Miller JD668503 Owner's manual

Miller
Brand
Miller
Model
JD668503
Category
Welding System
Type
Owner's manual

This manual is also suitable for

t~e
0~
096~
OWN
ERS
MANUAL
November1983
FORM:
OM-1537B
Effective
With
Serial
No.
J0668503
MODEL
SYSTEM
9
GAS
CONTROL
HUB
&
SPINDLE
WIRE
REEL
ITIIIIER
MILLER
ELECTRIC
MFG.
CO.
778
S.
BOUNDS
SI,
P.O.
Box
1079
APPLETON,
WI
54912
USA
NWSA
CODE
NO.
4579
PRINTED
IN
U.S.A.
LIMITED
WARRANTY
EFFECTIVE:
JUNE
1,
1979
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex~
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
,~j
LIMITED
WARRANTY-Subject
to
the
terms
and
conditions
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
t4
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
ranty
is
made
by
Miller
with
respect
to
engines,
trade
ac-
therefore
shall
be,
at
Millers
option
Ill
repair
or
12)
replacement
cessories
or
other
items
manufactured
by
others.
Such
or,
where
auttronzed
in
writing
by
Miller
in
appropriate
cases,
13)
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
141
payment
of
or
credit
for
the
purchase
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
Iless
reasonable
depreciation
based
upon
actual
usel
upon
date
of
original
purchase.
return
of
the
goods
at
Customers
risk
arid
expense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
clai
Except
as
specified
below,
Millers
warranty
does
not
apply
.
mant
on
the
warranty
claim
procedures
to
be
followed.
S
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-
wire
including
nozzles
and
nozzle
insulators
where
failure
does
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
not
result
from
defect
in
workmanship
or
material.
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION.
OPERATION
OF
LAW,
Miller
shall
be
required
to
honor
warranty
claims
on
war-
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
-
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
within
the
following
periods
from
the
date
of
delivery
of
Equip-
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
~
ment
to
the
original
user:
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EX
CLUDED
AND
DISCLAIMED
BY
MILLER.
1.
Arc
welders,
power
sources
and
components
. .
1
year
2.
Original
main
power
rectifiers
3years
EXCEPT
AS
EXPRESSLY
PROV1DED
BY
MILLER
IN
(!abor
-1
year
only)
WRITING.
MILLER
PRODUCTS
ARE
INTENDED
FOR
3.
All
welding
guns
and
feeder/guns
90
days
ULTIMATE
PURCHASE
BY
COMMERCIALi
INDUSTRIAL
4.
All
other
Millermatic
Feeders
1
year
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
5.
Replacement
or
repair
parts,
exclusive
of
labor
.
60
days
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
(
6.
Batteries
6months
WELDING
EQUIPMENT
AND
Nor
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER
WARRANTIES
DO
NOT
EXTEND
~
provided
that
Miller
is
notified
iii
writing
within
thirty
(301
days
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
of
the
date
of
such
failure.
.
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
~-~
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
In
this
manual.
AMENDMENT
TO
SECTION
7
MAINTENANCE
&
TROUBLESHOOTING
Amend
Figure
7-1.
Circuit
Diagram
For
Weld
Control
(see
Page
2
on
this
Errata
Sheet)
Add
Figure
7-9.
Circuit
Diagram
For
Voltage
Regulator
Board
PC12
Circuit
Diagram
No.
A-123
556
Figure
7-9.
CircuIt
Diagram
For
Voltage
Regulator
Board
PC12
AMENDMENT
TO
PARTS
LIST
(see
Page
3
on
this
Errata
Sheet)
-I
I
~
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I
___
_
C
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_________
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_______________
t.____...J0p....JZ.a~__.4
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TO
a~..
TO
PTGfl0
Circuit
Diagram
No.
C-097
891-B
Figure
7-1.
CIrcuit
Diagram
For
Weld
Control
Effective
With
Serial
No.
JF947217
~1
Ti
L;
~
(f.
j~i
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TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
-
SAFETY
RULES
FOR
OPERATION
OF
ARC
WELDING
POWER
SOURCE
1
-
1.
Introduction
1
1
-
2.
General
Precautions
1
1
-3.
Arc
Welding
4
1
-
4.
Standards
Booklet
Index
6
SECTION
2
-
INTRODUCTION
2
-
1.
General
Information
And
Safety
7
2
-
2.
Receiving-Handling
7
2
-
3.
Description
7
SECTION
3
-
INSTALLATION
3-1.
Location
7
3
-
2.
Shielding
Gas
Connections
8
3
-3.
Water
Connections
8
3
-
4.
Limit
Switch
Connections
3
-
5.
AuxiliaryOutput
Connections
10
3
-
6.
Weld
Control
Interconnections
10
3
-
7.
Field
Installation
Of
MHA-2
11
3
-
8.
Hub
And
Spindle
Assembly
Installation
13
3
-
9.
Installation
Of
Spool-Type
Wire
13
3-10.
Installation
Of
Reel-Type
Wire
13
3
-11.
Installation
Of
Wire
Reel
14
3-12.
Adjusting
Hub
Tension
14
SECTION
.4
-
DEFINITIONS
OF
PROGRAM
TERMS
4
-
1.
Program
Definitions
14
4
-
2.
Alpha
Numeric
Display
Definitions
15
SECTION
5
-
OPERATOR
CONTROLS
5
-
1.
Power
Emergency
Stop
Button
16
5
-2.
Run/Set
Up
Switch
16
5
-3.
Jogging
Controls
17
5
-4.
Auxiliary
Output
Indicators
17
5
-
5.
Alpha-Numeric
Display
17
5
-
6.
Weld
Program
Indicators
17
5
-
7.
Voltage
Reset
Button
18
5
-
8.
Purge
Push
Button
18
5
-
9.
Program
Select
Push
Button
18
5-10.
Program
Run
Push
Button
18
5-11.
Sequence
Advance
Push
Button
19
5-12.
Halt/Resume
Push
Button
19
SECTION
6
-
PROGRAMMING
6
-
1.
Mini-Cassette
Tape
Operation
19
6
-
2.
Programming
Module
Operation
20
6
-
3.
Programming
Examples
21
6
-
4.
Running
A
Program
22
SECTION
7
-
MAINTENANCE
&
TROUBLESHOOTING
7
-
1.
Running
The
Diagnostic
Program
33
7
-
2.
Inspection
And
Upkeep
33
7
-
3.
Memory
Batteries
33
7
-
4.
Troubleshooting
33
highly
toxic
gas,
and
other
lung
and
eye
irritating
pro
ducts.
The
ultraviolet
(radiant)
energy
of
the
arc
can
also
decompose
trichioroethylene
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
trichioroethylene
or
per
chioroethylene.
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
corn-
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).
Walls,
ceilings,
and
floor
near
work
should
be
protected
by
heat-resistant
covers
or
shields.
Fire
watcher
must
be
standing
by
with
suitable
fire
ex
tin~uishing
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
OM-1537
Page
2
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.
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
~ut
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
pin
when
pressurized,
nor
returns
to
stop
pin
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
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.)
Coil
excess
hose
to
prevent
kinks
and
tangles.
ICC
or
DOT
marking
must
be
on
each
cylinder.
It
is
an
assurance
of
safety
when
the
cylinder
is
properly
handled.
Identifying
gas
content.
Use
only
cylinders
with
name
of
gas
marked
on
them;
do
not
rely
on
color
to
identify
gas
content.
Notify
supplier
if
unmarked.
NEVER
DEFACE
or
alter
name,
number,
or
other
markings
on
a
cylinder.
It
is
illegal
and
hazardous.
Empties:
Keep
valves
closed,
replace
caps
securely;
mark
MT;
keep
them
separate
from
FULLS
and
return
promptly.
Prohibited
use.
Never
use
a
cylinder
or
its
contents
for
other
than
its
intended
use,
NEVER
as
a
support
or
roller.
Locate
or
secure
cylinders
so
they
cannot
be
knocked
over.
Passageways
and
work
areas.
Keep
cylinders
clear
of
areas
where
they
may
be
struck.
Transporting
cylinders.
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
flame,
etc.
that
may
cause
rupture.
Do
not
allow
contents
to
exceed
130F.
Cool
with
water
spray
where
such
exposure
exists.
Project
cylinders
particularly
valves
from
bumps,
falls,
falling
objects,
and
weather.
Replace
caps
securely
when
moving
cylinders.
Stuck
valve.
Do
NOT
use
a
hammer
or
wrench
to
open
a
cylinder
valve
that
can
not
be
opened
by
hand.
Notify
your
supplier.
Mixing
gases.
Never
try
to
mix
any
gases
in
a
cylinder.
Neler
refill
any
cylinder.
Cylinder
fittings
should
never
be
modified
or
exchang
ed.
Protect
hose
from
damage
by
sharp
edges,
and
by
sparks,
slag,
and
open
flame.
Examine
hose
regularly
for
leaks,
wear,
and
loose
con
nections.
Immerse
pressured
hose
in
water;
bubbles
in
dicate
leaks.
Repair
leaky
or
worn
hose
by
cutting
area
out
and
splic
ing
(1-2D3).
Do
NOT
use
tape.
4.
Proper
Connections
Clean
cylinder
valve
outlet
of
impurities
that
may
clog
orifices
and
damage
seats
before
connecting
regulator.
Except
for
hydrogen,
crack
valve
momentarily,
pointing
outlet
away
from
people
and
sources
of
ignition.
VVipe
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.
3.
Hose
Stand
to
side
of
regulator
while
opening
cylinder
valve.
Prohibited
use.
Never
use
hose
other
than
that
designed
for
the
specified
gas.
A
generalhose
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
io
keep
it
from
being
run
over,
stepped
on,
or
otherwise
damaged.
Open
cylinder
valve
slowly
so
that
regulator
pressure
in
creases
slowly.
When
gauge
is
pressurized
(gauge
reaches
regulator
maximum)
leave
cylinder
valve
in
following
position:
For
oxygen,
and
inert
gases,
open
fully
to
seal
stem
against
possible
leak.
For
fuel
gas,
open
to
less
than
one
turn
to
permit
quick
emergency
shutoff.
Use
pressure
charts
(available
from
your
supplier)
for
safe
and
efficient,
recommended
pressure
settings
on
regulators.
Check
for
leaks
on
first
pressurization
and
regularly
there-after.
Brush
with
soap
solution
(capful
of
Ivory
OM-15Z17
Page
3
Protect
filter
plate
with
a
clear
cover
plate.
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
im
mediately
for
repair.
See
User
Responsibility
statement
in
equipment
manual.
F.
Leaving
Equipment
Unattended
Close
gas
supply
at
source
and
drain
gas.
G.
Rope
Staging-Support
Rope
staging-support
should
not
be
used
for
welding
or
cutting
operation;
rope
may
burn.
1-3.
ARC
WELDING
-
Comply
with
precautions
in
1-1,
1-2.
and
this
section.
Arc
Welding,
properly
done,
is.a
safe
process,
but
a
careless
operator
invites
trouble.
The
equipment
carries
high
currents
at
significant
voltages.
The
arc
is
very
bright
and
hot.
Sparks
fly,
fumes
rise,
ultraviolet
and
infrared
energy
radiates,
weldments
are
hot,
and
compressed
gases
may
be
us
ed.
The
wise
operator
avoids
unnecessary
risks
and
pro
tects
himself
and
others
from
accidents.
Precautions
are
described
here
and
in
standards
referenced
in
index.
A.
Burn
Protection
Comply
with
precautions
in
1-2.
The
welding
arc
is
intense
and
visibly
bright,
Its
radia
tion
can
damage
eyes,
penetrate
lightweight
clothing,
reflect
from
light-colored
surfaces,
and
burn
the
skin
and
eyes.
Skin
burns
resemble
acute
sunburn,
those
from
gas-shielded
arcs
are
more
severe
and-
painful.
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.
lrademark
of
Proctor
&
Gamble.
Cracked
or
broken
helmet
or
shield
should
NOT
be
worn;
radiation
can
pass
through
to
cause
burns.
Cracked,
broken,
or
loose
filter
plates
must
be
replaced
IMMEDIATELY.
Replace
clear
cover
plate
when
broken,
pitted,
or
spattered.
Flash
goggles
with
side
shields
MUST
be
worn
under
the
helmet
to
give
some
protection
to
the
eyes
should
the
helmet
not
be
lowered
over
the
face
before
an
arc
is
struck.
Looking
at
an
arc
momentarily
with
unprotected
eyes
(particularly
a
high
intensity
gas-shielded
arc)
can
cause
a
retinal
burn
that
may
leave
a
permanent
dark
area
in
the
field
of
vision.
3.
Protection
of
Nearby
Personnel
Enclosed
welding
area.
For
production
welding,
a
separate
room
or
enclosed
bay
is
best.
In
open
areas,
surround
the
operation
with
low-reflective,
non-
combustible
screens
or
panels.
Allow
for
free
air
circula
tion,
particularly
at
floor
level.
Viewing
the
weld. Provide
face
shields
for
all
persons
who
will
be
looking
directly
at
the
weld.
Others
working
in
area.
See
that
all
persons
are
wearing
flash
goggles.
Before
starting
to
weld,
make
sure
that
screen
flaps
or
bay
doors-are
closed.
B.
Toxic
Fume
Prevention
Comply
with
precautions
in
1
-2B.
Generator
engine
exhaust
must
be
vented
to
the
outside
air.
Carbon
monoxide
can
kill.
C.
Fire
and
Explosion
Prevention
Comply
with
precautions
in
1-2C.
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
vuo~ent
rupture
or
lead
to
such
a
rupture
later
under
rough
handling.
D.
Compressed
Gas
Equipment
Comply
with
precautions
in
1-20.
OM-1537
Page
4
E.
Shock
Prevention
2.
Electrode
Holders
Exposed
hot
conductors
or
other
bare
metal
in
the
welding
circuit,
or
in
ungrounded,
electrically-HOT
equipment
can
fatally
shock
a
person
whose
body
becomes
a
conductor.
DO
NOT
STAND,
SIT,
LIE,
LEAN
ON,
OR
TOUCH
a
wet
surface
when
welding,
without
suitable
protection.
To
protect
against
shock:
Keep
body
and
clothing
dry.
Never
work
in
damp
area
without
adequate
insulation
against
electrical
shock.
Stay
on
a
dry
duckboard,
or
rubber
mat
when
damp
ness
or
sweat
can
not
be
avoided.
Sweat,
sea
water,
or
moisture
between
body
and
an
electrically
HOT
part
-
or
grounded
metal
-
reduces
the
body
surface
electrical
resistance,
enabling
dangerous
and
possibly
lethal
currents
to
flow
through
the
body.
1.
Grounding
the
Equipment
When
arc
welding
equipment
is
grounded
according
to
the
National
Electrical
Code,
and
the
work
is
grounded
according
to
ANSI
Z49.1
Safety
In
Welding
And
Cut
ting,
a
voltage
may
exist
between
the electrode
and
any
conducting
object.
Examples
of
conducting
objects
include,
but
are
not
limited
to,
buildings,
electrical
tools,
work
benches,
welding
power
source
cases,
workpieces,
etc.
Never
touch
the
electrode
and
any
metal
object
unless the
welding
power
source
is
off.
When
installing,
connect
the
frames
of
each
unit
such.
as
welding
power
source,
control,
work
table,
and
water
circulator
to
the
building
ground.
Conductors
must
be
adequate
to
carry
ground
currents
safely.
Equipment
made
electrically
HOT
by
stray
current
may
shock,
possibly
fatally.
Do
NOT
GROUND
to
electrical
conduit,
or
to
a
pipe
carrying
ANY
gas
or
a
flammable
li
quid
such
as
oil
or
fuel.
Three-phase
connection.
Check
phase
requirements
of
equipment
before
installing.
If
only
3-phase
power
is
available,
connect
single-phase
equipment
to
only
two
wires
of
the
3-phase
line.
Do
NOT
connect
the
equip
ment
ground
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
for
connection
to
a
switchbox,
connect
the
ground
lead
to
the
grounded
switchbox.
If
a
three-
prong
plug
is
added
for
connection
to
a
grounded
mating
receptacle,
the
ground
lead
must
be
connected
to
the
ground
prong
only.
If
the
line
cord
comes
with
a
three-prong
plug,
connect
to
a
grounded
mating
recep
tacle.
Never
remove
the
ground
prong
from
a
plug,
or
use
a
plug
with
a
broken
off
ground
prong.
Fully
insulated
electrode
holders
should
be
used.
Do
NOT
use
holders
with
protruding
screws.
3.
Connectors
Fully
insulated
lock-type
connectors
should
be
used
to
join
welding
cable
lengths.
4.
Cables
Frequently
inspect
cables
for
wear,
cracks
and
damage.
IMMEDIATELY
REPLACE
those
with
excessively
worn
or
damaged
insulation
to
avoid
possibly
-
lethal
shock
from
bared
cable.
Cables
with
damaged
areas
may
be
taped
to
give
resistance
equivalent
to
original
cable.
Keep
cable
dry,
free
of
oil
and
grease,
and
protected
from
hot
metal
and
sparks.
5.
Terminals
And
Other
Exposed
Parts
Terminals
and
other
exposed
parts
of
electrical
units
should
have
insulating
covers
secured
before
operation.
6.
Electrode
a.
Equipment
with
output
on/off
control
(con
tactor)
Welding
power
sources
for
use
with
the
gas
metal
arc
welding
(GMAW),
gas
tungsten
arc
welding
(GTAW).and
similar
processes
normally
are
equipped
with
devices
that
per
mit
on-off
control
of
the
welding
power
out
put.
When
so
equipped
the
electrode
wire
becomes
electrically
HOT
when
the
power
source
switch
is
ON
and
the
welding
gun
switch
is
closed.
Never
touch
the
electrode
wire
or
any
conducting
object
in
contact
with
the
electrode
circuit
unless
the
welding
power
source
is
off.
b.
Equipment
without
output
on/off
control
(no
contactor)
Welding
power
sources
used
with
shielded
metal
arc
welding
(SMAW)
and
similar
pro
cesses
may
not
be
equipped
with
welding
power
output
on-off
control
devices.
With
such
equipment
the
electrode
is
elecuically
HOT
when
the
power
switch
is
turned
ON.
Never
touch
the
electrode
unless
the
welding
power
source
is
off.
7.
Safety
Devices
Safety
devices
such
as
interlocks
and
circuit
breakers
should
not
be
disconnected
or
shunted
Out.
Before
installation,
inspection,
or
service,
of
equip
ment,
shut
OFF
all
power
and
remove
line
fuses
(or
lock
OM-1537
Page
5
or
red-tag
switches)
to
prevent
accidental
turning
ON
of
power.
Disconnect
311
cables
from
welding
power
source,
and
pull
all
115
volts
line-cord
plugs.
Do
not
open
power
circuit
or
change
polarity
while
welding.
If,
in
an
emergency,
it
must
be
disconnected,
guard
against
shock
burns,
or
flash
from
switch
arcing.
Leaving
equipment
unattended.
Always
shut
OFF
and
disconnect
all
power
to
equipment.
Power
disconnect
switch
must
be
available
near
the
welding
power
source.
1-4.
STANDARDS
BOOKLET
INDEX
For
more
information;
refer
to
the
following
standards
or
their
latest
revisions
and
comply
as
applicable:
1.
ANSI
Standard
Z49.1,
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from
the
American
Welding
Society,
550
Le
Jeune
Rd,
P.O.
Box
351040
Miami,
FL
33135.
2.
NIOSH,
SAFETY
AND
HEALTH
IN
ARC
WELDING
AND
GAS
WELDING
AND
CUTTING
obtainable
from
the
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
3.
OSHA,
SAFETY
AND
HEALTH
STANDARDS,
29CFR
1910,
obtainable
from
the
U.S.
Govern
mØnt
Printing
Office,
Washington,
D.C.
20402.
4.
ANSI
Standard
Z87.i,
SAFE
PRACTICES
FOR
OCCUPATION
AND
EDUCATIONAL
EYE
AND
FACE
PROTECTION
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
5.
ANSI
Standard
Z41.1,
STANDARD
FOR
MENS
SAFETY-TOE
FOOTWEAR
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
6.
ANSI
Standard
Z49.2,
FIRE
PREVENTION
IN
THE USE
OF
CUTTING
AND
WELDING
PRO
CESSES
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
7.
AWS
Standard
A6.0,
WELDING
AND
CUT
TING
CONTAINERS
WHICH
HAVE
HELD
COM
BUSTIBLES
obtainable
from
the
American
Welding
Society,
550
Le
Jeune
Rd.
P.O.
Box
351040,
Miami
FL
33135.
8.
NFPA
Standard
51,
OXYGEN
-
FUEL
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
518,
CUTTING
AND
WELDING
PROCESSES
obtainable
from
the
National
Fire
Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
11.
CGA
Pamphlet
P-i,
SAFE
HANDLING
OF
COM
PRESSED
GASES
IN
CYLINDERS
obtainable
from
the
Compressed
Gas
Association,
500
Fifth
Avenue,
New
York,
NY
10036.
12.
CSA
Standard
Wi
17.2,
CODE
FOR
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from
the
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1R3.
13.
NWSA
booklet,
WELDING
SAFETY
BIBLIOGRAPHY
obtainable
from
the
National
Welding
Supply
Association,
1900
Arch
Street,
Philadelphia,
PA
19103.
14.
American
Welding
Society
Standard
AWSF4.1
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
LeJeuneRd.
P.O.
Box351040,
M~mi,
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.
OM.1
537
Pa9e6
_J
2-7/8
in.
(73.0
mm)
TA-092
4-40
4
S
H
F
E
S.
TB-080
488-A
Overall
DImension,
Arid
MountIng
Hole
Layout
Inches
MIllimeters
A
19-1/2
496
8
21-7/8
556
C
13-3/4
349
D
3
76
E
2-1/2
63.5
F
3-1/2
88.9
G
4-1/2
114
H
10-11/16
275
Figure
3-1.
Dimensional
Views
3
-
2.
SHIELDING
GAS
CONNECTIONS
(Figure
3-4)
-
The
gas
in
and
gas
out
fittings
have
5/8-18
right
__________
hand
threads.
Connect
a
hose
from
the
shielding
gas
supply
to
the
gas
in
fitting
on
the
gas
control
assembly.
The
gas
flow
must
be
controlled
by
a
regulator
and
flowmeter.
Connect
a
hose
from
the
gas
out
fitting
to
the
barbed
fitting
on
the
wire
drive
housing.
9.5
in.
(241.3
mm)
19
in.
(482.6
mm)
5/16
in.
(7.9
mm)
4-1/8
In.
0
J:?et~
2
Holes
(105
mm)
L_
_
(251
mm)
~
9-7/8
In.
10-1/2
In.
(267
mm)
TA-080
429
25-27/32
in.
(656.4
mm)
26-1/2
In.
(673.1
mm)
TC-085
225-A
3-1/2
In.
(89
mm)
I
9-1/2
in.
(241.3
mm)
Add
1
in.
(25.4
mm)
for
connectors.
Add
1/2
in.
(12.7
mm)
for
front
panel
knob.
TAO8O
485
3
-
3.
WATER,
CONNECTIONS
(Optional)
CAUTION:
OVERHEATING
of
Gas
Metal-Arc
Welding
gun
can
damage
gun.
If
using
a
water-coo/ed
gun
and
recircula
ring
coo/ant
system,
make
connections
from
the
coo/ant
system
directly
to
the
gun
hoses.
Do
not
make
water
connections
to
the
gas
control
assemb/y.
Check
system
periodically
for
proper
coo/ant
flow.
OM-153/
Pages
SECTION
2
-
INTRODUCTION
Wire
Feed
Speed
Open-Circuit
Voltage
Control
Input
Power
Requirements
Weight
50-800
~pm
(1.3-20.3
mpm)
Depends
On
Welding
Power
Source
Open-Circuit
Voltage
115
Volts
AC
4
Amperes
83
lbs.
(37.6
kg.)
Figure
2-1.
Specifications
2
-
1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
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
ment.
B.
Safety
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
cl~ims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with
the
carrier~
A
copy
of
the
bill
of
lading
will
be
furnished
by
the
manufacturer
on
re
quest
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
it
is
essential
that
Model
Description
and
Serial
(or
Style)
Numbers
of
the
equipment
be
supplied.
WARNING
WARNING
I
CAUTION
CAUTION
IMPORTANT
quired.
SECTION
3
-
INSTALLATION
I
WA
I
~I1
~I
~
If
an
optional
motorized
slide
is
to
be
used
with
this
unit,
install
and
connect
slide
.as
in
structed
in
Owners
Manual
1096.
3
-
1.
LOCATION
(Figure
3-1)
-
The
location
should
allow
room
to
open
and
remove
covers
and
wrappers
for
installation,
maintenance
and
repair.
Lead
lengths
must
be
considered
when
locating
individual
com
ponents
of
the
system.
Mounting
holes
have
been
provided
in
each
component
for
mounting
purposes.
Figure
3-1
gives
unit
dimen
sions.
The
service
life
and
efficiency
of
the
system
are
reduced
when
it
is
subjected
to
high
levels
of
dust.
dirt.
moisture,
corrosive
vapors,
and
extreme
heat.
The
installation,
operation,
maintenance,
and
troubleshooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
installed,
operated,
and
maintained
only
by
qualified
persons
in
accordance
with
this
manual
and
all
ap
plicable
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source.
Safety
instructions
specifically
pertaining
to
this
unit
ap
pear
throughout
this
manual
highlighted
by
the
signal
words
____________
and
___________
which
identify
different
levels
of
hazard.
________
statements
include
installation,
operating,
an
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
thisequipment.
A
third
signal
word,
______________,
highlights
instruc
tions
which
need
special
emphasis
to
obtain
the
most
efficient
operation
of
this
equipment.
2
-
3.
DESCRIPTION
-
The
System
9
programmable
weld
control
is
designed
for
use
with
a
Deltaweld
welding
power
source
to
provide
automated
Gas
Metal-
Arc
Welding.
The
System
9-consists
of
a
weld
control
and
gas
control
assembly.
The
programmable
weld
control
has
a
microprocessor
which
receives
and
interprets
input
commands
and
sup
plies
output
commands
necessary
for
making
the
weld.
The
weld
control
can
be
programmed
for
nine
weld
pro
grams,
each
of
which
contain
several
sequences.
The
weld
control
will
start,
stop,
and
set
the
feed
rate
of
the
welding
wire;
start,
stop,
and
set
the
output
voltage
of
the
welding
power
source
(arc
voltage);
sequence
the
shielding
gas
and/or
water
valves;
time
each
se
quence
as
required,
and
operate
four
auxiliary
outputs
that
can
turn
on
and
off
with
each
sequence
as
re
The
gas
control
assembly
contains
the
gas
(and
optional
water)
valve
which
allows
gas
flow
as
programmed
on
the
weld
control.
The
gas
control
assembly
also
con
tains
a
reed
switch
through
which
one
weld
Output
cable
is
routed
to
provide
current
sensing
feedback.
OM-153;
Pj~7
The
water
in
and
water
out
fittings
have
5/8-18
left
hand
threads.
Connect
a
hose
from
the
water
supply
to
the
water
in
fitting
on
gas
control
assembly.
Connect
the
water
hose
from
the
torch
to
the
water
out
fitting
on
the
gas
control
assembly.
Connect
and
route
a
hose
from
the
torch
output
hose
to
a
proper
drain.
3
-
4.
LIMIT
SWITCH
CONNECTIONS
(Figure
3-2)
-
When
an
untimed
sequence
is
programmed,
an
external
limit
switch,
connected
to
terminal
strip
2T,
may
be
used
to
end
sequence
and
allow
the
unit
to
ad
vance
to
the
next
sequence.
Terminal
strip
2T
is
located
on~
the
component
panel.
Loosen
the
screws
from
the
front
door
and
open
door
to
gain
access
to
2T.
Route
leads
from
imit
switches
through
strain
relief
on
right
side
panel
to
2T.
Leads
must
be
shielded
twisted
pair
wire.
WARNING:
__________
ELECTRIC
SHOCK
can
kill.
Do
not
touch
liver
electrical
parts.
Shut
down
the
weld
control
and
disconnect
input
power
(115
vac)
before
making
any
terminal
strip
connections.
I I
I
C.,
C~
C.)
1
fi
fi
~
Remove
Jumper
I
IMHA-2
o
e~
~
~
I
Jumper
C~
~)
~
,-
I-
,-
4
=
C..)
0
~
:_
~
Wire
*
Customer
Supplied
Limit
Switches
AB
CD
E
FGHJ
Customer
Supplied
Switches
IC./
L-J-Remote
Haiti
Resume
K/L-M-Remote
Program
Run
0
C.)
~o
0
~
~
~
p.
,-
4
~
C.,
3
UJ
U.
C.~I
A
B
C
D
E
F
G
H
3T
RemoteAux.
Control
A-C
-
Aux.
C.
A-B
-
Aux.
0
il~I~J1:lf~iiIg
A
limit
switch
must
be
used
when
codes
5
or
6
are
used
(see
Table
4-2).
4
x
4
4
Make
connections
as
follows:
~I
:~~
K
L
M
iT
~n
in
I
I
I
A
B
C
D
E
F
G
H
J
K
2T
A/B-C
Weld
1
-
Weld
2
lImit
switch
AIB-D
Weld
2
-
Weld
3
limit
switch
A/B.E
Weld
3
-
Pause
limit
switch
A/B-F
Pause
-
PFŒf1QWQI
next
program
limit
switch
Customer
A
B
C
0
E
F
3
H
4T
Figure
3-2.
Terminal
Strip
Connections
TA.086
2734
OM-1537
Page
9
1.
Connect
insulated
wires
from
shielded
twisted
pair
wire
(Belden
8760
or
equivalent)
to
contacts
of
normally-open
momentary-contact
switch.
Cut
off
shielding
wire.
Repeat
for
each
limit
switch
required.
2.
Route
leads
from
switch(es)
through
stain
relief
clamp
(Figure
3-3)
to
terminal
strip
2T.
3
-
6.
WELD
CONTROL
INTERCONNECTIONS
(Figures
3-3
and
3-5)
WARNING:
____
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
interconnections.
3.
Open
weld
control
door.
4.
Connect
shielding
drain
wire(s)
to
control
chassis.
5.
To
advance
from
Weld
1
to
Weld
2
using
a
limit
switch,
make
switch
connections
between
2TA
and
2TC.
6.
To
advance
from
Weld
2
to
Weld
3
using
a
limit
switch,
make
switch
connections
between
2TA
and
2TD.
7.
To
advance
from
Weld
3
to
Crater
using
a
limit
switch,
make
switch
connections
between
2TA
and
2TE.
8.
To
advance
from
Pause
to
Preflow
of
the
next
program
using
a
limit
switch,
make
connections
between
2TA
and
2TF.
9.
Close
and
secure
weld
control
door.
3
-5.
AUXILIARY
OUTPUT
CONNECTIONS
(Figure
3-2)
-
Terminal
strips
11
and
3T
allow
the
user
access
to
relay
contacts
that
are
controlled
(on/off)
b~
the
settings
of
the
auxiliary
outputs.
Terminal
strip
4T
allows
the
user
to
remotely
control
the
energizing
of
C
and
D
auxiliary
output
relay
contacts.
IAI~1:hIlk~e~
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.
1.
Open
weld
control
door
2.
Route
leads
from
equipment
through
strain
relief
clamp
on
right
side
of
weld
control
to
terminal
strip(s)
1
T,
3T,
or
4T.
3.
Connect
equipment
leads
to
terminal
strip(s)
as
desired
according
to
program
needs
and
data
entered.
A
snubber
circuit
with
an
impedance
of
25K
ohms
at
60
Hertz
is
connected
across
each
of
the
auxiliary
output
contacts.
4.
Close
and
secure
weld
control
door.
IMPORTANT:
This
unit
is
supplied
with
the
necessary
interconnecting
cords.
Examine
and
select
the
proper
cord
for
each
of
the
following
connections.
A.
Voltage
Sensing
Connections
Connect
the
4-pin
plug
from
the
voltage
sensing
cord
to
weld
control
receptacle
A
(see
Figure
3-3).
Connect
re
maining
ends
as
follows:
Connect
leads
with
ring
ter
minals
to
weld
output
terminals
on
welding
power
source
(polarity
is
not
important).
B.
Voltage
Control
Connections
Connect
the
4-pin
plug
from
the
voltage
control
cord
to
weld
control
receptacle
B
(see
Figure
3-3).
Connect
re
maining
end
to
VOLTAGE
CONTROL
receptacle
on
welding
power
source.
Welding
power
source
VOLTAGE
CONTROL
switch
must
be
in
REMOTE
posi
tiOn.
C.
Motor
Control
Connections
Connect
the
14-pin
plug
from
the
motor
control
cord
to
weld
control
receptacle
C
(see
Figure
3-3).
Connect
re
maining
end
to
plug
from
drive
motor.
Fuse
Circuit
Breaker
Strain
Relief
Clamp
115
VAC
Power/
Contactor
Control-E
Gas
Control-D
Motor
Control-C
..oltage
Sensing-A
Voltage
Control-B
TC-O8S
225-A
Figure
3-3.
Weld
Control
Interconnections
D.
Gas
Control
Connections
Connect
the
14-pin
plug
from
the
gas
control
cord
to
weld
control
receptacle
0
(see
Figure
3-3).
Connect
re
maining
end
to
receptacle
on
gas
control
assembly
(see
Figure
3-4).
OM-l537PagelO
E.
Weld
Output
Connections
(Figure
3-4)
1.
Select,
prepare
and
attach
to
weld
output
ter
minals
proper
size
v~eld
cables
according
to
in
structions
in
welding
power
source
Owners
Manual.
2.
Remove
cover
from
gas
control
assembly.
3.
For
Reverse
Polarity,
route
positive
(+)
weld
cable
through
grommet
on
IN
panel
of
gas
assembly,
through
reed
switch
bracket,
and
out
grommet
on
opposite
end
(see
Figure
3-4).
For
Straight
Polarity,
route
negative
(-)
weld
cable
through
reed
switch.
4.
Route
and
connect
weld
cable
from
gas
control
assembly
to
weld
cable
terminal
on
wire
drive
housing
(see
OM-1538).
5.
Connect
remaining
weld
cable
from
the
welding
power
source
to
the
work.
6.
Reinstall
cover
onto
gas
control
assembly.
F.
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
3-3).
Connect
remaining
ends
to
welding
power
source
as
follows:
Connect
2-prong
twistlock
plug
to
CONTACTOR
CONTROL
receptacle,
and
connect
3-prong
plug
to
115
VOLTS
AC
twistlock
receptacle.
CONTACTOR
switch
on
welding
power
source
must
be
in
REMOTE
position.
1.
Open
weld
control
door.
2.
Remove
snap-in
blank
and
the
4
nearby
sheet
metal
screws
from
top
panel
of
weld
control
case.
3.
Remove
cover
from
MHA-2.
4.
Route
MHA-2
wiring
harness
with
edge
connec
tor
attached
through
opening
in
case
top
panel.
5.
Using
location
and
the
4
sheet metal
screws
from
Step
2,
install
and
secure
MHA-2
to
case
top
panel
with
two-receptacle
end
to
the
right.
6.
Using
supplied
spacers,
lock
washers,
and
four
6-32
x
5/8
screws,
install
supplied
MHA-2
circuit
card
assembly
onto
door
shield
between
wiring
harnesses
with
18-pin
edge
connector
to
the
left.
7.
Install
MHA-2
wiring
harness
connector
(routed
in
Step
4)
into
18-pin
edge
connector
on
MHA-2
circuit
card
assembly
installed
in
Step
6;
connec
tors
only
fit
together-one
way.
IMPORTANT
______________
Locate
and
examine
supplied
loose
wiring
harness
with
connectors
on
both
ends
of
leads;
The
8-pin
connector
isPLG51,
and
the
6-pin
connector
is
PLG.9.
IMPORTANT
______________
Depending
on
its
location,
the
weld
control
(5ystem
9)
may
have
to
be
removed
from
its
mounting
to
accomplish
this
installation.
Retain
a/I
hardware
removed
for
reinstal/ation
unless
specifically
told
otherwise.
Gas
Control
Receptacle
115
VAC/Contactor
Weld
Control
(System
9)
Weld
Cable
In
Opening
Deltaweld
Welding
Power
Source
Motor
Control
Cord
Gas
Control
Cord
Figure
3-4.
Gas
Control
Assembly
TA.O7O
483
3-7.
FIELD
INSTALLATION
OF
MHA-2
(Figure
3-6)
WARNING
Work
Gas
Control
Assembly
__________
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
the
weld
control
and
disconnect
input
power
(115
vac)
before
beginning
this
installation.
Wire
Drive
Assembly
TA
O872~
Figure
3-5.
Interconnection
Diagram
8.
Connect
PLG51
to
MHA-2
circuit
card
assembly.
OM-1537
Page
11
9.
Disconnect
PLG9
from
microprocessor
board
PCi.
Turn
plug
so
that
keying
fingers
are
on
the
bottom
when
holding
plug
in
hand.
Slide
the
flat
tened
end
of
a
20
or
22
gauge
wire
over
the
right
side
of
the
contact
to
release
the
contact
catch.
Pull
wire
from
plug
and
discard
plug.
Push
wire
into
empty
space
on
PLG9
from
MHA-2.
Con.
nect
PLG9
to
PCi
through
slot
in
door
shield.
Be
sure
connection
is
secure.
10.
Locate
one
lead
No.
31
at
pin
A
of
relay
CR1
in
weld
control.
CR1
is
enclosed
relay
to
left
of
other
relays.
Cut
cable
ties
as
necessary
to
gain
access
to
this
lead
No.
31.
IMPORTANT
______________
Install
supplied
adhesive
back
wiring
retainers
onto
case
as
necessary,
and
route
leads
pro
perly
through
retainers
before
making
connections.
11.
Using
supplied
tab
connector,
splice
lead
No.
31
from
PLG51
pin
1
to
lead
No.
31
near
CR1.
12.
Locate
terminal
A
on
terminal
strip
2T
inside
weld
control.
13.
Connect
lead
No.
42
from
PLG51
pin
2
to
ter
minal
A
on
strip
2T.
14.
Locate
lead
No.
54
that
goes
to
pin
7
of
recep
tacle
RC18.
RC18
is
the
motor
control
receptacle
(third
from
top)
on
side
of
weld
control
as
shown
in
Figure
3-3.
The
pin
numbers
can
be
identified
from
the
outside
of
the
receptacle.
Cut
cable
ties
as
necessary
to
gain
access
to
lead
No.
54.
15.
Using
supplied
tab
connector,
splice
lead
No.
54
from
PLG51
pin
6
to
lead
No.
54
near
rear
of
RC18.
16.
Disconnect
lead
from
terminal
K
on
strip
iT
and
remove
jumper
link
between
terminals
K
and
L
on
iT;
reconnect
removed
lead
back
onto
ter
minal
K
on
iT.
17.
Disconnect
lead
from
terminal
L
on
iT
and
reconnect
it
to
terminal
K
on
iT.
18.
Connect
one
end
of
supplied
19
in.
(483
mm)-
long
lead
to
terminal
L
on
terminal
strip
11.
19.
Connect
remaining
end
of
lead
from
Step
18
to
pin
12
on.receptacle
RC18
(see
Step
14
for
loca
tion
method
of
pin
numbers).
20.
Connect
supplied
10
in.
(254
mm)
long
lead
bet
ween
terminal
L
on
terminal
strip
1
T
and
male
friction
terminal
No.
3
on
SCR
network
circuit
card
PC7.
21.
Connect
supplied
7.5
in.
(191
mm)
long
lead
bet
ween
male
friction
terminals
No.
4
and
13
on
PC7.
22.
Locate
lead that
goes
from
male
friction
terminal
No.
14
on
PC7
to
terminal
G
on
terminal
strip
2T.
23.
Disconnect
end
of
lead
located
in
Step
22
from
2TG
and
cut
off
ring
terminal.
24.
Using
supplied
tab
connector,
splice
lead
(from
Step
23)
to
one
end
of
supplied
22
in.
(559
mm)
long
lead.
25.
Connect
remaining
end
of
new
lead
(from
Step
24)
into
pin
14
of
receptacle
RC18.
26.
Connect
one
end
of
supplied
5
in.
(127
mm)
long
lead
into
pin
ii
of
receptacle
RC18.
115
VAC/Contactor
Control
Deltawsid.
WeldIng
Power
Source
Figure
3-6.
Interconnection
Diagram
With
MHA-2
TA-O87
275
OM-1537
Page
12
27.
Connect
remaining
end
of
lead
from
Step
26
to
terminal
G
on
strip
2T.
28.
Using
supplied
cable
ties
and
clips,
secure
new
leads
to
existing
wiring
harnesses
where
possi
ble.
29.
Connect
one
end
of
supplied
cord
with
amp
plugs
on
both
ends
to
single
(left
end)
receptacle
on
MHA-2.
30.
Connect
remaining
end
to
motor
control
recep
tacle
on
side
of
weld
control
as
shown
in
Figure
3-3
and
3-6.
31.
Connect
one
motor
control
cord
to
one
drive
motor
and
connect
remaining
end
to
HEAD
NO.
1
receptacle
on
MHA-2
(see
Figure
3-6).
32.
Connect
another
(not
supplied)
motor
control
cord
to
remaining
drive
motor
and
connect
re
maining
end
to
HEAD
NO.
2
receptacle
on
MHA-2
(see
Figure
3-6).
33.
Connect
a
jumper
cable
of
adequate
size
(see
Welding
Power
Source
Owners
Manual)
bet
ween
the
two
wire
drive
assemblies
(see
Figure
3-6).
The
MHA-2
is
shipped
so
that
HEAD
NO.
us
activated
during
programs
1-5,
and
HEAD
NO.
2
is
activated
dur
ing
programs
6-9.
If
the
operation
requires
a
different
setup,
the
jumper.linkson
terminal
strips
iT
and
2T
in
the
MHA-2
unit
can
be
changed.
If
HEAD
NO.
1
is
to
be
activated
for
any
program,
no
jumper
link
should
be
placed
between
program
number
and
a
CR
terminal.
Ex
ample:
If
HEAD
NO.
1
is
to
be
run
by
program
9,
remove
the
jumper
link
between
2T9
and
2TCR.
DO
NOT
remove
wire
jumpers.
If
HEAD
NO.
2
is
to
be
ac
tivated
for
any
program,
a
jumper
link
must
be
placed
between
program
number
and
CR
terminal.
Example:
If
HEAD
NO.
2
is
to
be
run
by
program
2,
a
jumper
link
must
be
placed
between
1T2
and
1TCR.
Extra
jumper
links
are
located
on
2T.
If
shielding
media
(gas
or
flux)
is
used
with
HEAD
NO.
2,
make
electrical
connections
between
2TJ
and
ilL.
When
the
relays
in
MHA-2
energize,
115VAC
is
available
between
2TJ
and
1
TL
to
control
the
shielding
media
valve(s).
34.
Reinstall
cover
onto
MHA-2.
35.
Close
and
secure
weld
control
door.
WARNING
__________
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Both
weld
heads
are
energized
even
though
only
one
is
welding.
Do
not
make
contact
with
unused
head.
3
-
8.
HUB
AND
SPINDLE
ASSEMBLY
IN
STALLATION
(Figure
3-7)
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:
3-9
for
spool-type
wire;
and
3-10,
:3-11
for
reel-type
wire.
3
-
9.
INSTALLATION
OF
SPOOL-TYPE
WIRE
(Figure
37)
1.
Depress
the
two
spring-loaded
stops
(see
Figure
3-7)
on
retaining
ring,
and
slide
retaining
ring
off
hub.
2.
Slide
the
spool
of
wire
onto
the
hub
so
that
the
wire
feeds
off
the
bottom
with
the
minimum
bend
and
sharp
radius.
3.
Rotate
the
spool
until
the
hole
in
the
spool
aligns
with
the
pin
in
the
hub.
Slide
the
spool
onto
the
hub
until
it
seats
against
the
back
flange
of
the
hub.
4.
Depress
the
two
spring-loaded
stops
on
the
re
taining
ring,
and
slide
the
retaining
ring
into
the
proper
position
on
the
hub.
Release
the
two
stops.
Retaining
Ring
3-10.
INSTALLATION
OF
REEL-TYPE
WIRE
(Op.
tional)(Figure
3-7)
1.
Lay
the
wire
reel
(see
Figure
3-7)
flat
on
a
table
or
floor.
2.
Loosen
the
four
wing
nuts
on
the
fingers
of
the
wire
reel.
Hub
Support
Shaft
Brake
Washer
Nut
Wire
Ree1
Optlonal
Figure
3
-
7.
Hub
And
Reel
Installation
TB.070
886
OM.1537
Page
13
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.
3-11.
INSTALLATION
OF
WIRE
REEL
(Optional)
(Figure
3-7)
1.
Depress
the
two
spring-loaded
stops
(see
Figure
3-7)
on
retaining
ring,
and
slide
retaining
ring
off
hub.
2.
Slide
the
wire
reel
onto
the
hub.
Rotate
wire
reel
until
hub
guide
pin
is
seated
in
reel.
3.
Depress
the
two
spring-loaded
stops
on
the
re
taining
ring,
and
slide
retaining
ring
into
proper
position
on
hub.
Release
the
two
stops.
3-12.
ADJUSTING
HUB
TENSiON
(Figure
3-7)
-
Check
hub
tension
by
slowly
pulling
wire
toward
the
feed
roll.
The
wire
should
unwind
freely,
but
the
hub
tension
should
be
sufficient
to
keep
the
wire
taut
and
prevent
backlash
when
the
wire
feeder
is
shutoff.
If
ad
justment
is
required,
loosen
or
tighten
the
hex
nut
(see
Figure
3-7)
on
the
end
of
the
hub
support
shaft
accor
dingly.
SECTION
4
-
DEFINITIONS
OF
PROGRAM
TERMS
Recognized
Sequence
Codes
Feed
Time
Volts
Speed
(Sec.)
The
Run-In
sequence
ends
when
the
run-
in
time
elapses.
Standby
X
X
X
Preflow
1,
2,
3
. .
.
. .
.
0-99.9
Run-In
1,
2,
3
0-
99.9
0-
800
0
-
9~99
Weld
1
1
-
6
0
-
99.9
0
-
800
0
-
99.9
Weld
2
1
-
6 0
-
99.9
0
-
800
0
-
99.9
Weld
3
1
-
6
0
-
99.9
0
-
800
0
-
99.9
Crater
1,
2,
3
0-
99.9
0-
800
0-
9.99
Burnback
1,
2,
3
0-99.9
.
.
.
0-
.999
Postflow
1,
2,
3
. .
.
0
-99.9
Pause
0-6
.
.
.
0
-
99.9
NOTE:
_____
(Code
display
shows
code
programmed
into
pause
sequence.)
X
(Meters
blanked
when
in
sequence;
no
values
ac
cepted
at
programming.)
*Feed
speed
is
in
inches
per
minute.
(Only
aux.
outputs
programmed
in
this
sequence).
Table
4-1.
Weld
Program
Sequences
&
Variables
4
-
1.
PROGRAM
DEFINITIONS
A.
Sequence
-
One
of
a
series
of
controlled
ac
tions
that
produces
a
weld.
One
part
of
a
weld
-
program.
1.
Standby
-
see
Table
4-1.
The
unit
is
ready
to
operate.
2.
Preflow
-
see
Table
4-1.
When
the
PRO
GRAM
RUN
button
is
pressed,
the
shielding
gas
(and
optional
water)
valve
opens
allowing
shielding
gas
(and
water)
to
flow
before
an
arc
is
struck.
The
output
used
to
energize
the
shielding
gas
valve
could
also
be
used
for
on/off
control
of
other
shielding
media
such
as
flux
used
in
the
Submerged
Arc
Welding
process.
3.
Run-In
-
see
Table
4-1.
When
the
Preflow
sequence
is
finished,
the
unit
ad
vances
to
the
next
sequence:
Run-In.
At
the
beginning
of
the
Run-In
sequence
the
welding
power
source
contactor
is
energized
and
wire
begins
to
feed.
Run-in
time
does
not
start
until
an
arc
is
struck~
4.
Weld
1,2,
&
3-see
Tables
4-1
&
4-2.
After
the
arc
is
established
and
the
Run-In
time
has
expired,
the
unit
advances
to
the
weld
sequences.
As
shown
in
Tables
4-1
and
4-2,
the
weld
sequences
can
be
pro
grammed
for
a
wide
variety
of
conditions.
When
an
untimed
sequence
is
programm
ed,
an
external
limit
switch,
connected
to
terminal
strip
2T,
can
be
used
to
end
the
sequence
and
allow
the
unit
to
advance
to
the
next
sequence,
or
the
SEQUENCE
AD
VANCE
button
can
be
depressed
if
the
code
allows
sequence
advance
(see
Table
4-2).
See
Section
3-4
for
making
the
ex
ternal
limit
switch
connections.
5.
Crater
-
see
Table
4-1.
The
Crater
fill
se
quence
allows
a
time
before
the
arc
is
ex
tinguished
in
which
Volts
and
Feed
Speed
can
be
programmed
to
provide
crater
fill.
After
the
crater
time
elapses,
the
unit
ad
vances
to
the
next
sequence.
6.
Burnback
-
see
Table
4-1.
The
Burnback
sequence
allows
the
welding
wire
to
re
main
energized
after
the
wire
drive
motor
has
stopped.
The
burnback
parameters
should
be
set
to
allow
the
welding
wire
to
burn
back
out
of
the
weld
puddle.
After
the
burnback
time
expires,
the
unit
ad
vances
to
the
postflow
sequence.
7.
Poatflow
-
see
Table
4-1.
During
the
Postflow
sequence
shielding
gas
land
water)
flows
for
a
programmed
time
after
the
arc
is
extinguished
before
the
valveisi
close.
When
the
postflow
time
is
finis~ei
the
welding
portion
of
the
program
s
finished.
8.
Pause
-
see
Tables
4-1
&
4-2.
The
Pau~
is
a
sequence
that
can
be
used
to
ailo.~
time
between
weld
programs
for
rnsr~qs
such
as
reloading
a
fixture,
repositioning
of
work
or
gun,
etc.
Codes
1
through
6
OM-153#Pagel4
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Miller JD668503 Owner's manual

Miller
Brand
Miller
Model
JD668503
Category
Welding System
Type
Owner's manual
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