Miller AUTOMATIC 1 Owner's manual

November

1978

FORM:

OM-1518

FIILE

CQp

EFURN

TO

FOLDER

OV~NEHS

MANUAL

MILLER

ELECTRIC

MFG.

CO.

718

S.

BOUNDS

ST.

P.O.

Bo~

1079

APPLETON,

WI

54912

USA

ADDITIONAL

COPY

PRICE

70

CENTS

NWSA

CODE

NO.

4579

PRINTED

IN

U.S.A.

EffectiveWith

Seria

No.

HJ195967

MODEL

AUTOMATIC

I

i~

LIMITED

WARRANTY

EFFECTIVE:

FEBRUARY

20,

1978

This

warranty

supersedes

all

warranties

and

is

ex

clusive

with

no

other

guarantees

or

warranties

expressed

or

implied.

LIMITED

WARRANTYMiller

Electric

Mfg.

Co..

Apple-

1.

Arc

welders,

power

sources,

and

components.

-

1

year

ton,

Wisconsin

warrants

to

Customer

that

all

rrew

and

unused

2.

Original

main

power

rectifiers

3

years

Equipment

furnished

by

Miller

is

free

from

defect

in

(Labor

1

year

only)

warkmanship

and

material

as

of

the

time

and

place

of

3.

All

welding

guns

and

feeder/guns

90

days

delivery

by

Miller.

No

warranty

is

made

by

Miller

with

respect

to

engines,

trade

accessories

or

other

items

manu-

4.

All

other

Millermatic

Feeders

1

year

factured

by

others.

Such

engines,

trade

accessories

and

other

provided

that

the

user

so

notifies

Miller

in

writing

within

thirty

)

items

are

sold

subject

to

the

warranties

of

their

respective

(30)

days

of

the

date

of

such

failure.

manufacturers,

if

any.

The

manufacturers

warranty

on

5.

Replacement

or

repair

parts

exclusive

of

labor

60

days



engines

i~

for

~

period

Of

one

year.

MILLER

warranty

does

not

apply

to

components

having

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

normal

useful

life

of

less

than

one

(1)

year,

such

as

spot

HEREIN

AND

ANY

IMPLIED

WARRANTY.GUARANTY

welder

tips,

relay

and

contactor

points,

M!LLERMATIC

OR

REPRESENTATION

AS

TO

PERFORMANCE.

AND

parts

that

come

in

contact

with

the

welding

wire

including

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

WHICH,

nozzles

and

nozzle

insulators

where

failure

dQes

not

result

.

&UT

FOR

THIS

PROVISION,

MIGHT

ARISE

BY

14

from

defect

in

workmanship

or

material.

IMPLICATION.

OPERATION

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

INCLUDING

ANY

In

the

case

of

Millers

breach

of

warranty

or

any

other

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR OF

duty

with

respect

to

the

quality

of

any

goods,

the

exclusive

remedies

therefor

shall

be,

at

Millers

option,

(1)

repair

or

(2)

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

replacement

or,

where

authorized

in

writing

by

Miller

in

TO

ANY

AND

ALL

EQUIPMENT

FURNISHED

BY

appropriate

cases,

(3)

the

reasonable

cost

of

repair

or

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

~

replacement

at

an

authorized

Miller

service

station

or

(4)

payment

of

or

credit

for

the

purchase

price

(less

reasonable

EXCEPT

AS

EXPRESSLY

PROVIDED

BY

MILLER

IN

depreciation

based

upon

actual

use)

upon

return

of

the

goods

WRITING,

MILLER

PRODUCTS

ARE

INTENDED

FOR

at

Customers

risk

and

expense.

All

transactions

are

F.O.B.

Appleton,

Wisconsin.

Upon

receipt

of

n&ice

of

apparent

ULTIMATE

PURCHASE

BY

COMMERCIAL/INDUSTRIAL

USERS

AND

FOR

OPERATION

BY

PERSONS

TRAINED

defect

or

failure,

Miller

shall

instruct

the

claimant

on

the

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

warranty

claim

procedures

to

be

followed.

OF

WELDING

EQUIPMENT

AND

NOT,

FOR

CONSUMERS

As

a

matter

of

general

policy

only.

Miller

may

honor

an

OR

CONSUMER

USE.

MILLER

WARRANTIES

DO

NOT

original

useri

warranty

claims

on

warranted

Equipment

in

EXTEND

TO,

AND

NO

RESELLER

IS

AUTHORIZED

TO

the

event

of

failure

resulting

from

a

defect

within

the

following

periods

from

the

date

of

delivery

of

Equipment

to

EXTEND

MILLERS

WARRANTIES

TO,

ANY

the

original

user:

CONSUMER.

..,~

~%

j~:~

-~

ERRATA

SHEET

After

this

manual

was

printed,

refinements

in

equipment

design

occurred.

This

sheet

lists

exceptions

to

data

appearing

later

in

this

manual.

Item

Dia.

Part

No.

Listed

Replaced

With

No.

Mkgs.

In

Parts

List

Part

No.

Description

Quantity

5

S2

011

059

011

043

SWITCH,

toggle

DPDT

6

amp

125

volts

(Eff

with

S/N

HJ21

5887)

1

117

M

059

138

080

802

MOTOR,

gear

1/8

hp

115

volts

dc

2000

rpm

1

141

079911

080868

INSULATOR,

motor

1

142

079 910

080

869

BRACKET,

mounting

-

motor

1

080

806

STOP,

cover

1

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBERS

WHEN

ORDERING

REPLACEMENT

PARTS.

FIILE:

copy

4~

Ui~

~o

~

OM-1518

Page

A

ERRATA

SHEET

After

this

manual

was

printed,

refinements

in

equipment

designoccurred.

This

sheet

lists

exceptions

to

data

appearing

later

in

this

manual.

Item

Dia.

Part

No.

Listed

Replaced

With

No.

Mkgs.

In

Parts

List

Part

No.

Description

011

043

SWITCH,

toggle

DPDT

6

amp

125

volts

(Eff

with

S/N

HJ21

5887)

080

802

MOTOR,

gear

1/8

hp

115

volts

dc

2000

rpm

080

868

INSULATOR,

motor

080

869

BRACKET,

mountir~g

.

motor

080

806

STOP,

cover

OM-1518

Page

A

5

S2

011

059

-

117

M

059138

141

079911

142

079910



Quantity

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBERS

WHEN

ORDERING

REPLACEMENT

PARTS.

1

TABLE

OF

CONTENTS.

Section

No.

Page

No.

SECTION

1



INTRODUCTION

1-

1.

General

1

-

2.

Receiving-Handling

1

.

3.

Description

1

1-4.

Safety

1

SECTION

2INSTALLATION

2-

1.

Location

1

2-

2.

Control/Feeder

Interconnections

2

-

3.

Voltmeter

connections

2

2-

4.

Contactor

Connections

2

2-

6.

Secondary

Cormoctions

~Rever;e

Polarity)

2

2-

6..

Shielding

Gas

Connections

3

2-7.

Drive

Roll

And

Wire

Guide

Installation

3

2-

8.

Spindle

Assembly

Installation

4

2-

9.

Installation

Of

Spool-Type

Wire

4

2-10.

Installation

Of

Wire

Reel

(Optional)

4

2-11.

Installation

Of

Reel-Type

Wire

4

2-12.

Adjusting

Hub

Tension

4

2-13.

Welding

Wire

Threading

4

2-14.

Remote

Start

And

Stop

Connections

5

2-15.

Electrical

Input

Connections--~

5

SECTION

3

FUNCTION

OF

CONTROLS

3-

1.

Power

Switch

5

3-2.

Pilot

Light

5

3.

3

Retract-Advance

Switch

And

Inch

Push

Button

Switch

6

3-

4.

Purge

Push

Button

Switch

6

3-

5.

Start

Push

Button

Switch

6

3-

6.

Stop

Push

Button

Switch

6

3-7.

Run

In

Speed

Control

6

3-

8.

Wire

Feed

Speed

Control 6

3-

9.

Crater

&

Inch

Speed

Control

6

3-10.

Pre-Flow

Time

Control

6

3-11.

Spot-ContinuousSwitch

6

3-12.

Spot

Time

Control

6

3-13.

Crater

Time

Control

.6

3-14.

Burnback

Control

6

3-15.

Post-Flow

Time

Control

6

3-16.

Meters

7

3-17.

Overload

Protection

7

3-18.

Normally

Open

And

Normally

Closed

Contacts

7

SECTION

4SEQUENCE

OF

OPERATION

4-

1.

Gas.

Metal-Arc

Welding

(GMAW)



Continuous

7

4

-

2.

Gas

Metal-Arc

Welding

(GMAW)



Spot

7

4-

3.

Shutting

Down

7

SECTION.

5-.-MAINTENANCE

5-

1.

Inspection

And

Upkeep

8

5

-

2.

Cleaning

Of

Drive

Rolls

8

SECTION

6

TROUBLESHOOTING

44

SECTION

1

-

INTRODUCTION

Dimensions

(Inches)

Weight

(Pounds)

Height

Width

Depth

Weld

Control

15-1/2

13-7/8

6-1/8

29.5

Gas/Shunt

Control

4-1/8

5-1/8

10-1/2

5.5

Drive

Motor

10-1/4

11-1/2

9-1/4

18

Spindle

Assembly

21-7/8

10-11/16

19-112

6

Figure

1-1.

Specifications

I

generator

manual

should

be

read

completely.

This,

will

help

avoid

possible

injury

due

to

misuse

or

improper

welding

applications.

The

following

definitions

apply

to

CAUTION,

IMPORTANT,

and

NOTE

blocks

found

throughout

this

manual:



Under

this

heading,

~nttelbrion,

operat~ng,

and

main

tenance

procedures

or

practices

will

be

found

that

if

not

carefully

followed

tnay

create

a

hazard

to

per

sonnel.

L.

.

r~NTF:

-

Under

this

heading,

installatiOn,

operating,

and

main

tenance,

procedures

or

practices

will

be

found

that

if

not

carefully

followed

may

result

in

damage

to

equip

ment.

1-1.

GENERAL

This

manual

has

been

prepared

especially

for

use

in

familiar

izing

personnel

with

the

design,

installation,

operation,

main

tenance,

and

troubleshooting

of

this

equipment.

All

informa

tion

presented

herein

should

be

given

careful

consideration

to

assure

optimum

performance

of

this

equipment.

1-2.

RECEIVING-HANDLING

Prior

so

installing

this

equipment,

clean

all

packing

material

from

around

the

unit

~r,d

~arefuiiy

inspect

for

an~

dem~ge

that

may

have

occurred

during

shipment.

Any

claims

for

loss

or

dam~ge

that

may

have

occurred

in

transit

must

be

filed

by

the

purchaser

with

the

carrier.

A

copy

of

the

bill

of

lading

and

freight

bill

will

be

furnished

by

the

carrier

on

request

if

occasion

to

file

claim

arises.

-

When

requesting

information

concerning

this

equipment,

it

is

essential

that

Model

Description

and/or

Stock

Number

and

Serial

(or

Style)

Numbers

of

the

equipmentbe

supplied.

1

.

3.

DESCRIPTION

This

control/feeder

is

designed

to

automaticdlly

cycle

prepro

grammed

welding

events

and

provide

a

constant

wire

feed

speed

regardless

of

varying

motor

load

conditions.

This

unit

is

to

be

used

with

a

constant

potential

welding

power

source.

The

standard

weld

control

has

provisions

to

program

the

PRE-FLOW

TIME,

RUN

IN

SPEED,

WIRE

FEED

SPEED,

SPOT

TIME.

CRATER

&

INCH

SPEED,

CRATER

TIME,

BURNBACK

time,

and

POST-FLOW

TIME.

Normally

open

and

normally

closed

contacts

are

provided

on

each

time

control

to

interface

with

other

equipment

(i.e.,

starting

and

stoping

a

welding

fixture).

1-4.

SAFETY

Before

the

equipment

is

put

into

operation,

the

safety

sec

tion

at

the

front

of

the

welding

power

source

or

welding

~SECTION2-

2-1.

LOCATION

/

A

proper

installation

Site

should

be

sele~ted

for

the

control/

feeder

if

the

Unit

is

to

provide

dependable

service

and

remain

relatively

maintenance

free.

/

A

proper

installation

site

permits

freedom

of

air

movement

around

the

weld

control

and

also

least

subjects

the

control!

feeder

to

dust,

dirt,

moisture,

and

corrosive

vapors.

The

installation

site

should

also

permit

efficient

placement

of

all

components

to

provide

optimum

performance.

Provisions

have

been

made

for

mounting

the

gas/shunt

assembly

on

the

bottom

of

the

weld

control.

The

gas/shunt

assembly

may

also

be

mounted

in-line-with

the

welding

gun

thereby

avoiding

routing

the

weld

cables

and

gas

hpses

back

to

the

weld

control.

The

drive

motor

and

spindle

assembly

should be

placed

close

together

near

the

work

area.

The

pivot

bracket

can

be

removed

from

the drive

assembly

and

repositioned

for

ease

of

installation.

Remove

the

hex

head

screw

and

lock

washer

from

the

pivot

bracket

and

reposition

the

bracket;

replace

hardware

(see

Figure

2-4).

The

drive

motor

is

attached

to

a

ball

joint

and

mounting

bar

for

ease

of

installation.

Loosen

the

two

hex

head

bolts

on

the

ball

joint

and

adjust

the

position

of

the

drive

motor;

tighten

the

botts

to

lock

the

drive

motor

in

position.

The

installation

sight

should

also

permit

easy

access

to

all

components

for

operational

and

maintenance

functions.

Lead

lengths

must

be

considered

when

locating

all

components

of

the

control/

feeder.

-

NOTE

1



Under

this

heading,

explanatory

statements

will

be

found

that

need

special

emphasis

to

obtain

the

most

efficient

operation

of

the

equipment.

INSTALLATION

TC-080

430

Figure

2-1.

Overall

Dimensions

And

Mounting

Hole

Layout

(Continued

On

OM-1

518

Page~

1

TB-080

486

Figure

2-1.

Overall

Dimensions

And

Mounting

Hole

Layout

(Contd.)

Mounting

holes

are

provided

in

all

components

of

the

control/feeder.

Figure

2-1

gives

overall

dimensions

and

mounting

hole

layout.

2-2.

CONTROL/FEEDER

INTERCONNECTIONS

A.

Drive

Motor

Connections

Insert

three-pole

plug

PLG6

from

the

weld

control

into

plug

PLG1

1

at

the

drive

motor.

Rotate

plug

PLG6

threaded

outer

ring

clockwise

into

plug

PLG11

threaded

body

as

far

as

possible.

This

action

will

secure

the

connection.

B.

Control

Cable

Connections

Insert

ten-pole

plug,

PLG7

from

the

weld

control

into

receptacle

RC7

on

the

gas/shunt

assembly.

Rotate

the

plug

threaded

outer

ring

clockwise

into

the

receptacle

threaded,

body

as

far

as

possible.

This

action

will

secure

the

plug

in

the

receptacle.

-

2-3.

VOLTMETER

CONNECTIONS

For

reverse

polarity,

connect

the

lead

with-

ring

terminal

from

the

weld

control

voltmeter

to

the

negative

output

terminal

on

the

welding

power

source.

For

straight

polarity,

connect

the

lead

with

the

ring

terminal

from

the

weld

control

voltmeter

to

the

positive

output

terminal

on

the

welding-power

source.

Reverse

the

leads

on

the

weld

control

voltmeter

and

ammeter.

2-4.

CONTACTOR

CONNECTIONS

Insert

two-pole

twistlock

plug

PLG8

into

the

contactor

control

receptacle

on

the

welding

power

source

and

rotate

the

plug

as

far

as

it

will

turn

in

a

clockwise

direction.

Once-

fully

rotated,

the

plug

will

be

locked

in

the

receptacle.

2-

5.

SECONDARY

CONNECTIONS

(Reverse

Polarity)

-

(Figure

2-2)

1.

Remove

the

gas/shunt

assembly

cover.

2.

Insert

the

proper

size

weld

cable

from

the

positive

output

terminal of

the

welding

power

source

through

the

grommet

on

the

IN

side

of

the

gasfshunt

assembly.

Connect

the

weld

cable

to

the

shunt.

-

3.

Insert

the

proper

size

weld

cable

from

the

weld

cable

terminal

on

the

drive

motor

(Figure

2-3)

through

the

grommet

on

the

other

end

of

the

gas/shunt

assembly.

This

cable

must

be

routed

through

the

reed

switch

bracket.

Connect

the

weld

cable

to

the

shunt.

4.

Connect

the

proper

size

weld

cable

from

the

negative

output

terminal

of

the

welding

power

source

to

the

work.

5.

Replace

the

gaslshunt

assembly

cover.

-

Figure

2-2.

Gas/Shunt

Assembly

TA-080

485

4.18~

-~

5116

Diameter

-

2Holes

~T.

9-7/8

-

10-1/2

-

TA-080

429

To

Welding

Power

Source

Positive

Output

To

Weld

Cable

Terminal

On

Drive

Motor

Control

cable

Receptacle

RC7

TA-080

424

Page

2

2-

6.

SHIELDING

GAS

CONNECTIONS

(Figures

2-2

&

2-3)

Connect

a

hose

of

suitable

length

and

construction

from

.the

shielding

gas

supply

to

the

connector

on

the

IN

side

of

the

gas/shunt

assembly.

The

gas

flow

must

be

accurately

controlled

by

a

regulator

and

flowmeter

at

the

source.

Connect

the

supplied

hose

from

the

gas/shunt

assembly

to

the

barbed

fitting

on

the

motor/drive

assembly.

2-7.

DRIVE

ROLL

AND

WIRE

GUIDE

INSTALLATION

(Figure

2-3

&

2-4)

Upon

initial

installation,

or

as a

result

of

changes

in

wire

size

and

type,

it

is

necessary

to

install

the

required

drive

rolls

and

wire

guides.

~~lection

of

d

rive

rofls

upon

the

f

ollowing

recommended

usages:

1.

V-Groove

rolls

for

hard

wire.

2.

U-Groove

rolls

for

soft

~,nd

soft

shelled

cored

wiros

3.

U-Cog

rolls

for

extremely

soft

shelled

wires

(usually

hard

surfacing

types).

4.

Split

V-Knurled

rolls

for

hard

shelled

cŁred

wires

(self-shielding

and

CO2

shielded

types).

5.

Drive

roll

types

may

be

mixed

to

suit

particular

requirements

(example:

V-knurled

roll

in

combination

with

U-groove).

Having

selected

the

appropriate

drive

rolls

and

wire

guides,

proceed

to

the

following

installation

instructions:

Figure-2-3.

One-Piece-Drive

Roll

Installation

A.

One

Piece

Drive

Roll

(Figure

2-3)

NOTE

1Drive

rolls

(8

&

13)

are

of

the

double

usage

type.

When

the

grooves

become

worn,

reverse

each

drive

roll,

locating

the

unused

groove

in

position

to

feed

the

wire.

1.

Loosen

the

pressure

adjustment

wing

nut

(item

2,

Figure

2-3)

and

pivot

it

free

of

the

cover.

2.

Pivot

gear

cover

(4)

away

until

it

is

in

an

open

postion.

3.

Loosen

and

remove

the

three

securing

screws

(7

&

12)

on

each

drive

roll

gear

(5

&

9).

4.

Slide

one

drive

roll

(13)

Onto

lower

gear

(9)

with

holes

-~

aligned.

Insert

securing

screws

(12)

and

tighten.

NOTE

1

To

ensure

proper

gripping

action

of

U-Cog

drive

rolls,

1

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

upper

roll

directly

over

the

spaces.

between

the

teeth.

on

the

roll

as

illustrated

in

Figure

2-3.

5.

Slide

remaining

drive

roll

(8)

Onto

upper

gear

(5~

witl~

holes

aligned.

Insert

securing

screws

(7)

and

tighten.

B.

Split

Drive

Roll

(Figure

2-4)

Drive

rolls

(6

&

10)

are

of

the

double

usage

type.

When

the

knurled

groove

of

the

drive

rolls

becomes

worn,

the

split

halves

may

be

reversed

so

that

the

unused

edges

will

provide

a

new

knurled

groove.

2.

Pivot

gear

cover

(4)

away

until

it

is

in

an

open

position.

3.

Loosen

and

remove

the

three

securing

screws

(7

&

12)

on

each

drive

roll

gear

(5&

9).

4.

Separately

align

the

holes

on

each

pair

of

split

drive

rolls

(6

&

10)

and

insert

a

securing

screw

(7

&

12).

5.

Slide

a

pair

of

drive

rolls

(10)

with

securing

screw

(12)

onto

the

lower

gear

(9)

in

line

with

one

of

the

threaded

holes.

6.

Insert

remaining

screws

and

tighten.

7.

Repeat

steps

4

through

6

for

installation

of

upper

drive

rolls.

C.

Inlet

Wire

Guide

(Figure

2-3

&

2-4)

1.

Loosen

the

inlet

wire

guide

securing

screw

(item

3,

Figure

2-3).

I

NOTEJ~

1~ire

guides

should

be

installed

so

that

the

tip

of

the1

guide

is

as

close

to

the

drive

roll

as

possible

without

~~Jching.

I

Ball

Joint

Hex

Nuts

~

Ball

Joint

A

Pivot

Brat

Pivot

Bracket

-

HexNut

15

TC-080431

Weld

Cable

Terminal

Figure

2-4.

Split

Drive

Roll

Installation

1.

Loosen

the

pressure

adjustment

wing

nut

(item

2,

Figure

2-4)

and

pivot

it

free

of

the

cover.

Barbed

Gas

Fitting

On

Rear

Of

Assembly

OM-1518

Page

3

2.

Insert

the

inlet

wire

guide

into

drive

assembly

as

illustrated

in

Figure

2-3.

Secure

by

tightening

screw.

~nd

the

lowe

r

d

rive

ra

spring

wash

er

(s).

To

obtain

proper

alignment

of

the

lower

drive

roll

with



the

wire

guides

rotate

the

drive

roll

gear

securing

bolt

(11)

thereby

moving

the

drive

roll

in

or

out

to

the

desired

position.

The

top

drive

roll

will

locate

itself

on

the

wire

when

the

gear

cover

is

replaced

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

adjustment

has

been

factory

set,

but

if

the

adjustment

becomes

necessary.

loosen

mounting

bolts

(item

14,

Figure

2-3)

and

weld

terminal

nut

(15).

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

and

weld

terminal

nut.

2-8.

SPINDLE

ASSEMBLY

INSTALLATION

(Figure

2-5)

1.

Insert

spindle

support

shaft

(item

15,

Figure

2.5)

into

the

desired

hole

in

spindle

support

(16).

The

hole

to-be

utilized

in

the

spindle

support

116)

will

~Jepend

on

the

size

of

the

wire

spool

being

used.

-

2.

Secure

spindle

support

shaft

(15)

with

cotter

(17).

3.

Slide

the

following

items

onto

the

spindle

support

shaft

(15)

in

Order

given:

A.

Fiber

Wather

(14)

B.

Flat

Washer

(13)

C.

Hub

(12)

D.

Flat

Washer

(8)

E.

Fiber

Washer

(7)

F:

Keyed

Washer

(6)

G.

Spring

(5)

H.

Flat

Washer

(4)

4.

Rotate

hex

nut

(3)

onto

support

shaft

(15).

Hex

nut

(3)

should

be

rotated

only

until

a

slight

drag

is

felt

while

turning

hub

(12).

Figure

2-5.

Hub

And

Reel

Installation

2-9.

INSTALLATION

OF

SPOOL-TYPE

WIRE

(Figure

2-5)

1.

Slide

the

spool

of

wire

onto

the

hub

so

that

the

wire

feeds

off

the

bottom

or

top

(depending

on

installation)

with

the

minimum

bend

and

sharp

radius.

2.

Rotate

the

spool

until

the

hole

irs

the

spool

aligns

with

the

in

the

hub.

Slide

the

spool

onto

the

hub

until

it

seats

against

the

back

flange

of

the

hub.

-

3.

Depress

the

two

spring-loaded

stops

(item

1,

Figure

2-5)

on

the

retaining

ring

(2)

and

slide

the

retaining

ring

into

proper

position

on

the

hub

(12).

Release

the

two

stops

(1).

-

2-10.

INSTALLATION

OF

WIRE

REEL

(Optional)

(Figure

2-5)

1.

Slide

the

wire

reel

(item

11.

Figure

24)

onto

the

hub

-

(12).

Rotate

the

wire

reel

(11)

Until

the

hub

guide

is

seated

in

the

reel

(11).

2.

Depress

the

two

spring.loaded

stops

(1)

on

the

retaining

ring

(2)

and

slide

the

retaining

ring

(2)

into

proper

position

on

the

hub

(12).

Release

the

two

stops

(1).

4

2-11.

INSTALLATION

OF

REEL-TYPE

WIRE

(Figure

2-5)

-

1.:

Loosen

the

four

wing

nuts

(item

9,

Figure

2-5)

on

the

-

-

fingers

110)

or

the

wire

reel

~1

1).

2.

Pull

the

four

fingers

(10)

Out

until

they

can

be

rotated

toward

the

center

of

the

reel

(11).

3.

Install

the

wire

onto

the

reel

(11)

over

the

four

fingers

(10).

-

2-12.

ADJUSTING

HUB

TENSION

(Figure

2-5)

Check

hub

tension

by

slowly

pulling

wire

toward

the

feed

roll.

~rhe

wire

should

unwind

freely,

but

the

hub

tension

should

be

sufficient

to

keep

the

wire

taut

and

prevent

backlash

when

the

control/feeder

is

shut

off.

If

adjustment

is

required,

loosen

or

tighten

the

hex

nut

(item

3,

Figure

2-5)

on

the

end

of

the

spindle

support

shaft

(15)

accordingly.

2-13.

WELDING

WIRE

THREADING

1.

Connect

the

gun

to

the

drive

motor

assembly.

2.

Loosen

the

wing

nut

on

the

drive

roll

pressure

adjustment,

pivot

the

drive

roll

pressure

adjustment

free

of

the

cover,

and

pivot

the

pressure

gear

assembly

away

until

it

is

in

an

open

position.

3.

Cut

off

any

portion

of

the

free

end

of

the

welding

wire

which

is

not

straight.

Feed

the

welding

wire

through

the

inlet

wire

guide

in

thedrive

roll

assembly.

4.

Continue

to

feed

the

welding

wire

through

the

outlet

wire

guide.

5.

Pivot

the

pressure

gear

assembly

to

a

closed

position

--

making-sure

the

teeth

on

the

upper

gear

mesh

with

lower

drive

gear.

The

welding

wire

must

also

be

in

the

grooves

of

the

upper

and

tower

drive

rolls.

6.

Pivot

the

drive

roll

pressure

adjustment

into

the

slot

on

the

pressure

gear

assembly

making

sure

the

lower

flat

washer

is

above

the

pressure

gear

casing.

7.

Turn

the

wing

nut

on

the

drive

roll

pressure

adjust

ment

in

a

clockwise

direction

until

the

drive

rolls

are

tight

against

the

welding

wire.

Do

nor

overtighten.

Further

adjustment

can

be

made

after

the

welding

power

source

and

control/feeder

are

put

into

oper

ation.

8.

Energize

the

welding

power

source.

9.

Place

the

control/feeder

POWER

switch

in

the

ON

position.

10.

Set

the

CRATER

&

INCH

SPEED

control

to

desired

position.

Place.

the

RETRACT-ADVANCE

switch

in

the

ADVANCE

position.

11.

Depress

the

INCH

switch.

This

will

run

the

welding

wire

through

the

gun

without

placing

weld

current

on

the

welding

wire.

Release

the

INCH

switch

alter

the

4.

Rotate

the

four

fingers

(10)

back

to

their

proper

position.

Tighten

the

four

wing

nuts

(9).

5.

Proceed

to

install

welding

wire

according

to

the

applicable

Section:

2-9

for

spool-type

wire;

and

2-10,

2-11

for

reel-type

wire.

-

5

6 7

8

9*

10*

11*

13

16

17

*Optjona$

Page

4

end

of

the

welding

wire

is

approximately

one

inch

out

of

the

end

of

the

gun

tip.

2-14.

REMOTE

START

AND

STOP

CONNECTIONS

For

remote

control

of

starting

and

stopping,

connections

must

be

made

to

terminal

strips

11

and

2T

in

the

weld

control.

Loosen

screw

from

door

on

upper

panel

of

the

weld

control

and

open

door.

Terminal

strips

1

T

and

2T

are

located

on

the

right

side

of

the

control.

A.

Momentary

Contact

Push

Button

Switch

1.

Remove

jumper

between

iT

J

and

iT

11.

2.

Route

cable

from

switch

through

the

cable

clamp

on

the

right

side

of

the

weld

control.

3.

Attach

two

leads

from

the

normally

open

(start)

switch

to

lTHandlTK.

4.

Attach

two

leads

from

the

normally

closed

(stop)

switch

to

1TJ

and

1TH.

B.

Maintained

Contact.(ReIa

itch



1.

Rnove,umperbetwce

TJ

d

17,1-I.

2.

Route

cable

from

relay

t

rou9h

the

cable

clamp

on

the

right

side

of

the

weld

control.

3.

Connect

the

normally

open

maintained

cntact

of

the

-

relaytolTJandlTK.

.

4.

Closing

relay

Contact

will

start

unit

and

opening

relay

contact

will

stop

unit.

C.

Skip

Welding

1.

Removejumperlink

between

ITH

and

iTG.

2.

Route

cable

from

double-pole,

single

throw

maintained

contact

switch

through

the

cable

clamp

on

the

right

side

of

the

weld

control.

3.

Attach

leads

from

one

set

of

contacts

of

iT

H

and

iT

G.

4.

Attach

leads

from

the

other

set

of

contacts

to

iT

H

and

2T

A.

5.

Set

SPOT-CONTINUOUS

switch

to

SPOT

position.

6.

Closing

switch

will

start

weld

cycle

and

unit

will

weld

for

the

time

set

on

the

SPOT

TIME

control.

Wcld

current

ie

not

present

for

pre-flow

or

post-flow.

The

unit

will

automatically

recycle

through

the

weld

cycle

until

the

switch

is

opened.

After

all

connections

are

secured,

close

door

on

upper

panel-

of

wclo.

control

end

tighten

screw.

2-15.

ELECTRICAL

INPUT

CONNECTIONS

Insert

three-pole

twistlock

plug

PLG9

into

a

115

volts

ac

power

supply

and

rotate

the

plug

as

far

as

it

will

turn

in

a

clockwise

direction.

Once

fully

rotated,

the

plug

will

be

locked

in

the

receptacle.

SECTION

.3

-

FUNCTION

OF

CONTROLS

PreFloW

Tlme~

Spot-Continuous

Switch

Figure

3-1.WeId

Control

3-

1.

POWER

SWITCH

(Figure

3-1)

Placing

the

POWER

switch

in

the

OFF

position

does

not

remove

power

from

all

of

the

control/feeders

internal

circuitry.

Completely

terminate

all

electrical

power

to

the

control/feeder

by

removing

the

115

volts

ac

plug

from

its

power

supply,

and

ensure

that

machinery

lockout

procedures

have

been

employed

on

the

welding

power

sources

input

line

(see

Instruction

Manual

on

welding

power

source)

before

attempting

any

inspection

or

work

inside

the

unit.

Placing

the

POWER

switch

on

the

control/feeder

in

the

ON

position

will

apply

115

volts

ac

to

the

unit

and

thereby

place

it

in

an

operational

condition,

permitting

the

preprogrammed

welding

cycle

to

start

when

the

START

button

is

depressed,

or

gas

to

flow

when

the

PURGE

button

is

depressed,

or

welding

wire

to

feed

if

the

INCH

switch

is.depressed.

Placing

the

POWER

switch

in

the

OFF

position

will

shut

the

control/feeder

down.

3-2.

PILOT

LIGHT

(Figure

3-1)

The

pilot

light

PL1,

when

illuminated,

indicates

that

the

control/feeder

POWER

switch

is

ON

and

the

unit

is

ener

gized.

~fO~

ac

maybe

present

on

throl/feeder

internal

circuitry

even

though

the

pilot

light

is

not

illuminated

and

the

POWER

switch

is

in

the

OFF

position.

Completely

terminate

all

electrical

power

to

the

control/feeder

by

removing

the

115

volts

ac

plug

from

its

power

supply.

Votnietev

Ammeter,,

Fuse

Pilot

Light

Circuit

Breaker

Start

Switch

Stop

Switch

Run

In

Speed

~

Wire

Feed

Speed

Crater

&

Inch

Speed

Inch

Push

Button

Push

Button

/

Spot

Time

Crater

Time

BurnbaCk

~PostFloW

Time

TC-080

430

OM-1518

Page

5

3-9.

CRATER

&

INCH

SPEED

CONTROL

(Figure

3-1)

3-3.

RETRACT-ADVANCE

SWITCH

AND

INCH

PUSH

BUTTON

SWITCH

(Figure

3-1)

With

the

RETRACT-ADVANCE

switch

in

the

RETRACT

position,

the

welding

wire

will

retract

into

the

gun

at

the

speed

set

by

the

CRATER

&

INCH

SPEED

control

only

while

the

INCH

push

button

switch

is

depressed.

With

the

RETRACT-ADVANCE

switch

in

the

ADVANCE

position,

the

welding

wire

will

advance

from

the

gun

at

the

speed

set

by

the

CRATER

&

INCH

SPEED

control

only

while

the

INCH

push

button

switch

is

depressed.

The

INCH

push

button

switch

is

a

normally

open,

momen

tary

contact

switch.

Depressing

the

switch

will

energize

the

drive

motor

without

energizing

the

welding

power

source

contactor

or

gas

control

circuitry.

3-4.

PURGE

PUSH

BUTTON

SWITCH

(Figure

3-1)

-~

The

PURGE

push

button

switch

is

a

normally

open,

momentary

contact

switch.

Depressing

the

push

button

will

energize

the

gas

solenoid

and

thereby

purge

the

shielding

gas

line

to

the

gun...~..

-

---..,.~.--~-

3-5,

START

P!JSH~UTTQN

SWITCH

(F~gur~

3-1

&

3-2)-

Depressing

the

START

push

button

switch

will

start

the

preprogrammed

weld

cycle.

See

Figure

3-2

for-weld

cycle

events.

The

weld

cycle

will

continue

until

the

STOP

push

button

switch

is

depressed

or

the

SPOT

TIME

times

Out.

Ei

II

.-

-

CR5&01--1

1__~

-

&

_____________

__

CRS5*0}.._____.~l

-

L

~

-

CR5001

E1

CR51O,_____~

Run

In

Speed

o

,

Weld

Time

Spot

Time

a,

0-

infinity

r

0-2.5

Sec.

a,

E

~

.

Surnback

Time

~

0

Crater

Time

o-.25

sec.

~

crater&inz~fl~~~sFime

Arc

STOP

Time

START

Initiation

TB-080

432

The

0

condition

indicates

the

time

during

the

weld

cycle

that

the

control

relay

is

deenergized.

The

E

condition

indicates

the

time

during

the

weld

cycle

that

the

control

relay

is

energized.

See

Section

3-18

for

information

on

connecting

relays

to

interface

with

associated

equipment.

Figure

3-2.

Weld

Control

Cycle

3-

6.

STOP

PUSH

BUTTON

SWITCH

(Figure

3-1

&

3-2)

Depressing

the

STOP

push

button

switch

will

initiate

the

preprogrammed

crater

fill,

burnback,

and

post-flow

time.

See

Figure

3-2

for

weld

cycle

events.

3-7.

RUN

IN

SPEED

CONTROL

(Figure

3-1)

The

RUN

IN

SPEED

control

provides

a

means

of

selecting

the

rate

at

which

welding

wire

will

feed

prior

to

arc

initiation.

After

arc

initiation,

the

wire

feed

speed

is

governed

by

the

WIRE

FEED

SPEED

control.

The

RUN

IN

SPEED

control

is

marked

0-100

for

reference.

When

the

control

is

set at

0,

wire

will

feed

at

the

slowest

rate;

when

set at

100,

wire

will

feed

at

the

fastest

rate.

-

3-

8.

WIRE

FEED

SPEED

CONTROL

(Figure

3-1)

The

WIRE

FEED

SPEED

control

provides

a

means

of

selecting

the

rate

at

which

welding

wire

will

feed

into

the

weld

during

the

welding

cycle.

The

WIRE

FEED

SPEED

control

is

marked

0-100

for

reference.

When

the

control

is

set

at

0,

wire

will

feed

at

the

slowest

rate;

when

set

at

100,

wire

will

feed

at

the

fastest

rate;

The

CRATER

&

INCH

SPEED

control

provides

a

means

of

selecting

the

rate

at

which

wire

will

feed

into

the

weld

during

the

crater

fill

time

and

the

rate

at

which

wire

will

advance

or

retract

when

the

INCH

switch

is

depressed.

The

CRATER

&

INCH

SPEED

control

is

marked

0-100

for

reference.

When

the

control

is

set

at

0,

wire

will

feed

at

the

slowest

rate;

when

set

at

tOO,

wire

will

feed

at

the

fastest

rate.

-

3-10.

PRE-FLOW-TIME

CONTROL

(Figure

3-1)

An

adjustable

0

to

5

PRE-FLOW

TIME

control

is

provided

for

selecting

the

period

of

time

the

shielding

gas

flows

before

-

arc

initiation.

The

PRE-FLOW

TIME

control

starts

to

time

when

the

START

switch

is

depressed.

Rotating

the

control

in

a

clockwise

direction

increases

the

pre-f

low

time.

The

scale

surrounding

the

PRE-F

LOW

TIME

-

control

s

calibrated

in

seconds

to

aid

in

the

selection

of

a

pre-flow

time

period

suited

to

the

individual

welding

oper

ation.

--

-

3-11.

SPOT-CONTINUOUS

SWITCH

(Figure

3-1)

-

The

SPOT-CONTINUOUS

switch

provides

the

means

to

select

either

normal

weld

cycle

or

a

timed

weld

cycle.

Placing

the

SPOT-CONTINUOUS

switch

in

the

SPOT

position

will

provide

a

timed

weld

as

determined

by

the

SPOT

TIME

control.

Placing

the

SPOT-CONTINUOUS

switch

in

the

CONTINUOUS

position

will

cause

the

control/feeder

to-,

operate

normally.

-

3-12.

SPOTTIME

CONTROL

(Figure

3-1)

-.

An

adjustable

0

to

2.5

second

SPOT

TIME

control

is

provided

for

selecting

the

time

welding

wire

will

feed

into

the

weld

at

the

speed

selected

by

the

WIRE FEED

SPEED

control.

The

SPOT

TIME

control

starts

to

time

out

at

arc

initiation.

-

Rotating

the

control

in

a

clockwise

direction

increases

the

spot

time.

The

scale

surrounding

the

SPOT

TIME

control

is

calibrated

in

seconds

to

aid

in

the

selection

of

a

spot

time

suited

to

the

individual

welding

operation.

3-13.

CRATER

TIME

CONTROL

(Figure

3-1)

An

adjustable

0

to

2.5

second

CRATER

TIME

control

is

-

provided

for

selecting

the

time

welding

wire

will

feed

into

the

weld

at

the

rate

set

by

the

CRATER

&

INCH

SPEED

control.

The

CRATER

TIME

control

Starts

to

time

out

when

the

STOP

switch

is

depressed

or

when

the

SPOT

TIME

times

out.

Rotating

the

control

in

a

clockwise

direction

increases

the

crater

fill

time.

The

scale

surrounding

the

CRATER

TIME

control

is

calibrated

in

seconds

to

aid

in

the

selection

of

a

crater

fill

time

period

suited

to

the

individual

welding

operation.

-

3-14.

BURNBACK

CONTROL

(Figure

3-1)

An--adjustable---0-to-

.25

second

BURNBACK

control

is

provided

for

selecting

the

time

the

welding

wire

will

remain

electrically

energized

after

the

drive

motor

stops.

The

BURNBACK

control

starts

to

time

out

after

the

CRATER

TIME

control

has

timed

out.

Rotating

the

control

in

a

clockwise

direction

increases

the

burnback

time.

The

scale

surrounding

the

BURNBACK

control

is

calibrated

in

seconds.

By

adjusting

this

control

properly,

the

welding

wire

will

neither

freeze

in

the-

weld

puddle

nor

in

the

contact

tube

of

the

gun.

If

the

welding

wire

freezes

to

the

work,

increase

the

burnback

time.

II

the

welding

wire

burns

back

into

the

contact

tube,

decrease

the

burnback

time.

3-15.

POST-FLOW

TIME

CONTROL

(Figure

3-1)

-

An

adjustable

0-5

second

POST-FLOW

TIME

control

is.

provided

for

selecting

the

time

shielding

gas

will

flow

after

the

BURNBACK

control

has

timed

out.

Rotating

the

control

in

a

clockwise

direction

increases

the

post-flow

time.

The

scale

surrounding

the

POST-F

LOW

TI

ME

control

is

calibrated

in

seconds

to

aid

in

the

selection

of

a

post-flow

time

period

suited

to

the

individual

welding

operation.

-

---h

ii

-



4-~

II

Page

6

3-16.

METERS

(Figure

3-1)

The

meters

are

provided

to

monitor

the

welding

operation.

They

are

not

intended

for

exact

current

or

voltage

measure

ments.

The

voltmeter

will

indicate

the

voltage

at

the

output

terminals,

but

not

necessarily

the

actual

voltage

at

the

welding

arc

(due

to

cable

resistance,

poor

connections,

etc.).

The

ammeter

will

indicate

the

current

output

of

the

unit.

3-17.

OVERLOAD

PROTECTION

(Figure

3-1)

The

control/feeder

is

protected

from

damage

due

to

an

internal

short

or

excessive

overload

by

fuse

Fl.

Fuse

Fl

is

located

on

the

front

panel

of

the

weld

control.

If

fuse

Fl

should

open,

the

control/feeder

would

completely

shut

down.

The

drive

motor

is

protected

from

damage

due

to

overload

by

circuit

breaker

CB1.

Circuit

breaker

CB1

is

located

on

the

front

panel

of

the

weld

control.

If

circuit

breaker

CB1

should

open,

the

control/feeder

would

completely

shut

down.

The

reset

button

would

have

to

be

manually

depressed

in

order

to

reset

the

circuit

breaker.

3-18.

NORMALLY

OPEN

AND

NORMALLY

CLOSED

CONTACTS

A

set

of

normally

open

and

normally

closed

contacts

are

1.

Make

all

connections

as

instructed

in

Section

2.

Position-welding

gun

and/or

fixture.

3.

Set

wire

feed

speed

controls

and

weld

cycle

timers

to

desired

positions

to

program

the

weld

cycle.

Ensure

that

the

SPOT-CONTINUOUS

switch

is

in

the

CONTINUOUS

position.

4.

Turn

on

shielding

gas

at

the

source.

5.

Energize

the

welding

power

source.

:

6.

Place

the

control/feeder

POWER

switch

in

the

ON

position.

7.

Purge

the

gas

line

by

depressing

the

PURGE

button

for

one

minute.

,,-

,

8.

Depress

the

control/feeder

START

button.

I

The

welding

wire

and

all

metal

parts

in

contact

with

it

are

energized

while

welding.

Do

not

touch

the

welding

wire

or

any

metal

part

making

contact

with

it.

9.

To

terminate

the

weld

cycle,

depress

the

STOP

button.

4-

2.

GAS

METAL-ARC

WELDING

(GMAW)



SPOT

1.

Recheck

to

assure

proper

connections have

been

made

in

accordance

with

Section

2.

Position

weld

gun

and/or

fixture.

3.

Set

wire

feed

speed

controls

and

weld

cycle

timers

to

desired

positions

to

program

the

weld

cycle.

provided

to

work

in

conjunction

with

each

weld

cycle

timing

Circuit.

These

contacts

may

be

used

to

determine

fixture

movement

in

conjunction

with

the

weld

cycle.

Connections

can-

be

made

to

the

3/16

male

friction

connectors

on

receptacle

RC4

and

RC1Q

located

behind

the

timing

circuit

card

assembly

in

the

weld

control.

To

gain

access

to

these

receptacles

the

timing

Circuit

Card

assembly

may

be

removed

as

follows:

1.

Loosen

screw

from door

on

upper

panel

of

the

weld

control

and

open

door.

2.

Remove

three

screws

securing

timer

panel.

3.

Gently

pull

timer

panel

part

way

out.

4.

Remove

plugs

PLGI

and

PLG2

from

the

printed

circuit

card

assembly.

5.

Remove

timer

panel.

-

Route

leads

from

the

receptacles

through

the

cable

clamp

provided

on

the

side-of

the

weld

control.

After

connections-

are

made

to

the

receptacles,

reverse

thern

steps

above

tc~

install

the

timer

panel.

4.

Ensure

that

the-SPOT-CONTINUOUS

switch

is

in

the

SPOT

position.

Set

the

SPOT

TIME

control,

to

the

desired

setting.

5.

Turn

on

shielding

gas

at

the

source.

6.

Energize

the

welding

power

source.

7.

Place

the

control/feeder

POWER

switch

in

the

ON

position.

8.

Purge

the

gas

line

by

depressing

the

PURGE

button

for

one

minute.

Prior

to

welding,

it is

imperative

that

proper

protective

clothing

(welding

coat

and

gloves)

and

eye

protection

(glasses

and/or

welding

helmet)

be

put

on.

Failure

to

comply

may

result

in

serious

or

permanent

bodily

damage.

-

9.

Depress

the

control/feeder

START

button.



The

welding

wire

and

all

metal

parts

in

contact

with

it

-

-

-

are

energized

while

welding.

Do

not

touch

the

welding

wire

or

any

metal

part

making

contact

with

it.

10.

The

weld

cycle

will

automatically

terminate

when

the

SPOT

TIME

control

times

out.

4-3.

SHUTTING

DOWN

1.

Turn

the

shielding

gas

off

at

the

source.

If

welding

is

performed

in

a

confined

area,

failure

to

turn

off

gas

supply

could

result

in

a

build

up

of

gas

fumes,

endangering

personnel

reentering

the

welding



area.

2.

Place

the

control!feeder

POWER

switch

in

the

OFF

position.

3.

Turn

off

all

associated

equipment.

-

4-1.GAS

METAL-ARC

WELDING

(GMAW)



CONTINUOUS

SECTION

4

-

SEQUENCE

OF

OPERATION

Prior

to

welding,

it

is

imperative

that

proper

protective

clothing

(welding

coat

and

gloves)

and

eye

protection

(glasses

and/or

welding

helmet)

be

put

on.

Failure

to

-

comply

may

result

in

serious

and

even

permanent



bodily

damage.

OM-1518

Page.7

5-

1.

INSPECTION

AND

UPKEEP

Usage

and

shop

conditions

will

determine

the

frequency

and

type

of

maintenance.

Inspect

equipment

as

follows:

1.

Make

sure

welding

power

source

is

shut

down.

2.

Inspect

gun

for

broken

areas,

cracks

and

loose

parts:

tighten,

repair,

and

replace

as

required.

3.

Carefully

remove

any

weld

spatter

or

foreign

matter

which

may

accumulate

around

the

nozzle

orifice.

Use

a

hardwood

stick,

never

a

metal

tool.

4.

Repair

or

replace,

as

required,

all

hose

and

cable;

give

particular

attention

to

frayed

and

cracked

insulation

and

areas

where

it

enters

equipment.

5.

Remove

grease

and

grime

from

components;

moisture

from

electrical

parts

and

cable.

6.

Blow

out

the

gun

wire

guide

liner

with

compressed

air

when

changing

wire.

This

will

remove

any

metal

chips

and

dirt

that

may

have

accumulated.

5-2.

CLEANING

OF

DRIVE

ROLLS

Occasionally

it

will

become

necessary

to

clear,

the

wire

groove

on

the

drive

rolls.

This

cleaning

operation

can

be

performed

with

a

wire

brush.

To

clean

the

wire

grooves

it

will

be

necessary

to

first

remove

the

drive

roll(s).

See

Section

2-7

for

removal

and

installation

instructions.

SECTION

6

TROUBLESHOOTING

Hazardous

voltages

are

present

on

the

iiiternal

cir

cuitry

of

this

unit

as

long

as

power

is

connected.

Disconnect

power

before

attempting

any

inspection

or

work

on

the

inside

of

the

unit.

Troubleshooting

of

internal

circuitry

should

be

performed

by

qualified

t..,~~sonnel

only.

-

The

following

chart

is

designed

to

diagnose

and

provide

remedies

for

some

of

the

troubles

that

may

develop

in

this

unit.

ft

is

assumed

that

proper

installation

has

been

made,

according

to

Section

2

of

this

manual,

and

that

the

unit

has

been

functioning

propedv

until

this

trouble

developed.

Use

this

chart

in

conjunction

with

the

circuit

diagram

while

performing

troubleshooting

procedures.

If

the

trouble

is

not

remedied

after

performing

these

procedures,

the

nearest

Factory

Authorized

Service

Station

should

be

contacted.

In

all

cases

of

equipment

matfunction,

the

manufacturers

recommendations

should

be

strictly

followed.

If

it

becomes

necessary

to

replace

any

fuse

in

this

Unit,

ensure

that

a

fuse

of

the

proper

size

is

used.

SECTION

5

-

MAINTENANCE

NOTE

Failure.

to

properly

maintain

the-drive

rolls

can

result

in

a

build-up

of

wire

particles

which

will

decrease

the

efficiency

of

the

wire

feeding

operation.

-

TROUBLE

PRpBABLE

CAUSE

REMEDY

Depressing

START

button

will

not

start

weld

cycle.

Electrode

wire

is

not

energized

and

shielding

gas

does

not

flow.

ON-OFF

POWER

switch

in

wrong

position

or

defective.

.

Place

switch

to

ON

position.

Replace

defective

POWER

switch.

-.

.

Circuit

breaker

CB1

tripped.

~

Manually

reset

Circuit

breaker

by

depressing

the

button

on

the

frbnt

panel

of

the

control/feeder

labeled

RESET.

115

v6lts

ac

input

plug

is

not

secure

in

receptacle,

Insert

plug

fully

into

115

vac

receptacle

and

rotate

plug

1/2

turn

clockwise.

115

volts

input

fuse

Fl

open.

Replace

fuse.

Wire

feeds,

shielding

gas

flows,

but

electrode

wire

is

not

energized.

~

115

v~c

Contactor

Control

plug

is

not

secure

in

contactor

receptacle

on

welding

power

source.

Insert

plug

fully

into

receptacle

and

rotate

plug

1/2

turn

clockwise.

ContŁctor

Control

cable

leads

not

secure--.on---contactor~__pJug

terminals.

Secure

leads

to

plug

terminals.

--

~-

-

--

Defect

in

welding

power

source.

See

troubleshooting

section

in

welding

power

source

instruction

manual.

Wire

feeds

erratically.

.

~

Pressure

on

drive

rolls

is

insufficient,

Rotate

pressure

adjustment

wing

nut

clockwise

in

1/4

turn

increments

until

wire

slippage

stops.

Drive

roll

is

too

large

for

wire

size

being

used.

Change

to

proper

size

drive

roll.

See

Section

2-7.

Worn

drive

roll.

Replace

drive

roll.

See

Section

2-7.

Dirt

in

drive

roll.

Clean

drive

roll

as

instructed

in

Section

5-2.

Page

8

U)

I.

C54

0

CD

0

o

0

2

E

0

4...

C,

0

E

C,

O

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OM-1513Page9

November

1978

FORM:

OM-151

-PARTS

LIST

Effective

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No.

HJI

95967

MODEL

AUTOMATIC

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Page

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