August
1988
FORM:
OM-876
Effective
With
Style
No.
JF-24
MODEL
INTELLIMATICTM
PROCESS
SELECTOR
CONTROL
OWNER’S
MANUAL
IMPORTANT:
Read
and
understand
the entire contents of bath this
Miller Electric
Mfg.
Co.
manual
and
the
power
source
manual
used
with
this
unit,
with
special AMdIe~G,O~PUd
Con,pan~
emphasis
on
the safety
material
throughout
both
manuals,
before
in-
~o.
Box 1079
stalling, operating, or maintaining this equipment. This
unit
and
these
Appleton,
WI
54912
USA
instructions
are
for
use
only
by
persons
trained
and
experienced
in the
ThI.
4147349821
safe
operation of
welding
equipment.
Do
not allow untrained
persons
to
install,
operate,
or maintain this unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
Miller®
PRINTED
IN
U.S.A.
ADDITIONAL
COPY
PRICE
40
CENTS
MILLER’S
TRUE
BLUETM
LIMITED
WARRANTY
Effective
January
1,1992
(Equipment
with
a
serial
number
preface
of
“KC”
or
newer)
This
limited
warranty
supersedes
all
previous MILLER warranties
and
is
exclusive with no other
guarantees
or warranties expressed or
Implied
LIMITED WARRANTY
—
Subiect
to the
terms
and
conditions
below,
MILLER
Electric
• Accessory
Kits
Mfg.
Co.,
Appletos,
Wisconsin,
warrants
to
its
original
retail
purchaser
that
new
•
Replacement
Paris
MILLER
equipment
sold
alter the
effective
date
of
this
limited
warranty
is
tree
of
de
-
fects in
material
and
worhmanship
at
the
time
it
is
shipped
by
MILLER
THIS WAR
TM
RANTY
Is
EXPRESSLY
IN
LIEU
OF ALL
OTHER
WARRANTIES,
EXPRESS
O~
MILLER’S
True
Blue
Limited Warranty shall notapply to
IMPLIED.
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND FIT.
NESS.
I Items furnished by
MILLER.
but manufactured by
others,
such as
engines
or
trade
accessories.
These
items
are
covered
bythe manufacturer’s warranty,
if
Within the warranty periods
listed
below,
MILLER
will repair or
replace
any war- any
ranted
parts
or
components
that
fail
due
to
such
defects
In
material orworkmanship
MILLER
must
be
notified
in
writing
within
thirty
(30)
days of
such
defector
failure,
at 2 Consumable
components;
such
as
contact
tips,
cutting
nozzles,
contactors
which
time
MILLER will
provide
instructions
on
the
warranty
claim
procedures
lobe
and
relays
followed
3.
Equipmentthat
has
bees
modified by any party other than
MILLER,
or equip.
MILLER
shall
honor
warranty
claims on warranted
equipment
listed
below in the
ment
that
has
been
improperly
installed,
improperly
operated or
misused
event of such a failure
within
the
warranty
time
periods.
All warranty time periods
based
upon
industry
standards,
or
equipment
which
has
not
had
reasonable
start on the date that
the
equipment
was
delivered
to
the original
retail
purchauer,
and
necessary
maintenance,
or
equipment
which
has
been used
for
operation
and
are as follows
outsrde
of the
specifications
for the equipment.
1 5
Years Parts
-
3
Years Labor
MILLER
PRODUCTS
ARE
INTENDED
FORPURCHASE AND
USE
BY
COMMER
-
CIAL/INDUSTRIAL USERS AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
Original
main
power rectifiers
THE USE
AND
MAINTENANCE
OF
WELDING
EOUIPMENT
2
3
Years
—
Parts
and
Labor
In
the event
cIa
warranty
claimcovered by
this
warranty,
the esciusive remedies
Transformer/Rectifier
Power
Sources
shall
be,
at
MILLER’S
option.
(1)
repair;
or
(2)
replacement;
or,
where
authorized
in
Plasma
Arc
Cutting
Power
Sources
writing
by
MiLLER
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or replace-
Semi-Automatic
and
Autoniatic Wire
Feeders
ment
at
unauthorized
MILLERservice
station,
or (4)
payment
of
or credit
for
the
pur
-
chase
price (less
reasonabledepreciation bated
upon
actual
use)
upon
returnof
the
Robots
goodsat
customer’s
risk
and
espense. MILLER’S
Option
ot repair or
replacement
3.
2
Years—Parts
and
Labor
willbe
FOB.,
Factory
at
Appleton,
Wisconsin.
or
FOB.
ala
MILLER
authorized
ser
-
vice facility
as
determined
by
MILLER
Therefore
no compensation or
reimburse.
Engine
Driven
Welding
Generators
mast
for
transportation
costs
of any
kind
will be
allowed.
(NOTE:
Engines arewarranted separately
by
the
engine
manufacturer)
TO
THE
EXTENT PERMITTED
BY
LAW,
THE
REMEDIES PROVIDED
HEREIN
4.
1
Year—
Parts
and
Labor ARE
THE
SOLE
AND EXCLUSIVE
REMEDIES
IN
NO
EVENT SHALL MILLER
BE
Motor
Driven
Guns
LIABLE
FOR
DIRECT,
iNDIRECT.
SPECIAL.
INCIDENTAL
OR
CONSEOUENTIAL
• Process
Controllers DAMAGES (INCLUDING
LOSS
OF
PROFIT).
WHETHER BASED
ON
CON~
Water
Coolant systems
TRACT,
TORT
OR
ANY
OTHER LEGAL
THEORY
• HF Units ANY
EXPRESS
WARRANTY NOT
PROVIDED
HEREIN
AND ANY
IMPLIED
WAR-
Grids
PANTY,
GUARANTY
OR
REPRESENTATION
AS
TO
PERFORMANCE,
ANDANY
Spot
Welders
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER LEGAL
*
Load
Banks
THEORY
WHICH,
BUT
FORTHIS
PROVISION.
MIGHT
ARISE
BY
IMPLICATION,
*
SDX
Transformers
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE OF
DEALING,
iN
-
CLUDiNG ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
Running
‘~‘“~“~‘~
FOR
PARTICULAR
PURPOSE.
WITH
RESPECT
TO
ANY ANDALL EOUiPMENT
Field
Options FURNISHED
BY
MiLLER IS EXCLUDED AND DISCLAIMED
BY
MILLER.
(NOTE
Field
options are coveredunder
True Blue
for
the
remaining
warranty period of the
product
they
are
installed
in,
or fora
minimum
of Some
states
in
the
U.S.A.
do
not
allow limitalions of
how long
an
implied
warranty
lasts,
or
the
exclusion
of
incidental,
indirect,
special or
consequential
damages,
so
one
year
—
whichever
is
greater.)
the
above
limitation
or
esclusion
may
not
apply
to
you
This
warranty
provides
spa
-
5.
6
Months
-.-.
Butteres
cific
legal
rights,
and
other rights
may
be
available,
but
may vary
from state
to
state.
6.
90 Days
—
Paris
and
Labor
In
Canada, legislation in some provinces provides for
certain
additional warranties
•
MIG
Guns/TIG
Torches
or
remedes
other than
as
stated
herein,
and
to
the extent
that
they
may
not
be
waived,
the
limitations
and
exclusions
set
out above may
not apply.
This
Limited
•
.
Plasma Cutting Torches
Warranty
provides
specific
legal
rights.
and
other rights
may
be
available,
but
may
*
Remote Controls
vary
Irom
province
to
province.
-
rj
ii
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
-
INTRODUCTION
1
-
1.
General
Information
And
Safety
1
1
-
2.
Receiving-Handling
1
1
-
3.
Description
2
SECTION
2
-
INSTALLATION
2-1.
Location
2
2
-
2.
Installation
Onto
Wire
Feeder
2
SECTION
3
-
OPERATOR
CONTROLS
3
-
1.
Process
Selector Control
Switch
5
3
-
2.
Arc
Control Potentiometer
6
SECTION
4
-
PRESElTING
MANUAL
WELDING
&
CUlTING
PARAMETERS
4
-
1.
CV Mode
Operation
6
4
-
2.
CC
Mode
Operation
6
SECTION
5
-
MANUAL
WELDING,
CUlliNG
&
GOUGING:
KEY
SWITCH
IN
RUN
POSITION
5
-
1.
CV Mode
Operation
7
5
-
2.
CC
Mode
Operation
7
SECTION
6
-
MANUAL
WELDING,
CUlliNG
Et
GOUGING:
KEY
SWITCH
IN
SET
POSITION
6
-
1.
CV Mode
Operation
8
6
-
2.
CC
Mode
Operation
9
SECTION
7
-
MAINTENANCE
7
-
1.
Inspection
And
Upkeep
9
7
-
2.
Weld
Cables
9
SECTION
1
-
INTRODUCTION
Welding
Circuit
Rating
Weight
Net
Ship
100
Volts
8.5
lbs.
10.5
lbs.
650 Amps
j(3.9
kg)
(4.8
kg)
Figure
1
-
1.
Specifications
TB-092
2U-A
1
-
1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in this
manual and on
various
labels,
tags,
and plates on
the
unit
pertains
to
equip-
ment
design,
installation,
operation,
maintenance,
and
troubleshooting which
should
be
read,
understood,
and
followed
for
the
safe
and
effective
use
of
this
equip-
ment.
B.
Safety
The
installation,
operation,
maintenance,
and
troubleshooting of
arc
welding
equipment
require
prac
-
tices
and
procedures
which
ensure
personal
safety
and
safety
of
others. Therefore, this equipment
is
to
be
in
-
stalled,
operated,
and
maintained
only
by
qualified
per
-
sons
in accordance
with
this
manual and
all
applicable
codes
such
as,
but
not limited
to,
those
listed
at
the
end
of Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source in
the
welding
power
source
Owner’s
Manual.
Safety
instructions
specifically
pertaining
to
this
unit
ap
-
pear
throughout
this
manual
highlighted
by
the
signal
words
••
and
.0
which
identify
different
levels
of
hazard.
WARNING
statements
include
installation,
operation,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could result
in
serious personal
injury
or
loss
of
life.
CAUTION
statements
include
installation,
operation,
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.
1
-
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
Style
Numbers
of
the
equipment
be
supplied.
7/8
in.
(22.2
4-1/2
in.
(114.3 mm)
Add
4-1/4
In.
(103
mm)
for
switch
handle.
Figure
1
-
2.
Dimensions
OM-876
Page
1
1
-
3.
DESCRIPTION
-
This
manual
control
is
designed
for
use
with
an
INTELLIMATIC S-52M,
S-54M, D-52M, or
D-54M
wire feeder,
or
SS-12M,
SS
-
16M, DS-12M,
or
DS-16M SWINGARC
using
an
IN
-
TELLIWELD
650D
welding
power
source.
The
unit
allows
the
wire
feeder
control
to
preset 4
voltage
conditions
for
Air
Carbon
Arc
(ACA)
Cutting
and
Gouging
(Constant
Voltage
mode),
and 4
amperage
conditions
for
Shielded
Metal
Arc
Welding
(SMAW),
Air
Carbon
Arc
(ACA)
Cutting
and
Gouging,
or
scratch-start
Gas
Tungsten
Arc
Welding
(GTAW)
(Constant
Current
mode).
It
also
provides
the
ability
to
use
different
polarities
for
the
wire
feeder
and
stick
elec
-
trode.
SECTION
2
-
INSTALLATION
2
-
1.
LOCATION
-
The
Process
Selector Control
is
designed
for
installation
on
top
of
the
wire
feeder
con
-
trol
box
as
shown
in
Figure
2-1.
Figure
2
-
1.
Selector
Installation
Feeder
Control
box
The
location
should
allow
room
around
the
unit
for
making
necessary
connections
and
for
maintenance
and
repair
functions.
The
service
life
and
efficiency of
this
unit
are
reduced
when
subjected
to
high
levels
of
dust,
dirt,
moisture, corrosive
vapors,
and
extreme
heat.
2
-
2.
INSTALLATION
ONTO
WIRE
FEEDER
(Figure
2-1)
WARNING:
ELECTRIC
SHOCK
can kill.
•
Do
not
touch
live electrical
parts.
•
Shut
down
wire
feeder
and
welding
power
source
Mounting
and
disconnect
input
power
employing
Hardware
“lockout/tagging
procedures”
before
installing
and
connecting
unit.
Lockout/tagging
procedures consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse box,
or shutting
off
and
red-tagging
circuit
breaker
or
other disconnecting
device.
To
install
Process
Selector
Control
onto wire
feeder,
proceed
as
follows:
1.
Remove
wrapper from
Selector
Control.
IMPORTANT:
Refer
to
the
welding
power
source
Owner’s
Manual
for
proper
cable
information.
See
wire
feeder
and
welding
power
source Owner’s Manuals
for
TB-092
252-A
connection
points
and
necessary
associated
informa
-
tion.
On
Top
Of
Wire
Volt
Sense
Model
S-52M
Receptacle
Shown
Voltage
Sensing
Lead
LocatIon
Lug
InstallatIon
Rear
Unit
Manual
IN
TermInal
B
Feeder
OUT
Terminal
D
Feeder
IN
C
Weld
Cable
Weld Cable
Accega
Accees
Holes
(41
Hole
IdentIfIcation
Label
TA-099
328
Figure
2
-
2.
Switch
Terminal
Locations
And
Connections
OM-876
Page
2
INCORRECT INSTALLATION
PRO
-
CEDURES
can
cause personal
injury
and
equip
-
ment
damage.
•
Connect
cables
to proper
switch
terminals
on
this
unit
before
installing
unit onto wire
feeder.
This
control
must
have
wrapper
installed
before
it
can
be
secured
onto wire
feeder.
2.
Choose
one
of
the
interconnection
diagrams
as
shown
in
Figures
2-3, 2-4, 2-5, 2-6, or
2-7
as
desired
for
the
specific
application.
3.
Measure length
and
make
up
proper
cables
for
the
desired
Selector
location
and
application.
EXCESSIVELY
HIGH
WELDING
CUR
-
RENT
can
cause
the
electrode
wire to
vaporize.
•
Be
sure
the
voltage sensing
leads
are
connected
properly.
•
If
the
voltage
sensing
signal
is
not
connected,
the
Power
Source
Error
will
be displayed.
4.
Route
and
connect
weld
cables
to
switch
ter
-
minals
according
to
selected
Figure
2-3, 2-4,
2-5, 2-6, or 2-7.
5.
Connect
the
voltage
sensing
leads
to
the
volt
sense
pick
up
points
according
to
selected
Figure
2-3, 2-4,
2-5,
2-6, or
2-7
and
Figure
2-2
depen
-
ding
on
the
selected
electrode
polarities.
6.
Reinstall
wrapper onto
Process
Selector
Control.
TA-091
615
Figure
2
-
3.
Feeder Reverse
Polarity/Manual
Reverse
Polarity
CAUTION:
WELDING
CURRENT
present
on
grounded
wire
feeder
parts
can
damage
interface
cord
and
plug.
•
Do
not
allow
welding
cable
to touch grounded
feeder parts.
If
the
welding
cable
lug
or
exposed
welding
cable
is
in
contact
with
any
grounded
feeder
components during
operation,
the
interface
cord
and
plug
may
be
damag
-
ed.
7.
Remove
the
screws
(4)
at
top
of
feeder
control
box
that
match
mounting
holes
on
each
side
of
Selector wrapper.
8.
Slide
Selector down
onto
top
of
feeder
control
box
and replace
screws
through
Selector
wrap
-
per
holes
and
tighten
screws.
9.
Route
weld
cables
under
handle
and
wire
sup
-
port of
wire
feeder
base
as
shown
in
Figure
2-1,
and
connect
cables
to
appropriate
locations
on
wire
feeder
and
welding
power
source
for
desired
polarity
(see
selected
Figure
2-3,
2-4,
2-5, 2-6, or
2-7).
10.
Connect
and
secure
the
free
hanging
5-pin
plug
on
rear
of
Process
Selector
Control to
the
5-socket
receptacle
on
rear
of
wire
feeder
control
box.
11.
Connect
the
plug
on
the
voltage
sensing
cord
to
the
VOLT
SENSE
receptacle
on
front
of
wire
feeder
control box
(see Figure
2-1).
WARNING:
ELECTRIC
SHOCK
can
kill.
•
Do
not
touch
live
electrical
parts.
•
Shut
down
wire
feeder
and welding
power
source
and disconnect
input
power
before
making
con
-
nections.
WARNING:
ELECTRIC
SHOCK
can
kill.
•
Do
not
touch
live
electrical
parts.
•
Shut
down
wire
feeder
and
weldingpower
source
and
disconnect
input
power
before
making
con
-
nections.
Rear
VIw
Weld
Cable
Terminal
On
DrIve
Aasembly
TA-OSi
619
Figure
2
-
4.
Feeder
Reverse
Polarity
High
Induc
-
tor/Manual
Reverse
Polarity
For
Stainless
Steel
Applications
CAUTION:
Max.
Inductor
I
Poaltiva
Out.
CAUTION:
Work
Work
OM-876
Pag~3
ELECTRIC
SHOCK
can
kill.
•
Do
not
touch
live electrical
parts.
•
Shut
down
wire
feeder
and welding
power
source
and
disconnect
input
power
before
making
con
-
nections.
•
Isolate
unused
electrode
from
work.
•
Do
not
touch
work
and
unused
electrode
at
same
time.
•
The
unused
electrode
is
electrically
energized
while
welding.
Max.
Inductor
Poaitlva~
Rear
View
ELECTRIC
SHOCK
can kill.
•
Do
not
touch live electrical
parts.
•
Shut
down
wire
feeder
and welding
power
source
and
disconnect
input
power
before
making
con
-
nections.
•
Isolate
welding gun and
electrode
holder
from
each
other.
•
Do
not
touch
the
electrode
holder
and gun at
same
time.
•
The
unused
electrode
is
connected
to
the
work
while welding.
Selector
Points
work
Figure
2
-
5.
Feeder
Straight
Polarity/Manual
Straight
Polarity
TA-~91
618-A
Figure
2
-
6.
Feeder
Reverse
Polarity/Manual
Straight Polarity
OM-876
Page
4
WARNING:
ELECTRIC
SHOCK
can
kill.
•
Do
not
touch
live
electrical
parts.
•
Shut down wire
feeder
and weldingpower
source
and disconnect
input
power
before
making
con
-
nections.
•
Isolate
welding gun and
electrode
holder from
each
other.
•
Do
not
touch
the
electrode
holder and gun at
same
time.
•
The
unused
electrode
is
connected
to
the work
while
welding.
TA-OSi
617
Figure
2
-
7.
Feeder
Straight
Polarity/Manual
Reverse
Polarity
SECTION
3
-
OPERATOR
CONTROLS
When
the
handle
is
in
the
MANUAL
CV/CC
(right)
posi
-
tion,
the
stick
electrode will
be
electrically
energized and
have
either
reverse
or straight polarity
depending
on
connections
made
in
SECTION
2.
A
weld
output
mode
selection,
either Constant
Voltage
(CV)
or
Constant
Current
(CC),
can
also
be
made
in this
position
for
the
welding
operation.
When
the
handle
is
in
the
FEEDER
CV
(left)
position,
the electrode
from
the
wire
feeder
will
be
electrically
energized and have
either
reverse
or straight polarity
depending
on
connections
made
in
SECTION
2.
All
set
-
tings
and
selections
for
the
welding operation
need
to
be
made
at
the
wire
feeder
controls
in this
position.
TB92
244-A
Not
all
connections
in
SECTION 2
provide electrical
isolation between
wire
and
stick
electrodes.
3
-
1.
PROCESS
SELECTOR
CONTROL SWITCH
(Figure
3-1)
CAUTION:
tacts.
S
ARCING
can
damage switch
con-
Do
not
change
position
of
selector
switch while
welding or
under
load.
Arcing
causes
the
contacts
to
become
pitted
and
even-
tually inoperative.
~
INCOMPLETE
SWITCH
LEVER
MOVEMENT
can
cause
damage to
unit.
•
Place
switch lever
fully
to
left
or
right
positions.
Partial
switch
engagement
may
overload
and
damage
switch
Contacts.
WARNING:
ELECTRIC
SHOCK
can
kill.
•
Do
not
touch
live
electrical
parts.
•
Shut
down
wire
feeder
and weldingpower
source
and disconnect
input
power
before
making
con
-
nections.
•
Isolate
welding gun and
electrode
holder from
each
other.
•
Do
not
touch the
electrode
holder and gun
at
Same
time.
•
The
unused
electrode
is
connected
to the work
while
welding.
Place
Process
Selector
Control
switch
in
desired
posi-
tion
according to
the
application.
Figure
3
-
1.
Process
Selector Control
OM-876
Page
5
3
-
2.
ARC
CONTROL
POTENTIOMETER
(Figure
3-1)
~
The
ARC
CONTROL
potentiometer
is
disabled in
the CV
(Constant
Voltage)
mode.
The
ARC
CONTROL
potentiometer
provides
variable
selection
of
short-circuit
current
to
suit
individual
welding
conditions.
Rotating
this
control
clockwise
causes
the
current
to
increase
as
the
short-circuit
condi
-
tion
is
approached.
When
this
control
is
set
at
any
value
above
MIN.,
the
current
begins
to
increase
when
arc
voltage
drops
below
20
volts.
When
the
control
is
set
at
MAX.,
the
short-circuit
cur
-
rent
is
considerably higher
than
normal
welding
current.
This
provides
extra
current
for
arc
starting
in
out-of-
position
welds
as
well
as
for
certain types
of
electrodes.
When
the
control
is
set
at
MIN.,
the
short-circuit
cur
-
rent
is
the
same
as
normal
welding
current.
The
MIN.
position
provides
current
characteristics
associated
with
the
Gas
Tungsten
Arc
Welding
(GTAW)
process.
When
the
control
is set
midway
between
MIN.
and
MAX.,
the
short-circuit
current
is
approximately half
that of
the
MAX.
position
but still
higher
than
normal
welding
current.
The
midway
position
provides a
moderate
current increase
for
arc
starting
necessary
for
certain types
of
electrodes
and
applications.
Select
a
setting
best
suited
for
the
application.
—SECTION
4
-
PRESETTING
MANUAL
WELDING
& CUTTING
PARAMETERS—
WARNING:
ELECTRIC
SHOCK
can kill;
MOVING
PARTS
can
cause
serious injury;
WELDING
WIRE
can
cause
puncture
wounds.
•
Do
not
touch live
electrical
parts.
•
Keep
clear
of
pinch
points.
•
The
unused
electrode
is
connected
to
the
work
while welding.
•
Isolate
unused
electrode
from work
and
remaining
electrode.
•
Open
drive
roll
housings
to
release
pressure
on
wires.
•
Do
not
point
guns
toward any
part of
the
body,
any conductive
surface,
or
other
personnel.
4
-
1.
CV
MODE OPERATION
4.
If
the AMPS
Numeric
display
and
AMPS
In
-
dicator
light
turn
on,
depress
the
CV/CC
push
button
to
switch
to
CV
mode.
5.
Turn
key-switch
to
the
SET
position.
6.
Depress
PROGRAM
Select push
button
or
RPS-4
to
select PROGRAM
A,
B,
C,
or
D.
PRO
-
GRAM
A,
B,
C,
or
D
Indicator
light
turns
on,
and
the
Numeric displays
show
the
WELD
parameters
stored
in
memory
for
PROGRAM
A,
B,
C,
or
D.
7.
Depress
VOLTS
Increase
or
Decrease
push
but
-
ton
to
preset WELD voltage.
WARNING:
Read
and
follow
safety
information
at
beginning
of
entire Section
4
before
proceeding.
8.
Repeat
Steps
6 and
7
for
the
remaining
pro
-
grams.
1.
Energize
the
welding
power
source.
4
-2.
CC
MODE OPERATION
2.
Place
wire
feeder Power
switch
in
the
ON
posi-
tion. This
applies
power
to
the
wire
feeder
and
initiates
a
check
of
the
Numeric
displays
and
the
Indicator
lights.
This
check
involves
lighting
all
displays
and
lights
for
one
second
for
visual
in
-
spection.
Next,
a
diagnostic
check of
the
memory
and
system
inputs
is
performed
by
the
microprocessor.
If
a
fault
is indicated
on
the
displays,
see
wire
feeder
Owner’s
Manual.
3.
Place
Manual/Feeder
switch
in
the
MANUAL
CV/CC
position. This
connects
the electrode
holder
cable
to
the
MAXIMUM
INDUCTOR
weld
output
terminal, disconnects
the
welding
gun
from
the
MINIMUM
INDUCTOR
weld
output
ter
-
minal
(when both
electrode
and
welding
wire
are
reverse
polarity,
other
polarity
connections may
not
provide isolation:
see
selected
Figure
2-3,
2-4, 2-5,
2-6,
or
2-7),
and
signals
the
wire
feeder
to
switch
to
manual
welding.
The
VOLTS
Numeric
display
and
VOLTS
Indicator
light
or
the AMPS
Numeric
display
and
AMPS
Indicator
light
turn
on,
depending
on
which
mode
was
last
used.
WARNING:
Read
and
follow
safety
information
at
beginning
of
entire Section
4
before
proceeding.
1. Energize
the
welding
power
source.
2.
Place
wire
feeder
Power
switch
in
the
ON
posi
-
tion.
This applies
power
to
the
wire
feeder
and
initiates
a
check
of
the
Numeric
displays
and
the
Indicator
lights.
This
check
involves
lighting
all
displays
and
lights
for
one
second
for
visual
in
-
spection.
Next,
a
diagnostic
check
of
the
memory
and
system
inputs is performed
by
the
microprocessor.
If
a
fault
is indicated
on
the
displays,
see
wire
feeder
Owner’s
Manual.
3.
Place
Manual/Feeder
switch
in
the
MANUAL
CV/CC
position. This
connects
the electrode
holder
cable
to
the
MAXIMUM
INDUCTOR
weld
output
terminal, disconnects
the
welding
gun
from
the
MINIMUM
INDUCTOR
weld
output
ter
-
minal
(when both
electrode
and
welding
wire
are
reverse
polarity,
other
polarity
connections
may
not
provide
isolation:
see
selected
Figure
2-3,
2-4,
2-5,
2-6, or
2-7),
and
signals
the
wire
feeder
OM-876
Page
6
to
switch
to
manual
welding.
The
AMPS
Numberic display
and
AMPS
Indicator
light
or
the
VOLTS
Numeric
display
and
VOLTS
In
-
dicator
light
turn
on,
depending
on
which
mode
was
last
used.
4.
If
the
VOLTS
Numeric
display
and
VOLTS
In
-
dicator
light
turn
on,
depress
the
CV/CC
push
button
to
switch
to
CC
mode.
5.
Turn
key-switch
to
the
SET
position.
6.
Depress
PROGRAM
Select push
button
or
RPS-4
to
select PROGRAM
A,
B,
C,
or
D.
PRO
-
GRAM
A
Indicator
light
turns
on,
and
the
Numeric
displays
show
the WELD
parameters
stored
in
memory
for
PROGRAM
A, B,
C,
or
D.
7.
Depress
AMPS
Increase
or
Decrease
push
but
-
ton
to
preset WELD
current.
8.
Repeat
Steps
6 and 7
for
the
remaining
pro
-
grams.
SECTION
5
-
MANUAL
WELDING,
CUTUING
AND
GOUGING:
KEY
SWITCH
IN
RUN POSITION
WARNING:
ELECTRIC
SHOCK
can kill;
MOVING
PARTS
can
cause
serious
injury.
IMPROPER
AIR
FLOW
AND
EXPOSURE
TO
ENVIRONMENT can
damage
internal
parts.
•
Do
not
touch
live
electrical
parts.
•
Keep
clear
of
pinch
points.
•
Keep
all
covers
and
panels
in
place
while
operating.
Warranty
is
void
if
the
unit
is operated
with
any portion
of
the
outer
enclosure removed.
ARC
RAYS,
SPARKS,
AND
HOT
SURFACES
can
burn eyes
and
skin;
NOISE
can
damage hearing.
•
Wear
correct
eye,
ear,
and body protection.
FUMES
AND
GASES
can
seriously
harm
your
health.
•
Ventilate
to
keep
from
breathing
fumes
and
gases.
•
If
ventilation
is
inadequate,
use
approved
breathing
apparatus.
WELDING
WIRE
can
cause
puncture wounds.
•
Do
not
point
guns toward
any
part
of
the
body,
any
conductive
surface,
or
other
personnel.
HOT
METAL,
SPATTER,
AND
SLAG
can
cause
fire
and
burns.
•
Watch
for
fire.
•
Have
a fire
extinquisher
nearby
and
know
how
to
use
it.
•
Allow
work and equipment to cool
before
handl
-
ing.
MAGNETIC
FIELDS
FROM
HIGH CURRENTS
can
affect
pacemaker
operation.
•
Wearers
should consult
with
thek
doctor
before
going
near
arc
welding, gouging,
or
spot
welding
operations.
See
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source in
the
welding
power
source
Owner’s
Manual
for
basic
welding
safety
information.
4.
Turn
key-switch
to
the
RUN
position.
5.
Place
the
Manual/Feeder
switch
in
the
MANUAL
CV/CC
position.
If
the AMPS
Numeric
display
and
AMPS
Indicator
light
turn
on,
depress
the
CV/CC
push
button
to
switch
to
CV
mode.
The
preset
parameters
cannot
be
changed.
IMPORTANT:
If
the
RPS-4
is
installed,
the
program
will
automatically
be
selected
from
the
switch position
when
thearc
is
struck.
6.
Depress
the
PROGRAM
Select push
button
or
RPS-4
to
select
the
starting
program.
7.
Depress
the
CONTACTOR
push
button
to
energize
the
welding
power
source
contactor.
Open-circuit
voltage
will
be
available
as
long
as
the
contactor
is
energized.
8.
Begin
cutting.
The
VOLTS
Numeric
display
shows
actual
arc voltage; the AMPS
Numeric
display
shows
load
current. The
preset
voltage
cannot
be
changed.
Switch
to
selected
program
with
RPS-4
or DSS-9M.
9.
Stop
welding.
The
AMPS
Numeric
display
will
show
welding
amps
for
ten
seconds.
10.
Depress
the
CONTACTOR
push
button
to
deenergize
the
contactor.
11.
Shut
down
wire
feeder
and
welding
power
source.
5
-2.
CC
MODE OPERATION
WARNING:
Read
and
follow
safety information at
beginning
of
entire
Section
5
before proceeding.
1.
Make
all
necessary
connections
as
instructed
in
Section 2.
2.
Energize
the
welding
power
source.
3.
Place
the
wire
feeder
Power
switch
in
the
ON
position.
Read
and
follow
safety information at
beginning
of
entire
Section
5
before proceeding.
1.
Make
all
necessary
connections
as
instructed
in
Section
2.
2.
Energize
the
welding
power
source.
3.
Place
the
wire
feeder Power
switch
in
the
ON
position.
4.
Turn
key-switch
to
the RUN
position.
5
-
1.
CV
MODE
OPERATION
WARNING:
OM-876
Page
7
5.
Place
the
Manual/Feeder switch
in
the
MANUAL
CV/CC
position.
If
the
VOLTS
Numeric
display
and
VOLTS
Indicator
light
turn
on,
depress
the
CV/CC
push
button
to
switch
to
CC
mode.
The
preset
parameters
cannot
be
changed.
6.
Rotate
the ARC
CONTROL
potentiometer
to
the
desired
position
(see
Section
3-2).
IMPORTANT:
If
the
RPS-4
is installed,
the
program
will
automatically
be
selected
from
the
switch
position
when
the
arc
is
struck.
7.
Depress
the
PROGRAM
Select push
button
or
RPS-4
to
select
the
starting program.
8.
Depress
the
CONTACTOR
push
button
to
energize
the
welding
power
source
contactor.
Open-circuit
voltage
will
be
available
as
long
as
the
contactor
is
energized.
9.
Begin
welding.
The
VOLTS
Numeric
display
shows
actual
arc
voltage; the AMPS
Numeric
display
shows
load
current. The
preset
voltage
cannot
be
changed.
Switch
to
selected
program
with
RPS-4
or
DSS-9M.
10.
Stop
welding.
The
VOLTS
Numeric
display
will
show
arc
volts
for
ten
seconds.
11.
Depress
the
CONTACTOR
push
button
to
deenergize
the
contactor.
12.
Shut
down
wire
feeder
and
welding
power
source.
SECTION
6
-
MANUAL
WELDING, CUTTING
AND
GOUGING:
KEY
SWITCH
IN
SET
POSITION
WARNING:
ELECTRIC
SHOCK
can
kill;
MOVING
PARTS can
cause
serious injury.
IMPROPER
AIR
FLOW
AND
EXPOSURE
TO
ENVIRONMENT
can
damage internal parts.
•
Do
not
touch
live electrical
parts.
•
Keep
clear
of
pinch
points.
•
Keep
all
covers
and
panels in place while
operating.
Warranty
is
void
if
the
unit
is operated
with
any
portion
of
the
outer
enclosure
removed.
ARC
RAYS,
SPARKS,
AND
HOT
SURFACES
can
burn
eyes
and
skin; NOISE
can
damage hearing.
•
Wear
correct
eye,
ear,
and
body
protection.
FUMES
AND
GASES can
seriously
harm
your
health.
•
Ventilate
to
keep
from breathing
fumes
and
gases.
•
If
ventilation
is
inadequate,
use
approved
breathing
apparatus.
WELDING
WIRE
can
cause
puncture
wounds.
•
Do
not
point
gun
toward any
partof
the
body, any
conductive
surface,
or
other
personnel.
HOT
METAL,
SPATTER,
AND
SLAG
can
cause
fire
and
burns.
•
Watch
for
fire.
•
Have
a
fire
extinquisher nearby
and
know
how
to
use
it.
•
Allow
work
and
equipment
to
cool
before
handl-
ing.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.
•
Wearers
should consult
with
their
doctor
before
going
near
arc
welding, gouging,
or
spot
welding
operations.
See
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source in
the
welding
power
source
Owner’s
Manual
for
basic
welding
safety
information.
IMPORTANT:
1.
Make
all
necessary
connections
as
instructed
in
Section
2.
2.
Energize
the
welding
power
source.
3.
Place
the
wire
feeder
Power
switch
in
the
ON
position.
4.
Turn
key-switch
to
the
SET
position.
5.
Place
the Manual/Feeder switch
in
the
MANUAL
CV/CC
position.
If
the AMPS
Numeric
display
and
AMPS
Indicator
light
turn
on,
depress
the
CV/CC
push
button
to
switch
to
CV
mode.
The
preset
parameters
can
be
chang
-
ed.
If
the
RPS-4
is
installed,
the
program
will
automatically
be
selected
from
the
switch
position
when
the
arc
is
struck.
6.
Depress
the
PROGRAM
Select push
button
or
RPS-4
to
select
the
starting program.
7.
Depress
the
CONTACTOR
push
button
to
energize
the
welding
power
source
contactor.
Open-circuit
voltage
will
be
available
as
long
as
the
contactor
is
energized.
8.
Begin
cutting.
The
VOLTS
Numeric
display
shows
actual
arc voltage; the AMPS
Numeric
display
shows
load
current. The
preset
voltage
can
be
changed.
Switch
to
selected program
with
RPS-4
or DSS-9M.
9.
Siop
welding.
The
AMPS
Numeric
display
will
show
welding
amps
for
ten
seconds.
6
-
1.
CV
MODE OPERATION
WARNING:
Read
and
follow
safety
information
at
beginning
of
entire Section
6
before
proceeding.
10.
Depress
the
CONTACTOR
push
button
to
deenergize
the
contactor.
11.
Shut
down
wire
feeder
and
welding
power
source.
OM-876 Pages
IMPORTANT:
Read
and
follow
safety
information
at
beginning
of
entire Section
6
before
proceeding.
1.
Make
all
necessary
connections
as
instructed
in
Section 2.
2.
Energize
the
welding
power
source.
3.
Place
the
wire
feeder Power
switch
in
the
ON
position.
4.
Turn
key-switch
to
the
SET
position.
5.
Place
the
Manual/Feeder switch
in
the
MANUAL
CV/CC
position.
If
the
VOLTS
Numeric
display
and
VOLTS
Indicator
light
turn
on,
depress
the
CV/CC
push
button
to
switch
to
CC
mode.
The
preset
parameters
can
be
chang-
ed.
6.
Rotate
the
ARC
CONTROL
potentiometer
to
the
desired
position
(see
Section
3-2).
If
the
RPS-4
is installed,
the
program
will
automatically
be
selected
from
the
switch
position
when
the
arc
is
struck.
7.
Depress
the
PROGRAM
Select
push
button
or
RPS-4
to
select
the
starting program.
8.
Depress
the
CONTACTOR
push
button
to
energize
the
welding
power
source
contactor.
Open-circuit
voltage
will
be
available
as
long
as
the
contactor
is
energized.
9.
Begin
welding.
The
VOLTS
Numeric
display
shows
actual
arc
voltage; the AMPS
Numeric
display
shows
load
current.
The
preset
current
can
be
changed.
Switch
to
selected
program
with
RPS-4
or DSS-9M.
10.
Stop
welding.
The
VOLTS
Numeric
display
will
show
arc
volts
for
ten
seconds.
11.
Depress
the
CONTACTOR
push
button
to
deenergize
the
contactor.
12.
Shut
down
wire
feeder
and
welding
power
source.
SECTION
7
-
MAINTENANCE
IMPORTANT:
Every
six
months
inspect
the
labels
on
the
unit
for
legibility.
All
precautionary
labels
must
be
maintained
in
a
clearly
readable
state
and
replaced
when
necessary.
See Parts
List
for pert
number
of
precautionary
labels.
7
-
1.
INSPECTION
AND
UPKEEP
WARNING:
ELECTRIC
SHOCK
can
kill.
•
Do
not
touch
live electrical
parts.
•
Shut
down
wire
feeder
and welding
power
source
and disconnect
input
power
employing
“lockout/tagging
procedures”
before
inspecting,
maintaining,
or
servicing.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or shutting
off
and
red-tagging
circuit
breaker
or
other disconnect
device.
MOVING
PARTS
can
cause
serious
Injury.
•
Keep
clear
of
pinch
points.
HOT
SURFACES
can
cause
severe
burns.
•
Allow
cooling
period
before
servicing.
Maintenance
and
trot~ieshooting
of
internal
parts
to
be
performed
only
by
qualified
persons.
Usage
and
shop
conditions
will
determine
the
frequency
and
type
of
maintenance. Inspect
equipment every
six
months
as
follows:
1.
Remove grease
and
grime
from
components;
remove
moisture
from
electrical
parts and
cables.
2.
Check
switch
terminals.
Be
sure
the
connections
are
clean
and
tight.
7
-
2.
WELD
CABLES
~
ELECTRIC
SHOCK
can
kill.
•
Do
not
touch live electrical
parts.
•
Shut
down
wire
feeder
and welding
power
source
and
disconnect
input
power
employing
“lockout/tagging
procedures”
before inspecting,
maintaining,
or
servicing.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting off
and
red-tagging
circuit
breaker
or
other disconnecting
device.
Inspect
cables
for
breaks
in insulation,
and
ensure
that
all
connections
are
clean
and
tight.
Repair
or
replace
cables
if
insulation
breaks
are
present.
Clean
and
tighten
connections
at
each
inspection.
6
-2.
CC
MODE OPERATION
WARNING:
OM-876
Page
9
GRN.
CDIG)
MANUALIN
MANUALOUT
C
FEEDER
IN
S2
~-
FEEDER
OUT
Circuit
Diagram
No.
A-091
097-A
Figure
7
-
1.
Circuit
Diagram
C
WHT(MANUAL)
LSj
PLG$
OM-876
Page
10
Item
Dia.
No.
Mkgs.
Part
No.
Description
Quantity
Figure
A
041
790
Control,
Process
Selector
S2
091
598
LS1
603 946
091
957
010
650
059
804
004 214
091
600
123 154
091
032
093 666
PLG8
039
273
039 685
007
826
070 654
091
032
091
599
059
712
Ri
009
156
024 366
019
603
3
4
SWITCH,
selector (consisting
of)
SWITCH,
micro
HANDLE,
switch
PIN,
spring
1/8x1
TUBING,
copper
1/4
IPS
x
7/16
BUSHING,
snap
1-5/8
ID
x2
WRAPPER
LABEL, warning
general
precautionary
LABEL,
hook
up
diagram
LABEL,
hook
up
diagram
PLUG,
5pm
MS-3106A-165-1
P
CLAMP,
cable
CORD,
No.
183/c
(order
byft)
BUSHING,
strain
relief
.300
ID
x
.550
hole
LABEL,
hook
up-control
CASE
SECTION,
front/bottom/back
CLIP,
cable
POTENTIOMETER, carbon
1
turn
2
watt
2.5K
ohm
KNOB,
pointer
KNOB,
ball
NAMEPLATE
(order
by
model
&
serial
number)
1
2
3
4
5
6
7
8
9
9
10
11
12
13
14
15
16
17
18
19
20
1
1
1
4
4
1
1
1
1
1
1
3ft
1
2
1
1
1
20
12
13
14
15
17
Figure
A
-.
Control,
Process
Selector
TC-O91
934
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-876
Page
11
/