,
possibly
fatally.
Before
welding,
check
ground
for
continuity.
Be
sure
conductors
are
touching
bare
metal
of
equipment
frames
at
connections.
If
a
line
cord
with
a
ground
lead
is
provided
with
the
equipment
for
connection
to
a
switchbox,
connect
the
ground
lead
to
the
grounded
switchbox.
If
a
three-
prong
plug
is
added
for
connection
to
a
grounded
mating
receptacle,
the
ground
lead
must
be
connected
to
the
ground
prong
only.
If
the
line
cord
comes
with
a
three-prong
plug,
connect
to
a
grounded
mating
recep
tacle.
Never
remove
the
ground
prong
from
a
plug,
or
use
a
plug
with
a
broken
off
ground
prong.
Fully
insulated
electrode
holders
should
be
used.
Do
NOT
use
holders
with
protruding
screws.
3.
Connectors
Fully
insulated
lock-type
connectors
should
be
used
to
join
welding
cable
lengths.
4.
Cables
Frequently
inspect
cables
for
wear,
cracks
and
damage.
IMMEDIATELY
REPLACE
those
with
excessively
worn
or
damaged
insulation
to
avoid
possibly
-
lethal
shock
from
bared
cable.
Cables
with
damaged
areas
may
be
taped
to
give
resistance
equivalent
to
original
cable.
Keep
cable
dry,
free
of
oil
and
grease,
and
protected
from
hot
metal
and
sparks.
5.
Terminals
And
Other
Exposed
Parts
Terminals
and
other
exposed
parts
of
electrical
units
should
have
insulating
covers
secured
before
operation.
6.
Electrode
a.
Equipment
with
output
on/off
control
(con
tactor)
Welding
power
sources
for
use
with
the
gas
metal
arc
welding
(GMAW),
gas
tungsten
arc
welding
(GTAW)
and
similar
processes
normally
are
equipped
with
devices
that
per
mit
on-off
control
of
the
welding
power
out
put.
When
so
equipped
the
electrode
wire
becomes
electrically
HOT
when
the
power
source
switch
is
ON
and
the
welding
gun
switch
is
closed.
Never
touch
the
electrode
wire
or
any
conducting
object
in
contact
with
the
electrode
circuit
unless
the
welding
power
source
is
off.
b.
Equipment
without
output
on/off
control
(no
contactor)
Welding
power
sources
used
with
shielded
metal
arc
welding
(SMAW)
and
similar
pro
cesses
may
not
be
equipped
with
welding
power
output
on-off
control
devices.
With
such
equipment
the
electrode
is
electrically
HOT
when
the
power
switch
is
turned
ON.
Never
touch
the
electrode
unless
the
welding
power
source
is
off.
7.
Safety
Devices
Safety
devices
such
as
interlocks
and
circuit
breakers
should
not
be
disconnected
or
shunted
out.
Before
installation,
inspection,
or
service,
of
equip
ment,
shut
OFF
all
power
and
remove
line
fuses
(or
lock
OM-1
547
Page
5
or
red-tag
switches
to
prevent
accidental
turning
ON
of
power.
Disconnect
~ll
cables
from
welding
power
source,
and
pull
all
115
volts
line-cord
plugs.
Do
not
open
power
circuit
or
change
polarity
while
welding.
If,
in
an
emergency,
it
must
be
disconnected,
guard
against
shock
burns,
or
flash
from
switch
arcing.
Leaving
equipment
unattended.
Always
shut
OFF
and
disconnect
all
power
to
equipment.
Power
disconnect
switch
must
be
available
near
the
welding
power
source.
1-4.
STANDARDS
BOOKLET
INDEX
For
more
information,
refer
to
the
following
standards
or
their
latest
revisions
and
comply
as
applicable:
1.
ANSI
Standard
Z49.1,
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from
the
American
Welding
Society..
550
Le
Jeune
Rd,
P.O.
Box
351040
Miami,
FL
33135.
2.
NIOSH,
SAFETY
AND
HEALTH
IN
ARC
WELDING
AND
GAS
WELDING
AND
CUTTING
obtainable
from
the
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
3.
OSHA,
SAFETY
AND
HEALTH
STANDARDS,
29CFR
1910,
obtainable
from
the
U.S.
Govern
ment
Printing
Office,
Washington,
D.C.
20402.
4.
ANSI
Standard
Z87.1,
SAFE
PRACTICES
FOR
OCCUPATION
AND
EDUCATIONAL
EYE
AND
FACE
PROTECTION
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
5.
ANSI
Standard
Z41
.1,
STANDARD
FOR
MENî‚’S
SAFETY-TOE
FOOTWEAR
obtainable
from
the
American
Nationai
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
6.
ANSI
Standard
Z49.2,
FIRE
PREVENTION
IN
THE
USE
OF
CUTTING
AND
WELDING
PRO
CESSES
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
7.
AWS
Standard
A6.0,
WELDING
AND
CUT
TING
CONTAINERS
WHICH
HAVE
HELD
COM
BUSTIBLES
obtainable
from
the
American
Welding
Society,
550
Le
Jeune
Rd.
P.O.
Box
351040,
Miami
FL
33135.
8.
NFPA
Standard
51,
OXYGEN
-
FUEL
GA
SYSTEMS
FOR
WELDING
AND
CUTTING
ob
tainable
from
the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
9.
NFPA
Standard
70-1978,
NATIONAL
ELEC
TRICAL
CODE
obtainable
from
the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
10.
NFPA
Standard
51
B,
CUTTING
AND
WELDING
PROCESSES
obtainable
from
the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
11.
CGA
Pamphlet
P-i,
SAFE
HANDLING
OF
COM
PRESSED
GASES
IN
CYLINDERS
obtainable
from
the
Compressed
Gas
Association,
500
Fifth
Avenue,
New
York,
NY
10036.
12.
CSA
Standard
Wi
17.2,
CODE
FOR
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from
the
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1R3.
13.
NWSA
booklet,
WELDING
SAFETY
BIBLIOGRAPHY
obtainable
from
the
National
Welding
Supply
Association,
1900
Arch
Street,
Philadelphia,
PA
19103.
14.
American
Welding
Society
Standard
AWSF4.1
î‚“Recommended
Safe
Practices
for
the
Prepara
tion
for
Welding
and
Cutting
of
Containers
and
Piping
That
Have
Held
Hazardous
Substancesî‚”,
obtainable
from
the
American
Welding
Society,
550
LeJeuneRd.
P.O.
Box351040,
Miami,
FL33135.
15.
ANSI
Standard
Z88.2
î‚“Practice
for
Respiratory
Protectionî‚”
obtainable
from
the
American
Na
tional
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
OM-1
547
Page
6
SECTION
2
-
INTRODUCTION
Input
Power
Requirements
Electrode
Wire
Diameter
Capacity
Speed
Range
Control
Circuit
Voltage
At
Gun
Weight*
Net
Ship
115
VoItAC
50/60
Hz.
3
Amperes
.030-1/8
in.
(0.8-3.2
mm)
50-800
ipm
(1
.3-20.3
mpm)
15
Volts
47-1/2
lbs.
(21.5
kg)
56-1/2
lbs.
(25.6
kg)
*Add
1-1/2
lbs.
(0.7
kg)
for
4
-
drive
roll
models.
Figure
2
-
1.
Specifications
14
In.
(356
mm)
2
-
1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual and
on
various
labels,
tags,
and
plates
on
the
unit
pertains
to
equip
ment
design,
installation,
operation,
maintenance,
and
troubleshooting
which
should
be
read,
understood,
and
followed
for
the
safe
and
effective
use
of
this
equip
ment.
Safety
instructions
specifically
pertaining
to
this
unit
ap
pear
throughout
this
manual
highlighted
by
the
sijnal
words
____________
and
___________
which
identify
B.
Safety
The
installation,
operation,
maintenance,
and
troubleshooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
installed,
operated,
and
maintained
only
by
qualified
persons
in
accordance
with
this
manual
and
all
ap
plicable
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source.
CAUTION
____________
statements
include
installation,
operating,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
A
third
signal
word,
_______________,
highligh–s
instruc
tions
which
need
special
emphasis
to
obtain
the
most
efficient
operation
of
this
equipment.
2
-
2.
RECEIVING-HANDLING
-
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
and
carefully
inspect
for
any
damage
that
may
23
in.
(584
mm)
Figure
2
-
2.
Wire
Feeder
Overall
Dimensions
C-090
864
WARNING
different
levels
of
hazard.
CAUTION
WARNING
____________statements
include
installation,
operating,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
serious
personal
injury
or
loss
of
life.
OM-1547
Page
7
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
will
be
furnished
by
the
manufacturer
on
re
quest
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
it
is
essential
that
Model
Description
and
Serial
(or
Style)
Numbers
of
the
equipment
be
supplied.
2
-
3.
DESCRIPTION
-
This
unit
is
a
semiautomatic,
constant
speed,
digital
wire
feeder
with
a
program
mable,
microprocessor
based
control
and
a
permanent
magnet
wire
feed
motor.
It
is
designed
to
be
used
with
an
INTELLIWELD
6500
welding
power
source.
The
weld
control
is
capable
of
executing
two
complete
ly
separate
Gas
Metal
Arc
Welding
programs:
either
or
both
programs
can
be
timed.
It
is
also
capable
of
automatic
or
manual
dual
scheduling
of
the
weld
parameters
for
Gas
Metal-Arc
Welding.
With
the
use
of
an
optional
Process
Selector
control,
the
weld
control
can
preset
two
voltage
conditions
for
Air
Carbon
Arc
Cutting
&
Gouging
and
two
amperage
conditions
for
Shielded
Metal-Arc
Welding
or
Air
Carbon-Arc
Cutting
&
Gouging.
The
preset
welding
voltage
and
wire
speed
parameters
are
maintained
regardless
of
arc
or
load
variators
and
10%
line
variation.
Il~lIs]:I1~T~I~
Since
the
wire
feeder
control
when
equipped
with
the
optional
Process
Selector
ControI~,
can
also
preset
welding
conditions
for
Air
Carbon-Arc
Cutting
&
Gouging
and
Shielded
Metal-Arc
We/ding,
the
wire
feeder
control
will
be
referred
to
as
the
î‚“weld
controlî‚”
SECTION
3
-
INSTALLATION
Process
Selector
Control
Receptacle
TA-090
865
Figure
3
-
1.
Rear
Panel
Connections
TB-092
252-A
3
-
1.
LOCATION
(Figure
2-2)
-
Unit
location
should
allow
suitable
space
for
making
connections
and
perfor
ming
maintenance
functions.
Lead
lengths
must
also
be
considered
when
installing
the
unit.
The
wire
feeder
base
is
provided
with
mounting
holes
(see
Figure
2-2)
for
installing
the
unit
in
a
permanent
location.
A
slot
in
the
base
is
also
provided
for
installing
the
unit
over
the
lifting
eye
of
the
welding
power
source.
The
wire
support
can
be
equipped
with
an
op
tional
hanging
bail
for
suspending
the
unit
over
the
work
area.
prior
to
operation
of
the
wire
feeder.
The
vent
screw
can
be
removed
through
the
hole
in
the
rear
of
the
motor
shroud.
3
-
3.
SHIELDING
GAS
CONNECTIONS
(Figure
3-1)
-
Route
a
gas
hose
from
the
gas
supply,
under
the
handle
and
wire
support
on
the
wire
feeder
base
to
the
gas
input
fitting
on
the
rear
of
the
unit.
This
fitting
has
right-hand
threads.
Ensure
that
the
hose
does
not
in
terfere
with
wire
feed.
3
-
2.
DRIVE
MOTOR
-
The
drive
motor
is
provided
with
a
gear
case
vent
screw
which
must
be
removed
OM-1547
Page
8
Interface
Receptacle
3
-
4.
WATER
CONTROL
KIT
(Optional)
CONNEC
TIONS
CAUTION
_________OVERHEATING
of
Gas
Metal-Arc
Welding
gun
can
damage
gun.
î‚•
ff
using
a
water
cooled
gun
and
recirculating
coolant
system,
do
not
make
connections
from
the
coolant
pump
to
water
valve;
instead,
make
connections
directly
from
the
coolant
system
to
gun
hoses.
When
a
water-cooled
gun
is
used,
route
the
water
hose
from
the
water
supply,
through
the
handle
on
the
wire
feeder
base
to
the
water
input
fitting
on
the
rear
of
the
unit.
This
fitting
has
left-hand
threads.
Ensure
that
the
hose
does
not
interfere
with
wire
feed.
Connect
the
water
out
hose
to
the
adapter
on
the
weld
cable
terminal
on
the
drive
assembly.
These
fittings
have
left-hand
threads.
Route
the
water
out
hose
to
a
proper
disposal
or
cooling
system.
Water
is
available
when
the
Power
switch
in
placed
in
the
ON
position.
3
-
5.
WELD
CABLE
CONNECTION
(Figure
3-3)
IMPORTANT:
If
an
optional
Process
Selector
Con
trol
will
be
installed
on
the
weld
con
trol~,
proceed
to
Section
3-6.
Route
the
weld
cable
from
the
welding
power
source
LOW
INDUCTOR
weld
output
terminal,
under
the
han
dle
on
the
wire
feeder
base,
and
connect
to
the
weld
cable
terminal
on
the
wire
drive
housing
(see
Figure
3-3).
Be
sure
the
weld
cable
does
not
interfere
with
wire
feeding.
IMPORTANT
______________
Ensure
that
the
weld
cable
terminal
is
kept
clean
at
all
times.
Also
ensure
that
the
nut
on
this
terminal
is
secure.
If
either
one
of
the
above
conditions
is
not
met,
erratic
weld
current
could
result.
3
-
6.
OPTIONAL
PROCESS
SELECTOR
CON
TROL
INSTALLATION
(Figure
3-1)
WARNING
.
ELECTRIC
SHOCK
can
kill.
Shut
down
the
weld
control
and
the
welding
power
source
and
be
sure
that
neither
can
be
ac
cidentally
energized
before
installing
the
Process
Selector
Control.
1.
Remove
the
screws
along
the
top
of
the
weld
control;
remove
all
screws
holding
cover
on
Pro
cess
Selector
Control
and
set
the
Process
Selec
tor
Control
on
top
of
the
weld
control.
2.
Route
the
welding
cables
under
the
handle
and
the
wire
support
on
the
weld
control
base
as
il
lustrated
in
Figure
3-1
and
connect
to
the
ter
minals
on
the
Process
Selector
Control
switch
aligned
with
each
access
hole
to
obtain
the
desired
polarities
(see
Figure
3-2).
3.
Reinstall
cover
on
Process
Selector
Control
and
secure
to
weld
control.
4.
Connect
the
plug
on
the
Process
Selector
Con
trol
cord
to
the
receptacle
on
the
rear
of
the
weld
control
(see
Figure
3-1).
5.
Connect
the
voltage
sensing
leads
to
the
volt
sense
pick
up
points
shown
in
Figure
3-2
depen
ding
on
the
selected
electrode
polarities.
Intelliweld
6500
TA-091
615
Feeder
Reverse
Polarity/Manual
Reverse
Polarity
Weld
Cable
Terminal
On
Drive
Asoembly
TA.091
619
Feeder
Reverse
Polarity
High
Inductor/Manual
Reverse
Polarity
For
Stainless
Steel
Applications
Figure
3
-
2.
Connection
Diagrams
(Contî‚’d)
Intelliweld
650D
OM-1547
Page
9
T8-O4793~-C
Inlet
Wire
Guide
And
Securing
Screw
Intermediate
Wire
Guide
And
Securing
Screw
Slotted
Side
Of
Drive
Rell
Two
Drive
Roll
Feeder
T4.047
932-8
Drive
RoIIs
(Slotted
Side)
TA
-045
282-B
Figure
3
-
4.
U-Cog
Drive
Roll
Installation
lW
I
~.J
:
fUI
g
Sot/i
one-piece
and
split
drive
rolls
are
of
the
double
usage
type.
When
the
grooves
become
worn
reverse
the
one-piece
rolls
or
reverse
the
spilt
roll
halves
to
locate
the
unused
grooves
in
position
to
feed
the
wire.
î‚•
To
ensure
proper
gripping
action
of
U-cog
drive
rolls,
both
rolls
should
be
installed
showing
slots
on
the
side
or
both
should
show
the
side
without
slots.
Also,
it
is
necessary
to
line
up
the
blunted
teeth
on
the
pressure
gear
roll
directly
over
the
spaces
between
the
teeth
on
the
drive
gear
roll.
4.
Install
inlet
wire
guide
in
drive
housing
using
securing
screw
in
housing
so
that
the
tip
of
the
guide
is
as
close
to
the
drive
rolls
as
possible
without
touching.
IMPORTANT
______________
Behind
the
drive
gear
are
spring
washers.
To
obtain
proper
alignment
of
the
drive
roll
on
the
drive
gear
with
the
wire
guides
rotate
the
drive
gear
securing
bolt
thereby
moving
the
drive
roll
in
or
out
to
the
desired
position.
The
drive
roll
on
the
pressure
gear
will
locate
itself
on
the
wire
when
the
gear
cover
is
rep/aced
and
the
gears
mesh
together.
The
wire
drive
housing
is
made
with
mounting
holes
of
sufficient
clearance
to
provide
adjustment
of
the
wire
guides
up
or
down
in
relation
to
the
drive
rolls.
This
ad
/ustment
has
been
factory
set,
but
if
readjustment
becomes
necessary,
loosen
mounting
bolts
(see
F~gure
3-3),
weld
terminal
nut
and
bolt.
Slide
the
wire
drive
housing
upward
or
downward
until
the
wire
can
be
fed
straight
through
the
guides
while
seated
in
the
drive
roll
groove.
Tighten
mounting
bolts,
weld
terminal
bolt
and
nut.
Inlet
Wire
Guide
Securing
Screw
Split
Drive
Rolls
Adjustment
Gear
Cover
Split
Drive
Rolls
Pressure
Adjustment
Securing
Bolt
Screws
Terminal
Securing
Screws
Connector
Opening
Two
Drive
Roll
Feeder
Four
Drive
Roll
Feeder
Figure
3
-
3.
Drive
Roll
&
Wire
Guide
Installation
Connector
Opening
Weld
Cable
Terminal
18.070
887.A
Pressure
Drive
Rolle
(Slotted
Side)
Four
Drive
Roll
Feeder
OM-1547
Page
11
3
-
8.
WELDING
GUN
CONNECTIONS
A.
Outlet
Wire
Guide
(Figure
3-3)
1.
Loosen
the
gun/feeder
connector
securing
knob.
IMPORTANT
______________
Wire
guides
should
be
installed
so
that
the
tip
of
the
guide
is
as
close
to
the
drive
roll
as
possible
without
touching.
2.
Insert
the
gun/feeder
connector,
or
gun/feeder
adapter
if
required,
which
includes
the
installed
outlet
guide
into
the
drive
assembly
opposite
the
inlet
guide.
3.
Tighten
the
gun/feeder
connector
securing
knob.
B.
Gun
Trigger
(Figure
5-1)
The
TRIGGER
receptacle
is
provided
for
making
gun
trigger
control
connections.
Insert
the
plug
from
the
gun
into
the
TRIGGER
receptacle
and
rotate
the
thread
ed
collar
clockwise.
1.
Depress
the
two
spring-loaded
stops
(see
Figure
11-1)
on
retaining
ring,
and
slide
retaining
ring
off
hub.
2.
Slide
the
spool
of
wire
onto
the
hub
so
that
the
wire
feeds
off
the
bottom
with
the
minimum
bend
and
sharp
radius.
3.
Rotate
the
spool
until
the
hole
in
the
spool
aligns
with
the
pin
in
the
hub.
Slide
the
spool
onto
the
hub
until
it
seats
against
the
back
flange
of
the
hub.
4.
Depress
the
two
spring-loaded
stops
on
the
re
taining
ring,
and
slide
the
retaining
ring
into
pro
per
position
on
the
hub.
Release
the
two
stops.
3
-
10.
INSTALLATION
OF
REEL-TYPE
WIRE
(Op
tional)
(Figure
11-1)
1.
Lay
the
wire
reel
(see
Figure
11-1)
fIat
on
a
table
or
floor.
2.
Loosen
the
four
wing
nuts
on
the
fingers
of
the
wire
reel.
C.
Shielding
Gas
(If
Applicable)
(Figure
5-1)
An
integral
gas
input
fitting
is
provided
on
the
wire
drive
assembly
for
guns
utilizing
this
type
of
connection.
If
the
gun
requires
a
separate
shielding
gas
connection,
disconnect
the
hose
from
the
gas
fitting
on
the
front
of
the
control
and
connect
the
gas
hose from
the
gun
to
the
fitting.
This
fitting
has
right-hand
threads.
D.
Weld
Cable
(If
Applicable)
Connect
the
weld
cable
from
the
gun
(if
so
equipped)
to
the
weld
cable
terminal
on
the
drive
assembly
(see
Figure
3-3).
CAUTION
_________
WELDING
CURRENT
can
damage
in
terface
cord
and
connectors.
î‚•
Be
sure
the
weld
cable
lug
or
exposed
weld
cable
does
not
touch
the
wire
drive
housing
mounting
bolts.
E.
Water
(If
Applicable)
Connect
the
water
input
hose
from
the
gun
to
the
water
fitting
on
the
front
of
the
control.
Connect
the
water
hose
from
the
gun
to
the
adapter
at
the
weld
terminal
on
the
drive
assembly.
A
reducing
bushing
is
provided
to
accept
a
5/8-18
L.H.
fitting.
If
the
bushing
is
removed,
a
7/8-14
L.H.
fitting
can
be
ac
comodated.
3
-
9.
INSTALLATION
OF
SPOOL-TYPE
WIRE
(Figure
11-1)
IMPORTANT
If
it
should
become
necessary
to
replace
any
part
of
the
hub
assembly,
see
hub
assembly
reinstallation
instructions
in
Section
1
1-3.
3.
Pull
the
four
fingers
Out
until
they
can
be
rotated
toward
the
center
of
the
reel.
4.
Install
the
wire
onto
the
reel
over
the
four
fingers.
Ensure
that
the wire
feeds
off
the
bot
tom
of
the
reel.
The
reel
turns
in
a
counterclockwise
direction.
5.
Rotate
the
four
fingers
back
to
their
proper
posi
tion.
Tighten
the
four
wing
nuts.
3
-
11.
INSTALLATION
OF
WIRE
REEL
(Optional)
(Figure
11-1)
1.
Depress
the
two
spring-loaded
stops
(see
Figure
11-1)
on
retaining
ring,
and
slide
retaining
ring
off
hub.
2.
Slide
the
wire
reel
onto
the
hub.
Rotate
wire
reel
until
hub
guide
pin
is
seated
in
reel.
3.
Depress
the
two
spring-loaded
stops
on
the
re
taining
ring,
and
slide
retaining
ring
into
proper
position
on
hub.
Release
the
two
stops.
3
-
12.
ADJUSTING
HUB
TENSION
(Figure
11-1)
-
Check
hub
tension
by
slowly
pulling
wire
toward
the
feed
roll.
The
wire
should
unwind
freely,
but
the
hub
tension
should
be
sufficient
to
keep
the
wire
taut
and
prevent
backlash
when
the
wire
feeder
is
shut
off.
If
adjustment
is
required,
loosen
or
tighten
the
hex
nut
(see
Figure
11-1)
on
the
end
of
the
spool
support
bolt
accordingly.
3
-
13.
VOLTAGE
SENSING
CONNECTIONS
(Figure
5-1)
Connect
the
plug
on
the
voltage
sensing
cord
to
the
VOLT
SENSE
receptacle
on
the
wire
feeder.
Connect
OM-1547
Page
12
the
voltage
sensing
lead
with
the
ring
terminal
to
the
weld
cable
terminal
on
the
wire
drive
housing.
Connect
the
voltage
sensing
lead
with
the
clamp
to
the
work
clamp
or
work
piece.
Il~aI~S1:If~I~
If
an
optional
Process
Selector
î‚‘Con
trol
is
used,
connect
the
voltage
sensing
leads
as
II
lustra
ted
in
Figure
3-2.
EXCESSIVELY
HIGH
WELDING
CUR-
RENT
can
cause
the
electrode
wire
to
vaporize.
î‚•
Be
sure
the
voltage
sensing
leads
are
connected
properly.
ON
OFF
I_mlî‚’
im
I
IT
I
TI
I
TI
ml
If
the
volt
sense
signal
is
not
connected
weld
output
goes
to
the
maximum
the
welding
power
source
can
supply.
3
-
14.
INTERNAL
PROGRAM
OPTIONS
-
The
weld
control
is
equipped
with
eighteen
internal
(DIP)
switches
which
calibrate
the
microprocessor
to
the
motor
gear
ratio
and
select
built-in
options
for
running
programs
and
displaying
program
parameters.
Figure
3-5
shows
the
DIP
switch
configuration
for
the
standard
motor,
the
optional
low
and
high
speed
motors,
and
the
factory
configuration
for
the
built-in
options.
Figure
3
-
5.
DIP
Switches
ARC
HOURS
NO
RESET/ARC
HOURS
RESET
With
the
DIP
switch
in
the
Arc
Hours
No
Reset
position,
the
weld
control
accumulates
arc
hours
up
to
999
hours
before
rolling
over
to
zero.
A
visual
display
of
the
ac
cumulated
arc
hours
can
be
obtained
when
the
key-
switch
is
in
the
SET
position
(see
Section
7).
In
the
Arc
Hours
Reset
position,
visual
display
and
reset
of
the
accumulated
arc
hours
are
available
when
the
key-switch
is
in
SET
(see
Section
7).
SECONDS/
CYCLES
With
the
DIP
switch
in
the
Seconds
position,
sequence
times
are
preset
and
displayed
in
seconds.
In
the
Cycles
position,
times
are
preset
and
displayed
in
cycles.
WIRE
SPEED/AMPS
With
the
DIP
switch
in
the
Wire
Speed
position,
the
weld
control
displays
wire
speed
during
Standby
and
while
welding.
In
the
Amps
position,
the
weld
control
displays
wire
speed
during
Standby
and
welding
amperage
while
welding.
ERROR
BLINK/ERROR
SHUTDOWN
With
the
DIP
switch
in
the
Error
Blink
position,
a
devia
tion
of
more
than
–
1
volt
in
actual
welding
voltage
from
preset
voltage
for
more
than
1
.5
seconds,
or
a
deviation
of
more
than
2.5%
of
full
speed
in
actual
wire
speed
from
preset
wire
speed
for
more
than
1
.0
second
causes
the
appropriate
Numeric
display
to
blink
On-Off
indicating
the
deviation
from
preset
parameters.
This
deviation
can
be
the
result
of
presetting
a
voltage
beyond
the
range
of
the
welding
power
source
or
the
result
of
a
wire
feeding
problem
(incorrect
drive
roll
ten
sion,
worn
drive
rolls,
dirty
gun
liner,
etc.).
In
the
Error
Shutdown
position,
a
deviation
from
preset
parameters
causes
the
weld
control
to
sequence
im
mediately
to
CRATER,
BURNBACK,
and
POSTFLOW
and
shutdown.
A
blinking
Numeric
display
indicates
whether
a
voltage
or
wire
feeding
error
occurred.
OM-1547
Page
13
r
Motor
DIP
Switches
Positioned
For
Standard
Wire
Feed
Wire
(50-
800
1PM)
Arc
Hours
Reset
Cycles
Amps
Error
Shutdown
Meters
Per
Minute
Trigger
Latch
Abort
Interface
Printed
Circuit
Board
Arc
Hours
No
Reset
Seconds
Wire
Speed
Error
Blink
Inches
Per
Minute
Trigger
Dual
Scheduling
Nonabort
Factory
Set
I
TI
I
Ti
I
Ti
I
Ti
ml
I
mj
I
ml
ml
I
ED]
L
Er~H
I
TI
F
~l
iT
I
rm
I
U~L
Motor
DIP
Switches
Positoned
For
Low
Speed
Motor:
15-205
ipm
(.4-5
mpm)
TB-091
794
Motor
DIP
Switches
Positioned
For
High
Speed
Motor:
90-1429
1pm
(2.3
-
36.3
mpm)
To
reset
error
blink
or
error
shutdown,
cycle
the
Power
switch
On-Off
and
reset
the
parameteror
correct.the
wire
feeding
problem.
INCHES
PER
MINUTE/METERS
PER
MINUTE
With
the
DIP
switch
in
the
Inches
Per
Minute
position,
wire
speed
is
preset
and
displayed
in
inches
per
minute.
In
the
Meters
Per
Minute
position,
wire
speed
is
preset
and
displayed
in
meters
per
minute.
TRIGGER
DUAL
SCHEDULING/TRIGGER
LATCH
With
the
DIP
switch
in
the
Trigger
Dual
Scheduling
position,
a
momentary
release
of
the
gun
trigger
while
welding
(less
than
.25
seconds)
switches
weld
schedules
when
both
weld
schedules
are
untimed.
In
the
Trigger
Latch
position,
the
gun
trigger
can
be
released
during
PREFLOW,
RUN
IN
or
within
the
first
second
of
WELD
and
the
weld
control
will
continue
in
the
WELD
step
until
a
momentary
closure
of
tI~re.gun
trigger
sequences
the
weld
control
to
CRATER.
If
the
gun
trigger
is
held
closed
throughout
the
first
second
of
WELD,
the
trigger
does
not
latch
and
when
released,
sequences
the
weld
control
to
CRATER
as
in
a
normal
weld.
If
trigger
latch
is
set
during
PREFLOW
and
the
arc
is
not
started
three
seconds
after
the
start
of
RUN
IN,
the
weld
control
goes
to
Standby.
NON
ABORT/ABORT
With
the
DIP
switch
in
the
Non
Abort
position,
the
gun
trigger
can
be
released
during
a
timed
weld,
once
the
arc
is
started,
and
the
weld
control
will
complete
the
timed
program
automatically.
If
the
trigger
is
held
clos
ed
throughout
the
timed
weld
program,
the
trigger
must
be
released
at
the
end
of
POSTFLOW
before
the
next
weld
can
be
started.
In
the
Abort
position,
the
gun
trigger
must
be
held
clos
ed
for
the
duration
of
the
timed
weld.
If
the
trigger
is
released
before
the
timed
completion,
the
weld
control
immediately
sequences
to
BURNBACK.
3
-
15.
PRESETTING
INTERNAL
PROGRAM
OP
TIONS
-
The
DIP
switches
are
located
on
the
rear,
left
side
of
the
interface
board
(third
board
behind
front
panel)
inside
the
weld
control.
Proceed
as
follows
to
preset
the
DIP
switches:
WARNING
__________
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
the
welding
power
source
and
discon
nect
the
interface
cord
from
the
weld
control
before
presetting
DIP
switches.
1.
Place
the
Power
switch
in
the
OFF
position.
2.
Remove
weld
control
wrapper.
3.
Locate
DIP
switches
(see
Figure
5-1).
4.
Reposition
appropriate
DIP
switches
using
a
pointed
tool,
such
as
the
edge
of
a
small
screw
driver
blade.
5.
Replace
the
wrapper.
6.
Reconnect
interface
cord.
3
-
16.
WELD
CONTROL
-
WELDING
POWER
SOURCE
INTERFACE
CONNECTION
(Figure
3-1)
-
Route
the
26-socket
plug
on
the
4ft
(1
.2m)
inter
face
cable
through
the
handle
on
the
wire
feeder
base.
Connect
the
plug
to
the
26-pin
receptacle
on
the
weld
control.
Be
sure
the
cable
does
not
interfere
with
wire
feeding.
SECTION
4
-
TERMINOLOGY
Weld
Program:
The
series
of
steps
(preflow,
run
in,
weld,
crater,
burnback,
and
postflow)
making
up
a
complete
welding
sequence.
Dual
Scheduling:
Switching
back
and
forth
between
two
weld
conditions.
Dual
Programming:
Switching
back
and
forth
bet
ween
two
complete
welding
sequences.
Sequencing:
Advancing
step
by
step
through
a
welding
program.
Standby:
Idle
condition
where
the
weld
control
is
in
a
ready-to-weld
status.
The
numeric
displays
show
the
preset
WELD
parameters.
The
weld
contactor
is
off;
and
the
gun
trigger
is
off.
Shutdown:
Condition
of
no
output
-
weld
contactor
and
wire
feed
motor
off.
Shutdown
is
further
indicated
by
a
blinking
VOLTS
or
WIRE
SPEED/AMPS
numeric
display
in
the
event
of
a
voltage
or
wire
speed
error
(see
Section
5-1
1)
or
by
blank
numeric
displays
and
program
and
sequence
indicator
lamps
off
in
the
case
where
no
arc
has
been
started
within
three
seconds
of
energizing
the
weld
contactor.
Attempting
to
thread
the
welding
wire
with
the
gun
trigger
will
cause
the
weld
control
to
shutdown.
Jogging
the
welding
wire
with
the
gun
trig
ger
can
cause
the
weld
control
to
shutdown.
This
feature
helps
prevent
arcs
from
accidental
trigger
ac
tivation.
.
OM-1547
Page
14
SECTION.
5
-
PRESETTING
Volts
Numberic
Volts
Increase
&
Decrease
Pushbuttons
Purge/Amps/CP-CC
Pushbutton
Jog/Hours
Pushbuttons
Motor
Overload
Breaker
SEMIAUTOMATIC
WELDING
PROGRAMS
î‚—
Wire
Speed/Amps
Numeric
Display
TA-090
866
Welding
Sequence
Preflow
Run
In
Weld
Crater
Burnback
Postflow
Volts
Wire
Speed
Time
-
-
0-999
sec.
(0-999
cycles)
10-50
50-800
in.
(1.3-20.3
mpm)+
0-999
sec
(0-999
cycles)
10-50
50-800
in.
(1.3-20.3
mpm)
0-999
sec.
(0-999
cycles)
+
+
10-50
50-800
in.
(1
.3-20.3
mpm)
0-999
sec.
(0-999
cycles)
0-999
sec.
(0-999
cycles)
-
0-999
sec.
(0-999
cycles)
+
Standard
motor
speed.
Optional
motors
available.
+ +
Zero
means
continous
in
weld
sequence
only.
Zero
wire
speed
brakes
the
motor.
î‚“Burnback
voltage
same
as
preset
Crater
voltage.
Figure
5-2.
Welding
Parameter
Ranges
1.
Energize
the
welding
power
source.
2.
PLACE
WELD
CONTROL
POWER
SWITCH
IN
THE
ON
POSITION:
This
applies
power
to
the
weld
control
and
initiates
a
check
of
the
numeric
displays
and
the
Indicator
lamps.
This
check
in
volves
lighting
all
displays
and
lamps
for
one
se
cond
for
visual
inspection.
Next
a
diagnostic
check
of
the
memory
and
system
inputs
is
per
formed
by
the
microprocessor.
If
a
fault
is
in
dicated
on
the
displays,
see
Section
11-1.
3.
TURN
KEY-SWITCH
TO
THE
SET
POSITION.
4.
DEPRESS
PROGRAM
PUSHBUTTON
TO
SELECT
PROGRAM
A:
PROGRAM
A
indicator
lamp
lights
and
the
numeric
displays
show
the
WELD
parameters
stored
in
memory
for
PRO
GRAM
A.
5.
DEPRESS
SEQUENCE
ADVANCE
PUSHBUT
TON
TO
ADVANCE
TO
PREFLOW:
The
PREFLOW
Indicator
lamp
lights.
The
TIME
Numeric
display
shows
the
preflow
time
stored
in
memory.
The
SECONDS
or
CYCLES
Indicator
lamp
lights
to
show
the
time
unit.
Volts
Indicator
Lamp
Contactor
On
Indicator
Lamp
/
Inches
Indicator
Lamp
Indicator
Lamp
Amps
IndIcator
Lamp
Seconds
IndIcator
Lamp
Time
Numeric
Display
Cycles
Indicator
Lamp
Hours
Indicator
Lamp
0
Time
Increase
&
Decrease
Pushbuttons
Sequence
Lamps
Sequence
Advance/Contactor
Pushbutton
Key-Switch
Trigger
Receptacle
Power
Switch
Program
Select
Pushbutton
&
Program
Lamps
Gas
Out
Fitting
Receptacle
Figure
5-1.
Front
Panel
View
OM-1547
Page
15
II~I~.1:lf~UI~
Momentarily
depressing
the
SE
QUENCE
AD
VANCE
pushbutton
advances
the
we/ding
sequence
at
a
rate
of
one
step
per
closure;
holding
the
SEQUENCE
ADVANCE
pushbutton
closed
advances
the
we/ding
sequence
at
a
rate
of
one
step
per
second.
6.
DEPRESS
TIME
INCREASE
OR
DECREASE
PUSHBUTTONS
TO
PRESET
PREFLOW
TIME:
If
preflow
is
not
required,
decrease
preflow
time
to
zero.
If
the
Increase
or
Decrease
pushbut
ton
are
held
closed,
the
parameter
changes
at
an
ac
celerating
rate.
7.
DEPRESS
SEQUENCE
ADVANCE
PUSHBUT
TON
TO
ADVANCE
TO
RUN
IN:
The
RUN
IN
Indicator
lamp
lights.
THE
VOLTS,
WIRE
SPEED/AMPS
and
TIME
Numeric
displays
show
the
run
in
parameters
stored
in
memory.
The
VOLTS
Indicator
lamp
lights;
the
INCHES
or
METERS
Indicator
lamp
lights
to
show
the
wire
speed
unit;
the
SECONDS
or
CYCLES
Indicator
lamp
lights
to
show
the
time
unit.
8.
DEPRESS
TIME
INCREASE
OR
DECREASE
PUSHBUTTON
TO
PRESET
RUN
IN
TIME.
DEPRESS
VOLTS
INCREASE
OR
DECREASE
PUSHBUTTON
TO
PRESET
RUN
IN
VOLTAGE.
DEPRESS
WIRE
SPEED
INCREASE
OR
DECREASE
PUSHBUTTON
TO
PRESET
RUN
IN
WIRE
SPEED.
If
run
in
is
not
required,
decrease
run
in
time
to
zero.
Run
in
voltage
and
wire
speed
must
still
be
preset
even
if
no
run
in
time
is
preset
because
these
values
are
used
until
the
arc
is
struck.
9.
DEPRESS
SEQUENCE
ADVANCE
PUSHBUT
TON
TO
ADVANCE
TO
WELD:
The
WELD
In
dicator
lamp
lights.
The
VOLTS,
WIRE
SPEED,
and
TIME
Numeric
displays
show
the
WELD
parameters
stored
in
memory.
The
VOLTS
In
dicator
lamp
lights;
The
INCHES
or
METERS
In
dicator
lamp
lights
to
show
the
wire
speed
unit;
the
SECONDS
or
CYCLES
Indicator
lamp
lights
to
show
the
time
unit.
10.
DEPRESS
VOLTS
INCREASE
OR
DECREASE
PUSHBUTTONS
TO
PRESET
WELD
VOLTAGE.
DEPRESS
WIRE
SPEED
INCREASE
OR
DECREASE
PUSHBUTTON
TO
PRESET
WELD
WIRE
SPEED.
DEPRESS
TIME
IN
CREASE
OR
DECREASE
PUSHBUTTONS
TO
IMPORTANT
PRESET
WELD
TIME
IF
A
TIMED
WELD
WILL
BE
MADE.
11.
DEPRESS
SEQUENCE
ADVANCE
PUSHBUT
TON
TO
ADVANCE
TO
CRATER:
The
CRATER
Indicator
lamp
lights.
The
VOLTS,
WIRE
SPEED/AMPS,
and
TIME
Numeric
displays
show
the
crater
parameters
stored
in
memory.
The
VOLTS
Indicator
lamp
lights;
the
INCHES
or
METERS
Indicator
lamp
lights
to
show
the
wire
speed
unit;
the
SECONDS
or
CYCLES
Indicator
lamp
lights
to
show
the
time
unit.
12.
DEPRESS
TIME
INCREASE
OR
DECREASE
PUSHBUTTONS
TO
PRESET
CRATER
TIME.
DEPRESS
VOLTS
INCREASE
OR
DECREASE
PUSHBUTTON
TO
PRESET
CRATER
VOLTAGE.
DEPRESS
WIRE
SPEED
INCREASE
OR
DECREASE
PUSHBUTTON
TO
PRESET
CRATER
WIRE
SPEED.
If
crater
is
not
required,
decrease
crater
time
to
zero.
Burnback
voltage
is
the
same
as
crater
voltage.
Therefore,
if
burn-
back
will
be
required,
crater
voltage
must
be
preset
to
burnback
level.
13.
DEPRESS
SEQUENCE
ADVANCE
PUSHBUT
TON
TO
ADVANCE
TO
BURNBACK:
The
BURNBACK
Indicator
lamp
lights.
The
TIME
Numeric
display
shows
the
burnback
time
stored
in
memory.
The
SECONDS
or
CYCLES
Indicator
lamp
lights
to
show
the
time
unit.
14.
DEPRESS
TIME
INCREASE
OR
DECREASE
PUSHBUTTON
TO
PRESET
BUANBACK
TIME:
If
burnback
is
not
required,
decrease
BURNBACK
time
to
zero.
15.
DEPRESS
SEQUENCE
ADVANCE
PUSHBUT
TON
TO
ADVANCE
TO
POSTFLOW:
The
POSTFLOW
Indicator
lamp
lights.
The
TIME
Numeric
display
shows
the
postflow
time
stored
in
memory.
The
SECONDS
or
CYCLES
Indicator
lamp
lights
to
show
the
time
unit.
16.
DEPRESS
TIME
INCREASE
OR
DECREASE
PUSHBUTTONS
TO
PRESET
POSTFLOW
TIME:
If
postflow
is
not
required
decrease
postflow
time
to
zero.
17.
DEPRESS
PROGRAM
PUSHBUTTON
TO
SELECT
PROGRAM
B:
PROGRAM
B
Indicator
lamp
lights
and
the
Numeric
displays
show
the
WELD
parameters
stored
in
memory
for
PRO
GRAM
B.
Repeat
Steps
5-16
for
PROGRAM
B.
~SECTION
6
-
SEMIAUTOMATIC
WELDING:
KEY
SWITCH
IN
RUN
POSITION
6
-
1.
DUAL
SCHEDULING
VIA
THE
GUN
TRIG
GER
(Figure
6-1)
1.
Energize
the
welding
power
source.
2.
Place
the
weld
control
power
switch
in
the
ON
position:
The
preset
welding
parameters
cannot
be
changed;
however
the
SEQUENCE
AD
VANCE
pushbutton
can
be
used
to
preview
the
parameters.
3.
Turn
on
shielding
gas
supply.
4.
Depress
the
PURGE
pushbutton
to
purge
the
gas
line,
if
required.
OM-1547
Page
16
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Miller INTELLIMATIC S-52M Owner's manual

INTELLIMATIC S-52M
Miller
Brand
Miller
Model
INTELLIMATIC S-52M
Category
Welding System
Type
Owner's manual
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