Miller JB577755 Owner's manual

April

1982

FORM:

OM-1540A

Effective

With

Serial

No.

JB577755

MODEL

AUTOMATIC

2

OWNERS

MANUAL

r~

millER

MILLER

ELECTRIC

MFG.

CO.

718

S.

BOUNDS

ST.

P.O.

Box

1079

APPLETON,

WI

54912

uSA

NWSA

CODE

NO.

4579

PRINTED

IN

U.S.A.

%i~P

t.

L

~CzP

~J

~

LIMITED

WARRANTY

EFFECTIVE:

JUNE

1.

1979

This

warranty

supersedes

all

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

Miller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

tt4

ranty

is

made

by

Miller

with

respect

to

engines,

trade

ac-

therefore

shall

be,

at

Millers

option

(1)

repair

or

(2)

replacement

cessories

or

other

items

manufactured

by

others.

Such

or,

where

authorized

in

writing

by

Miller

in

appropriate

cases,

131

engines,

trade

accessories

and

other

items

are

sold

subject

to

the

reasonable

cost

of

repair

or

replacement

at

an

authorized

the

warranties

of

their

respective

manufacturers,

if

any

.

All

Miller

service

station

or

(4)

paymentof

or

credit

for

the

purchase

I

r

engines

are

warranted

by

their

manufacturer

for

one

year

from

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

date

of

original

purchase.

return

of

the

goods

at

Customers

risk

and

expense.

Upon

receipt

of

notice

of

apparent

defect

or

failure,

Miller

shall

instruct

the

clai-

f~

Except

as

specified

below,

Millers

warranty

does

not

apply

mant

on

the

warranty

claim

procedures

to

be

followed.

I

to

components

having

normal

useful

life

of less

than

one

(1)

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-

j9

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,

k~

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

f

ment

to

the

original

user:

ANY

AND

ALL

EOUIPMENT

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.

Allweldinggunsandfeeder/guns

90days

ULTIMATE

PURCHASE

BY

COMMERCIAL/INDUSTRIAL

1

F1

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

6.

Batteries

6

months

WELDING

EOUIPMENT

AND

NOT

FOR

CONSUMERS

OR

~

CONSUMER

USE.

MILLER

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

MILLERS

WARRANTIES

TO,

ANY

CONSUMER.

Jr

jr

,~,

Jr

~

j~

,t,

~1,

J~

Jr



>

3

~

m

a

Z-~

ii

a

~

m

a

2

cg~

I

C

P

~~2L

-a

-~

!2

~~&i1

2

m

3o

C

C)

o~

~

2

5~

~

2

~0)

~

0~

3

I

CD

PLC18

CD

U)

m

2

CD

.0

2

£.

C,

C

rn

3

CD

~

a

CD

o

~?.

C

C~

r

0

m

g

o

CD

o

9-

-I

2

~

C

U)

-4

U)

CD

C~)

CD

V

t.

0

U)

-.4

0

a

0)

-4

C,

Circuit

Diagram

No.

C-084

598-B

Figure

6

-

1~

A.

Circuit

Diagram

For

Models

Effective

With

Serial

No.

JB517155

Thru

JD695159

ALE

COLY

~P=~:

mc~

~fl

:7fl~

:~:

J

~U

INCI4-t,P

5,

PC4

oc

Pea

CR2

a

INCH

P

PRE

-FLUX

CR

RCA

ACi

GAS

VA

L

OCtOPI

I

worrovaIvt,oplI

PT

~

I

T2

-

5110141

i~~:._1

~

10

11

~

IMP



>

88

-

M>)~>2

IV>>

Pt

C,

o

~

14>>

~

-

N

>>~)~

R>>~_.~!._~.<XE____oT1)

WOIIP

21

RI

RCa

PC1

)_.

)-_.

t~~>~021~

B

(~)

(~)

5T

T

L~>2Q.~2r,,

IS4

PLUg

3

I

lb

20

21

5

II

I

3~1~0~~

Y,,Y~05

PLUISYP?

~~PLGI5

L

t~i

I

RuRneocn

08

8

CRATER

lIME

OX

~6

0

010

Ito

~

)

)~

-

(~)

A

________

50T

J

T5

T

1CR

1.~i

~~E02M



T~~a

l~RC5o

~

PLGISjO

t~YYYPLGIX~.OPIO

~j_~1~EJw

05

~

OPTON

C

5

~

CR5



4

CX,

REMOVE

JUMPERS

OR

REMOTE

PENDANT

Mo.94

N

052

P055

0058

00.67_-REMOAE

FOR

RUN-Il,

OPTICS

a

~66

OOj5

REMOVE

FOR

POST

FI~OW

OPT

ION

ER

80

FOR

PUN-IN

OPT

ION

Go.82

6083

TR/O

Loll

009

MO/V

CONTACTS

14013

P0/4

A~A

~l

CR6

I

~

<~

-~(<

-(Es

t~T_T1~

Il~

n~h::~

It~:J;

MI)

11)9

RI)

AR

II

32

~:~~:+~i

j4C

PB2

WV;

39

o

50

CR

o-~

INC,IUP

~

~--o~<

INCH

DOWN

INCH

DOWN

INCHUP

E

-0

t

4

R

P

4

~

T~ERIN

~

SPIED

~

CR0

I,~t

~5O~5~LS~

H24

OPIIOIIAL

CV

/

~

0fCI~/

~

IIR-R

4

RUrJ-1u101!<

Wit

oI~

1

I~I91S

?

001

/S~~~J

UOLTS(fJ

~,

~

P1010

~

j~lR~

PLGIO+

CObRA

~

V~-~10

L+~H

F-~~>--~

85

PIG

MLII

)t

-~

~

>,

>~

PPM-

F

A

110

0

-~

AC0

REMOTE

PENDANT

I

OPT

ORaL

I

Circuit

Diagram

No.

C-091883

Figure

6

-

1.

B.

Circuit

Diagram

For

Models

Effective

With

Serial

No.

JD695160

And

Following

Dia.

Part

**

Mkgs.

No.

________________________________________________________________

2-27

R5

084

140

3-91

A

082

987

3-92

V

082

988

4-10

VR1

082722

8-

D50-56

026

202

**First

digit

represents

page

no

-

digits

following

dash

represents

item

no.

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

Amend

Figure

6

-

3.

Circuit

Diagram

For

Sensing

Board

PC3

:57

4-ISV.

I

S~-1IEL

4

Figure

6

-

3.

Circuit

Diagram

For

Sensing

Board

PC3

For

Models

Effective

With

Serial

No.

JD695160

Circuit

Diagram

No.

A-092

128

Replaced

With

Description

084

141

POTENTIOMETER,

carbon

1

turn

2

watt

15K

ohm

082

987

METER,

amp

ac/dc

0-1500

scale

082

988

METER,

volt

dc

0-1

00

scale

Deleted

(Eff

w/JD695160)

026

202

DIODE,

(qty

chg)(Eff

w/JD6951

60)

Quantity

7

OM-1

540A

Page

3

TABLE

OF

CONTENTS

Section

No.

Page

No.

SECTION

1

-

SAFETY

RULES

FOR

OPERATION

OF

ARC

WELDING

POWER

SOURCE

1

-

1.

Introduction

1

2.

General

Precautions

1

-3.

ArcWelding

4

1

-

4.

Standards

Booklet

Index

5

SECTION

2

-

INTRODUCTION

2

-

1.

General

Information

And

Safety

7

2

-

2.

Receiving-Handling

7

2

-

3.

Description

7

SECTION

3

-

INSTALLATION

3-1.

Location

8

3

-

2.

Remote

Pendent

Control

8

3

-

3.

Flux

Hopper

With

Automatic

Valve

8

3

-

4.

Shielding

Gas

Connections

8

3

-

5.

Water

Connections

9

3

-

6.

Auxiliary

Relay

Contacts

9

3

-7.

Hub

And

Spindle

Assembly

Installation

10

3

-

8.

Installation

Of

Spool-Type

Wire

10

3

-

9.

Installation

of

Reel-Type

Wire

10

3-10.

Installation

of

Wire

Reel

10

3

-11.

Weld

Control

Interconnections

11

SECTION

4

-

OPERATOR

CONTROLS

4

-

1.

Power/Emergency

Stop

Switch

13

4

-

2.

Pilot

Light

13

4

-

3.

Start

Push

Button

13

4

-

4.

Stop

Push

Button

13

4

-

5.

Preflux

Push

Button

13

4-6.

lnchUpPushButton

13

4

-

7.

Inch

Down

Push

Button

13

4

-

8.

Weld

Voltage

Control

13

4

-

9.

Wire

Feed

Speed

Control

14

4-10.

Pre-FluxTimeControl

14

4-11.

RunlnSpeedControl

14

4-12.

RunlnVoltageControl

14

4-13.

RunlnTimeControl

14

4-14.

Crater

Voltage

Control

14

4-15.

Crater

&

Inch

Speed

Control

14

4-16.

Crater

Time

Control

14

4-17.

BurnbacklimeControl

14

4-18.

Post-Flow

Time

Control

14

4-19.

Meters

15

4-20.

Overload

Protection

15

SECT~ON

5

-

SEQUENCE

OF

OPERATION

5-1.

Weld

Cycle

Events

15

5-2.

Submerged

Arc

Welding

15

5

-

3.

Gas

Metal-Arc

Welding

15

5

-

4.

Shutting

Down

15

SECTION

6

-

MAINTENANCE

&

TROUBLESHOOTING

6

-

1.

Inspection

And

Upkeep

16

6-2.

General

16

6

-

3.

Troubleshooting

Chart

16

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

installaition,

use,

and

service.

1-2.

GENEI~AL

PRECAUTIONS

A.

Burn

Prevention

Wear

protective

clothing

-

leather

(or

asbestos)

gauntlet

gloves,

hat,

and

high

safety-toe

shoes.

Button

shirt

collar

aiid

pocket

flaps,

and

wear

cuff

less

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

iror

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

par

sons

intending

to

weld

or

cut.

B.

Toxic

Fume

Prevention

Adequate

ventilation.

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

Standard

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.

Acte

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

highly

toxic

gas,

and

other

lung

and

eye

irritating

pro

ducts.

The

ultraviolet

(radiant)

energy

of

the

arc

can

also

decompose

trichloroethylene

and

per

chloroethylene

vapors

to

form

phosgene.

DO

NOT

WELD

or

cut

where

solvent

vapors

can

be

drawn

into

the

welding

or

cutting

atmosphere

or

where

the

radiant

energy

can

penetrate

to

atmospheres

containing

even

minute

amounts

of

trichloroethylene

or

per

chloroethylene.

OM-1540

Page

1

C.

Fire

and

Explosion

Prevention

Causes

of

fire

and

explosion

are:

combustibles

reached

by

the

arc,

flame,

flying

sparks,

hot

slag

or

heated

material;

misuse

of

compressed

gases

and

cylinders;

and

short

circuits.

BE

AWARE

THAT

flying

sparks

or

falling

slag

can

pass

through

cracks,

along

pipes,

through

windows

or

doors,

and

through

wall

or

floor

openings,

out

of

sight

of

the

goggled

operator.

Sparks

and

slag

can

fly

35

feet.

To

prevent

fires

and

explosion:

Keep

equipment

clean

and

operable,

free

of

oil,

grease,

and

(in

electrical

parts)

of

metallic

particles

that

can

cause

short

circuits.

If

combustibles

are

in

area,

do

NOT

weld

or

cut.

Move

the

work

if

practicable,

to

an

area

free

of

combustibles.

Avoid

paint

spray

rooms,

dip

tanks,

storage

areas,

yen

tilators.

If

the

work

cannot

be

moved,

move

com

bustibles

at

least

35

feet

away

out

of

reach

of

sparks

and

heat;

or

protect

against

ignition

with

suitable

and

snug-fitting,

fire-resistant

covers

or

shields.

Walls

touching

combustibles

on

opposite

sides

should

not

be

welded

on

(or

cut).

Wails,

ceilings,

and

floor

near

work

should

be

protected

by

heat-resistant

covers

or

shields.

Fire

watcher

must

be

standing

by

with

suitable

fire

ex

tinguishing

equipment

during

and

for

some

time

after

welding

or

cutting

if:

a.

appreciable

combustibles

(including

building

construction)

are

within

35

feet

b.

appreciable

combustibles

are

further

than

35

feet

but

can

be

ignited

by

sparks

c.

openings

(concealed

or

visible)

in

floors

or

walls

within

35

feet

may

expose

com

bustibles

to

sparks

d.

combustibles

adjacent

to

walls,

ceilings,

roofs,

or

metal

partitions

can

be

ignited

by

radiant

or

conducted

heat.

Hot

work

permit

should

be

obtained

before

operation

to

ensure

supervisors

approval

that

adequate

precautions

have

been

taken.

After

work

is

done,

check

that

area

is

free

of

sparks,

glowing

embers,

and

flames.

An

empty

container

that

held

combustibles,

or

that

can

produce

flammable

or

toxic

vapors

when

heated,

must

never

be

welded

on

or

cut,

unless

container

has

first

been

cleaned

as

described

in

AWS

Standard

A6.O,

listed

3

in

Standards

index.

This

includes:

a

thorough

steam

or

caustic

cleaning

(or

a

solvent

or

water

washing,

depending

on

the

com

bustibles

solubility)

followed

by

purging

and

inerting

with

nitrogen

or

carbon

dioxide,

and

using

protective

equipment

as

recommended

in

A6.O.

Waterfilling

just

below

working

level

may

substitute

for

inerting.

Page

2

A

container

with

unknown

contents

should

be

cleaned

(see

paragraph

above).

Do

NOT

depend

on

sense

of

smell

or

sight

to

determine

if

it

is

safe

to

weld

or

cut.

Hollow

castings

or

containers

must

be

vented

before

welding

or

cutting.

They

can

explode.

Explosive

atmospheres.

Never

weld

or

cut

where

the

air

may

contain

flammable

dust,

gas,

or

liquid

vapors

(such

as

gasoline).

D.

Compressed

Gas

Equipment

Standard

precautions.

Comply

with

precautions

in

this

manual,

and

those

detailed

in

CGA

Standard

P-i,

PRECAUTIONS

FOR

SAFE

HANDLING

OF

COMPRESSED

GASES

IN

CYLINDERS,

listed

6

in

Standards

index.

1.

Pressure

Regulators

Regulator

relief

valve

is

designed

to

protect

only

the

regulator

from

overpressure;

it

is

not

intended

to

protect

any

downstream

equipment.

Provide

such

protection

with

one

or

more

relief

devices.

Never

connect

a

regulator

to

a

cylinder

containing

gas

other

than

that

for

which

the

regulator

was

designed.

Remove

faulty

regulator

from

service

immediately

for

repair

(first

close

cylinder

valve).

The

following

symptoms

indicate

a

faulty

regulator:

Leaks

-

if

gas

leaks

externally.

Excessive

Creep

-

if

delivery

pressure

continues

to

rise

with

downstream

valve

closed.

Faulty

Gauge

-

if

gauge

pointer

does

not

move

off

stop

when

pressurized,

nor

returns

to

stop

after

pressure

release.

Repair.

Do

NOT

attempt

repair.

Send

faulty

regulators

for

repair

to

manufacturers

designated

repair

center,

where

special

techniques

and

tools

are

used

by

trained

personnel.

2.

Cylinders

must

be

handled

carefully

to

prevent

leaks

and

damage

to

their

walls,

valves,

or

safety

devices:

Avoid

electrical

circuit

contact

with

cylinders

in

cluding

third

rails,

electrical

wires,

or

welding

cir

cuits.

They

can

produce

short

circuit

arcs

that

may

lead

to

a

serious

accident.

(See

1-3C.)

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

MI;

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.

With

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

fleme,

etc.

that

may

cause

rupture.

Do

not

allow

contents

to

exceed

130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

suppliei~.

Mixing

gases.

Never

try

to

mix

any

gases

in

a

cylinder.

Never

refill

any

cylinder.

Cylinder

fittings

should

never

be

modified

or

exchang

ed.

3.

Hose

Prohibited

use.

Never

use

hose

other

than

that

designed

for

the

specified

gas.

A

general

hose

identification

rule

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.

Coil

excess

hose

to

prevent

kinks

and

tangles.

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

RIGHT

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.

Stand

to

side

of

regulator

while

opening

cylinder

valve.

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

Liquid*

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

irn

mediately

for

repair.

See

User

Responsibility

statement

in

equipment

manual.

*Trademark

of

Proctor

&

Gamble.

OM-1540

Page

3

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.

DONT

GET

BURNED;

COMPLY

WITH

PRECAU

TIONS.

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.

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

bevented

to

the

outside

air.

Carbon

monoxide

can

kill.

C.

Fire

and

Explosion

Prevention

Comply

with

precautions

in

1

-2C.

Equipment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

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

conductor.

DO

NOT

STAND,

SIT,

LIE,

LEAN

ON,

OR

TOUCH

a

wet

surface

when

welding,

without

suitable

protection.

Page

4

To

protect

against

shock:

5.

Terminals

And

Other

Exposed

Parts

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

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.

Grou~nding

the

Equipment

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

lead

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

lor

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.

2.

Electrode

Holders

Fully

insulai:ed

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.

Terminals

and

other

exposed

parts

of

electrical

units

should

have

insulating

covers

secured

before

operation.

6.

Electrode

Wire

Electrode

wire

becomes

electrically

HOT

when

the

power

switch

of

gas

metal-arc

welding

equipment

is

ON

and

welding

gun

trigger

is

pressed.

Keep

hands

and

body

clear

of

wire

and

other

HOT

parts.

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

or

red-tag

switches)

to

prevent

accidental

turning

ON

of

power.

Disconnect

all

cables

from

welding

power

source,

and

pull

all

11

5

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,

14:30

Broadway,

New

York,

NY

10018.

5.

ANSI

Standard

Z41

.1,

STANDARD

FOR

MENS

SAFETY-TOE

FOOTWEAR

obtainable

from

the

American

National

Standards

Institute,

14:30

Broadway,

New

York,

NY

10018.

OM-1

540

Page

5

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

GAS

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

1

R3.

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

Recommended

Safe

Practices

for

the

Prepara

tion

for

Welding

and

Cutting

of

Containers

and

Piping

That

Have

Held

Hazardous

Substances,

obtainable

from

the

American

Welding

Society,

550

Le

Jeune

Rd.,

P.O.

Box

351040,

Miami,

FL

33135.

15.

ANSI

Standard

Z88.2

Practice

for

Respiratory

Protection

obtainable

from

the

American

Na

tional

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Page

6

SECTION

2

-

INTRODUCTION

Overall

Dimensions*

Weightt

Height

Width

Depth

Weld

Control

20-1/2

in.

(521

mm)

17

in.

(432

mm)

9-3/4

in.

(248

mm)

43

lbs.

(19.5

kg)

Current

.

Sensing

Assembly

14

in.

(356

mm)

8-3/4

in.

(222

mm)

4

in.

(102

mm)

11

lbs.

(5.0

kg)

Weld

Volts

And

Amps

Capacity

AC

or

DC

0

to

100

Volts

0

to

1500

Amperes

*For

Wire

Manual

1538.

tSupplied

Cables

Weigh

5-1/2

lbs.

(2.5

kg).

Drive

Assembly

Specifications,

See

Owners

Figure

2-1.

Specifications

2

-

1.

GENERAL

INFORMATION

AND

SAFETY

A.

General

ment.

B.

Safety

WARNIN~

CAUTION

IMPORTANT

Information

presented

in

this

manual

and

on

various

labels,

tags,

and

plates

provided

on

the

unit

pertains

to

equipment

design,

installation,

operation,

maintenance,

and

troubleshooting

which

should

be

read,

understood,

and

followed

for

the

safe

and

effective

use

of

this

equip-

The

installation,

operation,

maintenance,

and

troubleshooting

of

arc

welding

equipment

requires

practices

and

procedures

which

ensure

personal

safety

and

the

safcty

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.

Safety

instructions

specifically

pertaining

to

this

unit

ap

pear

throughout

this

manual

highlighted

by

the

signal

words

~:hlIi~e1

and

___________

which

identify

different

levels

of

hazard.

~

statements

include

installation,

operating,

and

maintenance

procedures

or

practices

which

if

not

carefully

followed

could

result

in

serious

personal

injury

or

loss

of

life.

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.

A

third

signal

word,

_______________,

highlights

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

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)

Number

of

the

equipment

be

supplied.

2

-

3.

DESCRIPTION

-

This

unit

consists

of

a

weld

control,

current

sensing

assembly,

and

wire

drive

assembly

designed

to

automatically

cycle

preselected

welding

conditions

for

Submerged

Arc

(SAW)

or

Gas

Metal-Arc

(GMAW)

welding

processes

using

either

ac

or

dc

constant

potential

welding

power

sources.

This

unit

is

a

heavy-duty

constant-speed

automatic

wire

feeder

with

capability

for

wire

sizes

from

.030

through

1/4

in.

(0.8

through

6.4

mm)

diameter.

The

standard

weld

control

has

provisions

for

selecting

the

WELD

VOLTAGE,

WELD

SPEED,

PREFLUX,

INCH

UP,

INCH

DOWN,

PRE-FLUX

TIME,

RUN

IN

SPEED,

CRATER

VOLTAGE,

CRATER

&

INCH

SPEED,

CRATER

TIME,

and

BURNBACK

TIME,

with

RUN

IN

VOLTAGE,

RUN

IN

TIME,

and

POST-FLOW

TIME

con

trols

optional.

Additionally,

relay

contacts

are

provided

for

fixture

control,

etc.

The

weld

control

has

a

lockable

hinged

cover

over

the

recessed

subpanel

controls

as

standard

equipment.

For

information

on

the

wire

drive

see

Owners

Manual

1538.

OM-1540

Page

7

SECTION

3

-

INSTALLATION

Figure

3-1.

Overall

Dimensions

And

Mounting

Hole

Layout

3

-

1.

LOCATION

(Figure

3-1)

-

The

service

life

and

efficiency

of

this

unit

and

associated

components

will

be

reduced

when

they

are

subjected

to

high

levels

of

dust,

dirt,

moisture,

corrosive

vapors,

and

extreme

heat.

The

location

should

allow

room

to

open

the

front

panel

and

to

remove

wrapper(s)

for

installation,

inspection,

maintenance,

and

repair

functions.

Mounting

holes

are

provided

in

the

weld

control

and

current

sensing

assembly.

Figure

3-1

gives

overall

dimensions

and

mounting

hole

layout.

IMPORTANT

______________

When

selecting

locations

for

the

various

components

of

this

unit;

keep

in

mind

that

a/I

provided

interconnecting

cords

are

10

feet

(3

m)

long.

Mount

the

standard

components

in

the

desired

location

using

information

from

Figure

3-1

and

from

the

drive

assembly

Owners

Manual

(OM-

1538).

Lead

lengths

must

be

considered

when

locating

and

mounting.

3

-

2.

REMOTE

PEN

DENT

CONTROL

(Optional)

WARNING

__________

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

the

weld

control

and

disconnect

input

power

(115

vac)

before

making

any

terminal

strip

connections.

This

control

allows

remote

operation

of

the

pilot

light,

START,

STOP,

INCH

UP,

INCH

DOWN,

and

PREFLUX

controls.

To

install

this

control,

connect

the

plug

from

the

pen-

dent

control

cord

to

the

remote

pendent

control

recep

tacle

on

the

side

of

the

weld

control

(see

Figure

3-3).

Remove

and

retain

jumper

links

connected

across

ter

minals

K

and

L,

and

Land

M

on

terminal

strip

iT

inside

the

weld

control.

~

If

the

remote

pendent

control

is

disconnected

from

the

weld

control,

the

jumper

links

must

be

reinstalled

on

the

terminal

strip

or

the

weld

con

trol

will

not

function.

3

-3.

FLUX

HOPPER

WITH

AUTOMATIC

VALVE

(Optional)

WARNING

__________

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

the

weld

control

and

disconnect

input

power

(115

vac)

before

making

any

terminal

strip

connections.

Mount

the

flux

hopper

in

the

desired

location

as

in

structed

in

the

Owners

Manual.

Route

leads

from

automatic

valve

through

strain

relief

clamp

on

side of

weld

control

(see

Figure

3-3).

Connect

leads

to

ter

minals

B

and

E

on

terminal

strip

iT

inside

weld

control

(polarity

is

not

important).

The

automatic

valve

will

energize

and

flux

will

flow

whenever

the

START

or

PREFLUX

button

is

depressed.

3

-4.

SHIELDING

GAS

CONNECTIONS

(Optional)

WARNING

__________

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

the

weld

control

and

disconnect

input

power

(115

vac)

before

making

any

internal

con

nections.

2

in.

Add

1-1/2

in.

5/16

in.

(38.1

mm)

For

(7.9

mm)

Front

Panel

Knobs

Die.

4

Holes

TC-083

441

4

in.

(101.6

mm)

TA-083

354

Page8

Install

the

shielding

gas

valve

and

associated

com

ponents

acc:ording

to

instructions

provided

with

the

kit.

Connect

a

hose

(not

supplied)

of

proper

lengthand

con

struction

Irom

shielding

gas

supply

(regulator

flowmeter)

1:o

fitting

on

the

IN

panel

of

current

sensing

assembly

(s~e

Figure

3-4).

The

gas

fittings

are

5/8-18

connectors

with

righthand

threads.

The

gas

flow

must

be

accurately

controlled

by

a

regulator

and

flowmeter

at

the

source.

Connect

supplied

gas

hose

from

remaining

fitting

on

current

sensing

assembJy

to

barbed

fitting

on

wire

drive

housing.

Shielding

gas

will

flow

whenever

the

START

or

PREFLUX

button

is

depressed.

When

a

shielding

gas

valve

is

installed,

the

PREFLUX

button

functions

as

a

Purge

button.

Also,

the

PRE-FLUX

TIME

control

func

tions

as

a

gas

preflow

control,

etc.

3

-

5.

WATER

CONNECTIONS

(Optional)

CAUTION

E

OVERHEATING

WELDING

GUN

can

damage

gun.



If

using

a

water-cooled

gun

and

recirculating

coolant

system,

make

connections

from

the

coolant

system

directly

to

the

gun

hoses.

Do

not

use

water

connections

on

the

current

sensing

assembly.

Check

system

periodically

for

proper

coolant

flow.

Install

the

water

valve

and

associated

components

ac

cording

to

the

instructions

provided

with

the

kit.

When

a

recirculating

coolant

system

is

not

employed,

and

use

of

the

installed

solenoid

valve

is

desired,

make

water

connections

at

current

sensing

assembly.

The

water

fittings

are

5/8-18

connectors

with

left-hand

threads.

Connect

a

water

hose

from

supply

to

fitting

Ofl

IN

panel

of

current

sensing

assembly

(see

Figure

3-4).

Connect

another

hose

between

remaining

fitting

on

cur

rent

sensing

assembly

and

gun

IN

fitting.

Connect

and

route

a

hose

from

gun

OUT

fitting

to

a

proper

drain.

Check

system

periodically

for

proper

coolant

flow.

Water

will

flow

whenever

the

START

button

is

depress

ed.

3

-

6.

AUXILIARY

RELAY

CONTACTS

(Figure

3-2)

WARNING

ELECTRIC

SHOCK

can

kill.

Do

not

touch

live

electrical

parts.

Shut

down

the

weld

control

and

disconnect

input

power

(115

vac)

before

making

any

terminal

strip

connections.

*See

Section

3-6

For

Auxiliary

Contact

Information.

**Connection

example

shown

starts

fixture

moving

at

arc

in

itiation

and

stops

fixture

when

STOP

button

is

depressed.

See

Section

3-6

for

additional

information.

.

S

(pC~

o~

1 -~

L

C-084

598-A

a

C

V

Weld

Time

0-

Infinity

Run

In

Speed

.Pre.Flow

Time



(i-S

Sec.

Crater

Time

0-2.5

Sec.

V

a

UI

V

START

Burnback

Time

0-0.25

Sec.

Arc

initiation

-

ft

M

J

Time

Figure

3-2.

Weld

Control

Cycle

TB-080

432-B

OM-1540

Page9

Three

sets

of

normally-open

relay

contacts

are

provided

for

customer

use.

The

connection

points

for

the

con

tacts

are

terminals

J

through

P

on

terminal

strip

21

in

side

the

weld

control.

These

terminals

provide

on/off

control

only.

When

making

connections,

route

leads

through

strain

relief

clamp

on

side

of

weld

control

(see

Figure

3-3).

The

terminals

and

functions

available

are

as

follows:

Terminals

J

and

K

on

2T

close

(energize)

at

end

of

PRE-FLUX

(Preflow)

TIME

and

open

(deenergize)

at

end

of

BURNBACK

TIME.

Terminals

L

and

M

on

21

close

(energize)

at

end

of

PRE-FLUX

(Preflow)

TIME

and

open

(deenergize)

when

the

STOP

button

is

depressed.

Terminals

N

and

P

on

21

close

(energize)

at

arc

initiation

and

open

(deenergize)

at

end

of

CRATER

TIME.

Various

combinations

of

these

contacts

will

allow

a

variety

of

fixture

start

and

stop

points

as

illustrated

in

the

following

example.

For

connections

that

start

fixture

movement

at

arc

in

itiation

and

stop

fixture

when

STOP

button

is

depress

ed,

see

Figure

3-2

and

proceed

as

follows:

1.

Make

up

a

jumper

lead

and

connect

it

between

terminals

M

and

N

on

terminal

strip

2T.

2.

Connect

fixture

leads

to

terminals

L

and

P

on

2T

(polarity

is

not

important).

3.

Terminals

L

and

P

(fixture

leads)

will

close

(energize)

at

arc

initiation

and

open

(deenergize)

when

the

STOP

button

is

depressed.

Connect

equipment

to

terminals

as

desired.

3

7.

HUB

AND

SPINDLE

ASSEMBLY

STALLATION

(Figure

3-3)

1.

Remove

hex

nut

from

hub

support

shaft

and

in

sert

shaft

through

one

of

the

sets

of

holes

in

the

spindle

support

(hole

selection

depends

on

size

of

wire

spool).

Ensure

that

the

brake

washers

are

properly

seated

in

the

hub.

2.

Replace

hex

nut

and

tighten

until

a

slight

drag

is

felt

while

turning

hub.

3.

Install

welding

wire

according

to

the

applicable

Section:

3-8

for

spool-type

wire;

and

3-9,

3-10

for

reel-type

wire.

3

-

8.

INSTALLATION

OF

SPOOL-TYPE

WIRE

(Figure

3-3)

1.

Depress

the

two

spring-loaded

stops

(see

Figure

3-3)

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

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

the

proper

position

on

the

hub.

Release

the

two

stops.

3

-

9.

INSTALLATION

OF

REEL-TYPE

WIRE

(Op

tional)

(Figure

3-3)

1.

Lay

the

wire

reel

(see

Figure

3-3)

fIat

on

a

table

or

floor.

2.

Loosen

the

four

wing

nuts

on

the

fingers

of

the

wire

reel.

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

-

10.

INSTALLATION

OF

WIRE

REEL

(Optional)

(Figure

3-3)

1.

Depress

the

two

spring-loaded

stops

(see

Figure

3-3)

on

retaining

ring,

and

slide

retaining

ring

off

hub.

2.

Slide

the

wire

reel

onto

the

hub.

Rotate

wire

reel

until

hub

guide

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.

ilning

Ring

IN-

Wire

Reei*

Spi

Wing

Nuts*

*Optional

Spindle

Support

TB-070

886

Figure

3-3.

Hub

And

Reel

Installation

Page

10

4-Pin;

Voltage

Sensing

-

A

4-Pin;

Voltage

Control

-

B

-9-Pin;

Motor

Control

-

C

14-Pin;

Current

Sensing

Assembly

-

D

4-Pin;

115

VAC

And

Contactor

Control

-

E

Figure

3-4.

Interconnection

Points

On

Weld

Control

TC-083

142

3

-

11.

WELD

CONTROL

INTERCONNECTIONS

(Figures

3-4

and

3-6)

IYATIi~~ll~Ic1

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

welding

power

source

and

be

sure

it

cannot

be

accidentally

energized

before

making

interco-inections.

This

unit

is

supplied

with

the

necessary

interconnecting

cords.

Examine

and

select

the

proper

cord

for

each

of

the

following

connections.

A.

VoIt~ige

Sensing

Connections

Connect

the

4-pin

plug

from

the

voltage

sensing

cord

to

weld

control

receptacle

A

(see

Figure

3-4).

Connect

re

maining

end

with

ring

terminal

attached

to

workpiece.

B.

Voltage

Control

Connections

D.

Current

Sensing

Assembly

Connections

Connect

the

14-pin

plug

from

the

current

sensing

assembly

cord

to

weld

control

receptacle

D

(see

Figure

3-4).

Connect

remaining

end

to

receptacle

on

current

sensing

assembly

(see

Figure

3-5).

Current

Sensing~

Receptacle

Connect

Weld

Cable

From

Bus

Bar

To

Wire

Drive

Housing

Connect

the

4-pin

plug

from

the

voltage

control

cord

to

weld

control

receptacle

B

(see

Figure

3-4).

Connect

re

maining

end

to

VOLTAGE

CONTROL

receptacle

on

welding

power

source.

Place

VOLTAGE

CONTROL

switch

on

welding

power

source

in

the

REMOTE

posi

tion.

C.

Motol

Control

Connections

Connect

the

9-pin

plug

from

the

motor

control

cord

to

weld

control

receptacle

C

(see

Figure

3-4).

Connect

re

maining

end

to

plug

from

drive

motor.

-

Figure

3-5.

Current

Sensing

Assembly

E.

115

VAC

And

Contactor

Control

Connec

tions

Connect

the

4-pin

plug

from

the

115

volts

ac

and

con

tactor

control

cord

to

weld

control

receptacle

E

(see

Figure

3-4).

Connect

remaining

ends

to

welding

power

source

as

follows:

Connect

2-prong

plug

to

CONTAC

TOR

CONTROL

receptacle,

and

connect

3-prong

plug

to

115

VOLTS

AC

twistlock

receptacle.

Place

CON

TACTOR

CONTROL

switch

on

welding

power

source

~n

the

REMOTE

position.

10-Pin;

Remote

Pendent

Control

Receptacle

Strain

Relief

Clamp

(For

Options

Or

User

Connections)

Shunt

Connect

Weld

Cable

From

Power

Source

To

Bus

Bar

Rear

Panel

Weld

Cable

Opening

In

P~nel

TA-083

353

OM-1

540

Page

11

F.

Weld

Output

Connections

(Figure

3-5)

IYAYI~:l~II~e~

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

the

we/ding

power

source

and

be

sure

it

cannot

be

accidentally

energized

before

making

weld

output

connections.

1.

Select

and

prepare

proper

size

weld

cables

ac

cording

to

welding

power

source

Owners

Manual.

2.

Remove

cover

from

current

sensing

assembly.

3.

Route

weld

cable(s)

from

welding

power

source

output

terminal

through

opening

on

IN

panel

of

current

sensing

assembly

and

connect

to

bus

bar

on

shunt

(see

Figure

3-5).

4.

Connect

and

route

another

weld

cable(s)

from

remaining

bus

bar

on

opposite

end

of

shunt

through

rear

opening

of

current

sensing

assembly

to

provided

terminal

on

wire

drive

housing.

I l~

I

~i]

~

f~i~

I

~

For

in

formation

on

the

wire

drive

and

spool

support

assemblies,

see

Owners

Manual

1538.

5.

Reinstall

cover

onto

current

sensing

assembly.

115

VAC/Contactor

6.

Connect

weld

cable

from

remaining

welding

power

source

output

terminal

to

the

workpiece.

Welding

Power

Source

*Optional

Right

Side

View

Of

Weld

Control

Remote

Pendent

Control*

TA-083

508

Flux

Hopper

And

Valve*

Figure

3-6.

Connection

Diagram

Page

12

Page is loading ...

Miller JB577755 Owner's manual

This manual is also suitable for

Miller JB577755 Owner's manual

Related papers

Other documents