Miller HK270136 Owner's manual

April

1979

FORM:

OM-1522

FLE

COPY

RETURN

TO

FOLDER

Effective

With

Serial

No.

HK270136

MODEL

SWINGARC

DIGITAL

-

1

12

SWINGARC

DIGITAL

-

1

16

OWNERS

MANUAL

HilliER

MILLER

ELECTRIC

MFG.

CO.

718

S.

BOUNDS

ST.

P.O.

Box

1079

APPLETON.

WI

54912

USA

ADDITIONAL

COPY

PRICE

70

CENTS

NWSA

CODE

NO. 4579

PRINTED

IN

U.S.A

LIMITED

WARRANTY

EFFECTIVE:

JANUARY

1,1979

This

warranty

supersedes

all

warranties

and

is

cx-

S

clusive

with

no

other

guarantees

or

warranties

expressed

or

implied.

LIMITED

WARRANTYSubject

to

the

terms

and

conditions

As

a

matter

of

general

policy

only,

Miller

may

honor

claims

hereof,

Miller

Electric

Mfg.

Co.,

Appleton,

Wisconsin

warrants

to

submitted

by

the

original

user

within

the

foregoing

periods.

its

Distributor/Dealer

that

all

new

and

unused

Equipment

furnished

In

the

case

of

Millers

breach

of

warranty

or

any

other

duty

by

Miller

is

free

from

defect

in

workmanship

and

material

as

of

the

time

and

place

of

delivery

by

Miller.

No

warranty

is

made

by

Miller

with

respect

to

the

quality

of

any

goods,

the

exclusive

remedies

therefor

shall

be,

at

Millers

option,

(1)

repair

or

(2)

replacement

or,

with

respect

to

engines,

trade

accessories

or

other

items

manu-

where

authorized

in

writing

by

Miller

in

appropriate

cases,

(3)

the

factured

by

others.

Such

engines,

trade

accessories

and

other

reasonable

cost

of

repair

or

replacement

at

an

authorized

Miller

ser

items

are

sold

subject

to

the

warranties

of

their

respective

manu

facturers,

if

any.

At

the

present

time,

the

manufacturers

warranty

on

vice

station

or

(4)

payment

of

or

credit

for

the

purchase

price

(less

the

Mag-Diesel

engine

on

DEL-200

is

limited

to

six

months

and

on

reasonable

depreciation

based

upon

actual

use)

upon

return

of

the

all

other

engines

to

one

year

goods

at

Customers

risk

and

expense.

Upon

receipt

of

notice

of

apparent

defect

or

failure,

Miller

shall

instruct

the

claimant

on

the

Except

as

specified

below,

Millers

warranty

does

not

apply

to

warranty

claim

procedures

to

be

followed.

components

having

normal

useful

life

of

less

than

one

(I)

year,

such

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

as

spot

welder

tips,

relay

and

contactor

points,

MILLERMATIC

parts

ANY

IMPLIED

WARRANTY

GUARANTY

OR

REPRESENTA

~

that

come

in

contact

with

the

welding

wire

including

nozzles

and

TION

AS

TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

nozzle

insulators

where

failure

does

not

result

from

defect

in

BREACH

OF

CONTRACT

WHICH,

BUT

FOR

THIS

PROVISION,



workmanship

or

material.

MIGHT

ARISE

BY

IMPLICATION,

OPERATION

OF

LAW,

CUS

TOM

OF

TRADE

OR

COURSE

OF

DEALING

INCLUDING

ANY

Miller

shall

be

required

to

honor

warranty

claims

on

warranted

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OROF

FITNESS

Equipment

in

the

event

of

failure

resulting

from

a

defect

within

(he

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

TO

ANY

AND

following

periods

from

the

date

of

delivery

of

Equipment

to

the

ALL

EQUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

original

user:

AND

DISCLAIMED

BY

MILLER.

I.

Arc

welders,

power

sources

and

components

.

. .

1

year

EXCEPT

AS

EXPRESSLY

PROVIDED

BY

MILLER

IN

WRIT-

)

2.

Onginal

main

power

rectifiers

3

years

ING

MILLER

PRODUCTS

ARE

INTENDED

FOR

ULTIMATE

(labor

-

1

year

only)

PURCHASE

BY

COMMERCIAL/INDUSTRIAL

USERS

AND

FOR

3.

All

welding

guns

and

feeder/guns

90

days

OPERATION

BY

PERSONS

TRAINED

AND

EXPERIENCED

IN

4.

All

other

Millermatic

Feeders

1

year

THE

USE

AND

MAINTENANCE

OF

WELDING

EQUIPMENT

AND

5.

Replacement

or

repair

parts,

exclusive

of

labor.

.

60

days

NOT

FOR

CONSUMERS

OR

CONSUMER

USE.

MILLER

WAR-

)

6.

Batteries

6

months

RANTIES

DO

NOT

EXTEND

TO,

AND

NO

RESELLER

IS

provided

that

Miller

is

notified

in

writing

within

thirty

(30)

days

of

AUTHORIZED

TO

EXTEND

MILLERS

WARRANTIES

TO,

the

date

of

such

failure.

ANY

CONSUMER.

.~

J~

.

.-.....

-

.

.....-~

CAUTION

C

ERRATA

SHEET

After

this

manual

was

printed,

refinements

in

equipment

design

occurred.

This

sheet

lists

exceptions

to

data

appearing

later

in

this

manual.

Effective

With

Serial

No.

HK270154

Ii

l~

Delete

all

reference

to

Switch

Control

receptacle

in

this

manual

and

replace

with

TRIGGER

receptacle.

AMENDMENT

TO

SECTION

6



TROUBLESHOOTING

Add

CAUTION

block

after

Troubleshooting

Chart

Wire

drive

motor

repairs

should

be

limited

to

brush

replacement.

Attempting

further

repairs

may

result

in

personal

injury

in

addition

to

motor

damage.

Warranty

is

void

if

the

motor

is

tampered

with.

For

further

repair

and

replacement

in

formation

contact

the

Factory

Service

Department.

See

Page

B

for

Circuit

Diagram.

OM-1

622

Page

A

GAS

SOLENOID

WATER

SOLENOID

(OPTIONAL)

RC3

P)53

C-047

809

ISO

>

2

S

a.

m

Co

C

-

S

9)

C-)

~~1

C,

C

I:

0

a)

Co

2

Circuit

Diagram

No.

C-047

809

S

Figure

6-1.

Circuit

Diagram

For

Models

Effective

With

Serial

No.

HK210154

And

Following

S.

Item

Dia.

No.

Mkgs.

A50-53

C50

C51

C52,61

C53,62

CM

C55,

66-77

C56

C57

C60

C63,64

C65

CR50

D50-54,

56-58.

D55

1C50

Q50,53

Q51

Q52

R50

R51

.53-57,63,

74,75,81,82,

84,89

R52

R58,62,65,

66,71,72,

76,77,90

R59

R60,87,88

R64,67

R68,80

R70

R73,83

R78

R79

R85

R86

T50

VR5O

VR51

RC7

Part

No.

Listed

Replaced

With

In

Parts

List

Part

No

048

837

603

106

047

311

047

312

047

636

079

535

048

283

079

535

047

227

009

159

039

482

031

699

073

739

035

833

005

023

031

643

073

549

035

835

035

561

031

694

031

721

081

797

080

910

081

800

037

200

037

824

039

355

030

839

039

335

039

331

035

886

048

015

039

328

039

108

039

106

030

937

030

090

036

143

081

799

047

272

047

123

047637

079

534

048 282

079

534

047

224

047

170

047

171

023 562

Description

HOSE

ASSEMBLY,

gas

HOSE,

neoprene

-

braided

No.

1

(order

by

foot)

CORD,

motor

l5ft

CORD,

motor

19

ft.

(consisting

of)

HOUSING

PLUG

&

PINS

.TERMINAL,malesizel6

18-l4wire

RECEPTACLE,

w/pins

(consisting

of)

TERMINAL,

male

1

CIRCUIT

CARD

ASSEMBLY,

motor

speed

(consisting

of)

AMPLIFIER,

operational

32

volts

dc

CAPACITOR,

electrolytic

100

uf

35

volts

dc..

CAPACITOR,

mylar

0.0022

uf

200

volts

dc

CAPACITOR,

ceramic

0.1

uf

50

volts

CAPACITOR,

mylar

0.033

uf

100

volts

dc.

CAPACITOR,

tantalum

2.2

uf

20

volts

CAPACITOR,

ceramic

0.01

uf500voltsdc

CAPACITOR,

mylar0.Ol5uf200volts

CAPACITOR,

electrolytic

4.7

uf

35

volts

CAPACITOR,

mylar

4

uf

200

volts

CAPACITOR,

mylar

0.47

uf

200

volts

dc

CAPACITOR,

mylar

0.22

uf

200

volts

dc

RELAY,

enclosed

24

volts

ac

4PDT

Quantity

Model

12

I

16

1

loft,

lOft.

1

6

1

4

13

1

9

8

056420

13

603

106

29

049869

29

048619

30

PLG7

073

517

78

RC1

081

905

83

049016

1

6

1

4

1

4

1

2

1

13

1

2

1

8

1

2

1

4

1

2

1

13

1

2

1

8

1

2

1

026

202

.

DIODE,

rectifier

1

amp

400

volts

straight

polarity

DIODE,

zener

l5volts5watt

INTEGRATED

CIRCUIT,

converter

TRANSISTOR,

200

MA

40

volts

NPN

THYRISTOR,

SCR

7.4

amp

200

volts

TRANSISTOR,

unijunction

15MA

40

volts

RESISTOR,

WW

fixed

5

watt

220

ohm

84

94

117

035

827

.

RESISTOR,

carbon

film

0.25

watt

10K

ohm...

052

138

.

RESISTOR,

carbon

film

0.25

watt

20K

ohm...

035

884

.

RESISTOR,

carbon

film

0.25

watt

lOOK

ohm..

030

007

.

POTENTIOMETER,

cermet

trimmer

15

turn

0.75

watt

50K

ohm

RESISTOR,

carbon

film

0.25

watt

47K

ohm...

RESISTOR,

carbon

film

0.25

watt

4700

ohm..

RESISTOR,

carbon

film

0.25

watt

22K

ohm...

RESISTOR,

carbon

film

0.25

watt

10

meg

ohm

RESISTOR,

carbon

film

0.25

watt

1500

ohm..

RESISTOR,

carbon

film

0.25

watt

82K

ohm...

RESISTOR,

carbon

film

0.25watt470

ohm

RESISTOR,

carbon

0.5

watt

10

ohm

RESISTOR,

carbon

0.5watt47

ohm

TRANSFORMER,

pulse

control

REGULATOR,

voltage

8

volts

3

terminals

REGULATOR,

voltage

l2voIts3

terminals

STAND-OFF,

No.

4-40

x

2-5/8

(consisting

of)

HOUSING

RECEPTACLE

&

SOCKETS

..TERMINAL,

female

1

socket

RECEPTACLE,

w/socket

(consisting

of)

TERMINAL,

female

1

socket

KNOB,

plastic

TUBING,

neoprene

3/8

ID

x

0.093

wall

x

12.

LINER,

monocoil

x

13

CLAMP,

hose

5/16-7/8

clamp

dia

R

C2

049

292

073

515

081

560

144

073

695

1

3

2

1

2

1

2

1

4

1

4

.1

1

3

2

1

2

1

2

1

4

1

4

1

OM-1

522

Page

C

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

And

Assembly

1

2-2.

DriveMotor

3

2-

3.

Installation

Of

Wire

Support

3

2

-

4.

Reinstallation

Of

Hub

Assembly

3

2-

5.

Installation

Of

Wire

Reel

3

2-

6.

Drive

Roll

And

Wire

Guide

Installation

3

2-

7.

Water

Control

Kit

Connections

4

2

-

8.

Shielding

Gas

Connections

4

2

-

9.

Welding

Gun

Connections

4

2-10.

Boom

Adjustments

5

2-11.

Motor

Control

Connection

5

2-12.

Switch

Control

Connection

5

2-13.

Weld

Cable

Connection

6

2-14.

115

Volt

And

Contactor

Connection

6

2-15.

Remote

Control

Connection

6

2-16.

Installation

Of

Spool-Type

Wire

6

2-17.

Installation

Of

Reel-Type

Wire

6

2-18.

Adjustment

Of

Hub

Tension

6

2-19.

Welding

Wire

Threading

6

SECTION

3



FUNCTION

OF

CONTROLS

3-

1.

Power

Switch

7

3

-

2.

Remote

Control

Receptacle

And

Switch

7

3

-

3.

Purge

Button

7

3-4.InchSwitch

7

3

-

5.

Wire

Speed

Control

7

3

-

6.

Inches

Per

Minute

Meter

7

3-

7.

Reset

Circuit

Breaker

7

3

-

8.

Burnback

Control

7

SECTION

4



SEQUENCE

OF

OPERATION

4

-

1.

Gas

Metal-Arc

Welding

(GMAW)

7

4

-

2.

Shutting

Down

7

SECTION

5

MAINTENANCE

5-

1.

Inspection

And

Upkeep

8

5

-

2.

Cleaning

Of

Drive

Rolls

8

5-3.Fuse

8

SECTION

6

TROUBLESHOOTING

SECTION

1

-

INTRODUCTION

Model

Single

12

Single

16

Speed

Range

50-785

1P.M.

Boom

Length

12

ft.

16

ft.

Swing

3600

Vertical

Lift

Horizontal

To

60

Above

Maximum

Height

(With

4

Ft

Post)

At

Full

Lift

Of

Boom

I

17

ft.

21

ft.

Counterbalance

(Patented)

Compression

Spring

Is

Designed

To

Balance

Boom

At

Any

Angle.

Pressure

Adjustment

Is

Provided

To

Hold

The

Boom

At

Any

Desired

Angle

Or

To

Limit

The

Vertical

Lift

At

40.

50.

or

60.

Weight

(Pounds)

Net

Ship

Net

Ship

Figure

1-1.

Specifications

1-1.

GENERAL

This

manual

has

been

prepared

especially

for

use

in

famil.

iarizing

personnel

with

the

design,

installation,

operation.

maintenance,

and

troubleshooting

of

this

equipment.

All

information

presented

herein

should

be

given

careful

con

sideration

to

assure

optimum

performance

of

this

equip

ment.

1-2.

RECEIVING-HANDLING

Prior

to

installing

this

equipment,

clean

all

packing

ma

terial

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

and

freight

bill

will

be

furn

ished

by

the

carrier

on

request

if

occasion

to

file

claim

arises.

When

requesting

information

concerning

this

equipment,

it

is

essential

that

Model

Description

and

Serial

(or

Style)

Numbers

of

the

equipment

be

supplied.

1-3.

DESCRIPTION

This

unit

is

a

boom

mounted

digital

wire

control/feeder.

The

control/feeder

is

of

the

constant

wire feed

speed

type

and

is

designed

to

be

used

in

conjunction

with

a

constant

potential

welding

power

source.

The

boom

is

a

patented

design

allowing

both

vertical

lift

and

swing.

Cables

are

routed

through

the

boom

from

the

feeder

control

to

the

weld

head

assembly.

The

control/feeder

is

a

heavy

duty

wire

feeding

unit

com

bining

both

the

wire

feeder

and

the

digital

control.

It

Contains

all

the

controls

and

equipment

needed

to

supply

welding

wire

and

shielding

gas

to

the

welding

gun.

14.

SAFETY

The

following

definitions

apply

to

CAUTION,

PM.

PORTANT,

and

NOTE

blocks

found

throughout

this

manual:

CAUTION

I

Under

this

heading,

insta

Ilation,

~ting,

and

maintenance

procedures

or

practices

will

be

found

that

if

not

carefully

followed

may

create

a

hazard



to

personnel.



TA~

I

Under

this

heading,

installation,

operating,

and

maintenance

procedures

or

practices

will

be

found

that

if

not

carefully

followed

may

result

in

damage



to

equipment.

~thi~

heading,

explanatory

statements

will

be

found

that

need

special

emphasis

to

obtain

the



most

efficient

operation

of

the

equipment

SECTION

2

-

INSTALLATION

2-1.

LOCATION

AND

ASSEMBLY

(Figure

2-1)

A.

Location

A

suitable

location

for

this

unit

will

allow

room

for

the

boom

to

swing

horizontally

in

the

desired

arc.

and

to

pivot

upward

to

the

desired

angle.

Proper

placement

will

also

provide

sufficient

clearance

from

obstruction

at

the

wire

support

end

of

the

unit

when

the

boom

swings.

The

structure

to

which

the

unit

is

being

installed

should

be

of

sufficient

construction

to

support

the

weight

of

the

unit

when

the

boom

is

in

the

horizontal

position.

B.

Assembly

a.

Uncrate

and

remove

all

packing

material

from

the

unit.

b.

Mount

pipe

post

(14)

to

the

desired

structure.

~IL~~IU.1~1

I

The

structure

to

which

the

pipe

post

is

mounted

I

must

be

of

sufficient

construction

to

support

the

weight

of

the

unit

when

the

boom

is

in

the

hon.

zontal

position.

1.

Existing

Support

(Customer

Supplied).

rTA~)

c.

Proceed

to

Sub-section

B2,

Steps

c

through

k.

2.

Post

Support

(Optional)

I

In

selecting~the

pipe

used

to

support

the

unit

the

1

model

utilizing

a

12

foot

boom

requires

a

2-1/2

inch

diameter,

Schedule

40

pipe

(wall

thickness

of

.203

inches).

The

model

with

a

16

foot

boom

re

quires

a

5

inch

diameter,

Schedule

40

pipe

(wall



thickness

of

.258

inches).

a.

Uncrate

and

remove

all

packing

material

from

the

Unit.

b.

Mount

post

support

(14)

to

the

desired

structure.

OM-1522

Page

1

Figure

2-1.

Base

And

Boom

Assembly

CAUTION



The

structure

to

which

the

p~ppo~is

mounted

must

be

of

sufficient

construction

to

sup

port

the

weight

of

the

unit

when

the

boom

is

in

the

horizontal

position.

c.

Remove

yoke

(1),

nut

(10)

washers

(9

&

17)

and

bolt

(18)

from

the

yoke

(3)

and

swivel

plates

(16).

Do

not

remove

safety

collar

(11)

~linstructed

to

do

so.

The

swivel

base

(8)

contains

high

pres

sure

springs

to

counter

balance

the

weight

at

the



weld

head.

i.

Grasp

bar

(20),

and

pull

boom

down

slightly.

The

boom

should

be

pulled

down

only

far

enough

to

remove

the

pressure

which

is

applied

to

the

safety

collar

(11).

j.

Remove

the

safety

collar

(11).

k.

The

boom

should

now

balance

in

any

position

from

horizontal

to

60

degrees

above

horizontal.

If

the

boom

does

not

balance

properly,

proceed

to

Section

2-10.

~stsupport(1withafittingfor

4)

is

provided

lubricating

the

swivel

periodically,

to

prevent

pre

mature

wear

and

to

ease

turning

during

operation.

Excessive

greasing

of

support

fitting

is

not

required

or

recommended.

3.

Base

Support

(Optional)

U

If

an

optional

base

support

was

hased

with

the

I

unit,

mounting

holes

are

provided

for

fastening

the



base

5

upport

to

the

floor.



I

When

an

optional

base

support

is

used,

the

base

must

be

securely

mounted

to

the

floor.

As

a

mini

mum,

1/2

dia.,

S.A.E.

grade

5

bolts,

with

ade

quate

corrosion

protection

should

be

used

to

secure

the

base.

If

the

unit

is

to

be

mounted

in

an

ex

tremely

damp

environment,

mounting

bolts

made

of

a

non-corrosive

material

with

a

strength

equiva



lent

to

S.A.E.

grade

5

steel

should

be

used.

a.

Uncrate

and

remove

all

packing

material

from

the

unit.

b.

Fasten

base

support

to

the

floor.

c.

Complete

Steps

c

through

k,

Subsection

B2.

su

ppo

rt

is

p

Wv

ided

w

ith

a

f

itt

ing

f

or

lubricating

the

swivel

periodically,

to

prevent

pre

mature

wear

and

to

ease

turning

during

operation.

Excessive

greasing

of

support

fitting

is

not

required



or

recommended.

4.

Swingpak

Base

(Optional)

a.

Uncrate

and

remove

all

packing

material

from

the

Swingpak

base.

d.

Place

bearing

(13)

on

top

of

post

(14)

and

insert

swivel

(8)

into

post

(14).

e.

Place

the

boom

base

plate

(19)

in

between

the

two

swivel

plates.

f.

Slide

washer

(17)

onto

bolt

(18)

and

insert

bolt

(18)

through

hole

(15).

Slide

washer

(9)

onto

bolt

(18)

and

install

nut

(10)

onto

bolt

(18).

Tighten

nut

(10);

then

back

off

nut

(10)

1/2

turn.

g.

Insert

(1)

through

yoke

(3),

hole

(2),

and

in

stall

cotter

(4)

through

(1).

h.

Connect

the

welding

gun

to

the

drive

assembly

as

instructed

in

the

Owners

Manual

for

the

desired

welding

gun.

sta

Ilation

of

the

w!ng

p

owe

r

sou

rce

on

to

the

Swingpak

base

should

precede

mounting

of

the

Swungarc

unit

in

order

to

prevent

tipping

of

the

frame

under

the

weight

of

the

boom.

b.

Uncrate

and

remove

all

packing

material

from

the

Swingarc

Unit.

c.

Complete

Steps

c

through

k,

Subsection

B2.

1

I0

12

U

3

.14

TB-080

040

I

Page

2

~ing

pa

k

base

is

ed

with

a

f

itting

f

or

lubricating

the

swivel

periodically,

to

prevent

pre

mature

wear

and

to

ease

turning

during

operation.

Excessive

greasing

of

support

fitting

is

not

required

or

recommended.

2-2.

DRIVE

MOTOR

The

drive

motor

is

provided

with

a

vent

screw

which

must

be

removed

prior

to

the

operation

of

the

control/

feeder.

The

vent

screw

can

be

removed

through

the

hole

(21)

provided

in

the

motor

shroud

(see

Figure

2-1).

2

-

3.

INSTALLATION

OF

WIRE

SUPPORT

(Figure

2-1)

1.

Remove

the

securing

screws

(5)

and

lock

washers

(6)

from

the

swivel

base

(8).

2.

Lift

the

wire

support

(7)

in

place

over

the

holes

in

the

swivel

base

(8).

3.

Insert

securing

screws

(5)

with

lock

washers

(6)

and

tighten.

2-

4.

REINSTALLATION

OF

HUB

ASSEMBLY

(Figure

2-2)

Figure

2-2.

Wire

Support

And-Hub

Assembly

If

it

should

become

necessary

to

replace

the

hub

as

sembly,

install

the

new

hub

assembly

as

follows:

1.

Slide

the

following

items

onto

the

spindle

support

shaft

(1)

in

order

given:

A.

Fiber

Washer

(2)

B.

Flat

Washer

(3)

C.

Hub

(4)

D.

Flat

Washer

(5)

E.

Fiber

Washer

(6)

F.

Keyed

Washer

(7)

G.

Spring

(8)

H.

Flat

Washer

(9)

2.

Rotate hex

nut

(10)

onto

support

shaft

(1).

Hex

nut

should

be

rotated

only

until

a

slight

drag

is

felt

while

turning

hub

(4).

3.

Depress

the

two

spring

loaded

stops

(11)

on

the

re

taining

ring

(12)

and

slide

the

retaining

ring

(12)

into

proper

position

on

the

hub

(4).

Release

the

two

stops

(11).

2-

5.

INSTALLATION

OF

WIRE

REEL

(Optional)

(Figure

2-3)

1.

Remove

the

retaining

ring

(5).

038

2.

Slide

the

wire

reel

(1)

onto

the

hub

(6).

Rotate

the

wire

reel

(1)

until

the

hub

guide

(7)

is

seated

in

the

reel

(1).

3.

Depress

the

two

spring-loaded

stops

(4)

on

the

re

taining

ring

(5)

and

slide

the

retaining

ring

(5)

into

proper

position

on

the

hub

(6).

Release

the

two

stops

(4),

2-6.

DRIVE

ROLL

AND

WIRE

GUIDE

INSTAL

LATION

(Figure

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.

NOTE

Base

selection

of

drive

rolls

upon

the

following

recommended

usages:

1.

V-Groove

rolls

for

hard

wire.

2.

U-Groove

rolls

for

soft

and

soft

shelled

cored

wires.

3.

U-Cog

rolls

for

extremely

soft

shelled

wires

(usually

hard

surfacing

types).

4.

Split

V-Knurled

rolls

for

hard

shelled

cored

wires

(self-shielding

and

CO2

shielded

types).

5.

Drive

roll

types

may

be

mixed

to

Suit

particular

requirements

(example:

V-knurled

roll

in

combi



nation

With

U-groove).

Having

selected

the

appropriate

drive

rolls

and

wire

guides,

proceed

to

the

following

installation

instructions:

A.

One

Piece

Drive

Roll

(Figure

2-4)

m

Drive

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.

Figure

2-3.

Reel

Installation

TB-080

037

OM-1522

Page

3

1.

Loosen

the

pressure

adjustment

wing

nut

(item

2,

Fig

ure

24)

and

pivot

it

free

of

the

cover.

2.

Pivot

gear

cover

(4)

away

until

it is

in

an

open

posi

tion.

3.

Loosen

and

remove

the

three

securing

screws

(7

&

12)

on

each

gear

(5

&

9).

4.

Slide

one

drive

roll

(13)

onto

drive

gear

(9)

with

holes

aligned.

Insert

securing

screws

(12)

and

tighten.

N

OlE

To

ensure

proper

gripping

action

of

U-Cog

drive

rolls,

both

rolls

should

be

installed

showing

slots

on

the

side

or

both

should

show

the

side

without

slots.

Also,

it

is

necessary

to

line

up

the

blunted

teeth

on

the

pressure

gear

roll

directly

over

the

spaces

between

the

teeth

on

the

drive

gear

roll

as

i

illustrated

in

Figure

2-5.

5.

Slide

remaining

drive

roll

(8)

onto

pressure

gear

(5)

with

holes

aligned.

Insert

securing

screws

(7)

and

tighten.

B.

Split

Drive

Roll

(Figure

2-4)

rn

Drive

rolls

(6

&

10)

are

of

the

double

usage

type.

1

When

the

knurled

groove

of

the

drive

rolls

becomes

worn,

the

split

halves

may

be

reversed

so

that

the

unused

edges

will

now

provide

a

new

knurled



groove.

1.

Loosen

the

pressure

adjustment

wing

nut

(item

2,

Fig

ure

2-4)

and

pivot

it

free

of

the

cover.

2.

Pivot

gear

cover

(4)

away

until

it is

in

an

open

posi

tion.

3.

Loosen

and

remove

the

three

securing

screws

(7

&

12)

on

each

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

drive

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

drive

rolls

onto

the

pressure

gear

(5).

C.

Inlet

Wire

Guide

(Figure

2.4)

1.

Loosen

the

inlet

wire

guide

securing

screw

(3).

I

Wire

guides

should

be

installed

so

that

the

tip

of

U

the

guide

is

as

close

to

the

drive

roll

as

possible



without

touching.

2.

Insert

the

inlet

wire

guide

(1)

into

drive

assembly

as

illustrated

in

Figure

24.

Secure

by

tightening

screw

(3).

NOTE

Behind

the

drive

gear

is

a

spring

washer(s).

To

ob

tain

proper

alignment

of

the

drive

roll

on

the

drive

gear

with

the

wire

guides

rotate

the

drive

gear

se

curing

bolt

(11)

thereby

moving

the

drive

roll

in

or

out

to

the

desired

position.

The

drive

roll

on

the

pressure

gear

will

locate

itself

on

the

wire

when

the

gear

cover

is

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

readjustment

becomes

necessary,

loosen

mounting

bolts

(item

15,

Figure

2-4),

weld

terminal

nut

(16)

and

bolt,

located

behind

mounting

plate

(19).

Slide

the

wire

drive

housing

upward

or

downward

until

the

wire

can

be

fed

straight

through

the

guides

while

seated

in

the

drive

roll

groove.

Tighten

mounting

bolts,

weld

terminal



bolt

and

nut.

2-7.WATER

CONTROL

KIT

(Optional)

CON

NECTIONS

When

a

water-cooled

gun

is

to

be

used,

connect

a

hose

from

the

water

supply

to

the

Water

input

fitting

at

the

rear

of

the

control.

This

fitting

has

a

left-hand

thread.

The

water

output

hose

routed

through

the

boom

is

to

be

connected

to

the

Water

output

fitting

at

the

front

of

the

control.

A

water

drain

hose

connects

to

the

adapter

at

the

weld

terminal

on

the

drive

assembly

and

is

routed

through

the

boom

to

an

appropriate

disposal.

2-8.

SHIELDING

GAS

CONNECTIONS

A

hose

is

supplied

with

the

unit

for

making

connections

from

the

shielding

gas

source

to

the

Shielding

Gas

input

fitting

at

the

rear

of

the

control.

These

fittings

have

right-hand

threads.

The

gas

hose

routed

through

the

boom

connects

to

the

Shielding

Gas

output

fitting

at

the

front

of

the

control.

.

7

Figure

2-4.

Drive

Roll

Installation

TB-080

030

I

TB-080

158

Figure

2-5.

U-Cog

Drive

Rolls

Installation

2-9.

WELDING

GUN

CONNECTIONS

A.

Outlet

Wire

Guide

(Figure

2-4)

Page

4

~tletguideis

provided

as

part

of

the

gun

~

assembly.

~

1.

Loosen

the

outlet

guide

adjustable

knob

(16).

I

Wire

guides

should

be

installed

so

that

the

tip

of

I

the

guide

is

as

close

to

the

drive

roll

as

possible



without

touching.

2.

Insert

the

adapter

(14)

which

includes

the

installed

outlet

guide

(15)

into

the

drive

assembly

opposite

the

inlet

wire

guide

as

illustrated

in

Figure

24.

3.

Tighten

the

outlet

guide

adjustable

knob

(16).

B.

Weld

Cable

(Figure

2-4)

A

terminal

is

provided

on

the

lower

portion

of

the

drive

assembly

to

serve

as

a

junction

point

for

joining

together

the

weld

cables

from

the

welding

power

source

and

the

gun

(if

so

equipped).

Remove

weld

terminal

nut

(18),

lock

washer,

and

flat

washer;

slide

the

weld

cable

from

the

gun

onto

weld

terminal;

replace

flat

washer,

lock

washer,

nut

(18)

and

tighten.

C.

Shielding

Gas

The

shielding

gas

hose

from

the

gun

is

to

be

connected

to

the

gas

hose

which

protrudes

from

the

motor

end

of

the

boom.

~tegral

gas

inp

ut

nt

ting

is

p

rovided

on

the

weld

head

for

guns

utilizing

this

type

of

con

nection.

See

the

appropriate

welding

gun

Owners

Manual

for

instructions

on

making

this

connection.

If

the

hose

is

provided

with

a

fitting,

cut

the

fitting

of

1,

and

push

the

hose

onto

the

barbed



fitting

on

the

drive

assembly.

D.

Switdh

Control

The

plug

from

the

gun

switch

is

to

be

inserted

fully

into

the

switch

control

cable

and

rhe

locking

ring

rotated.

When

the

switch

connected

across

this

receptacle

is

closed,

the

contactor

in

the

welding

power

source

will

energize,

shielding

gas

will

flow

and

wire

will

begin

to

feed.

E.

Water

(If

Applicable)

Connect

the

water

input

hose

from

the

gun

to

the

water

output

hose

from

the

control.

Connect

the

water

return

hose

from

the

gun

to

the

adapter

at

the

weld

terminal

on

the

drive

assembly.

A

re

ducing

bushing

is

provided

to

accept

a

5/8-18

L.H.

fitting.

If

the

bushing

is

removed,

a

7/8-14

L.H.

fitting

can

be

accomodated.

2-10.

BOOM

ADJUSTMENTS

(Figure

2-6)

A.

Weight

Lift

Adjustment

I

Ensure

that

during

all

adjustment

procedures,

full

threads

on

the

adjustment

rod

are

maintained

through

the

yoke.

If

full

threads

are

not

main

tained,

the

boom

may

suddenly

drop

down

and



cause

injury

to

personnel

or

damage

to

equipment.



amount

of

weight

that

the

boom

can

lift,

loosen

the

jam

nut

and

rotate

the

adjustment

rod

so

that

the

adjustment

rod

threads

into

the

yoke.

When

the

proper

adjustment

is

obtained,

tighten

the

jam

nut

against

the

base

of

the

yoke.

If

a

lighter

gun

is

used

with

the

Swingarc.

rotate

the

adjustment

rod

so

that

the

adjustment

rod

threads

out

of

the

yoke.

Figure

2-6.

Boom

Adjustments

B.

Locking

Knob

TB-003

40g-A

By

rotating

the

Locking

Knob

in

a

clockwise

direction,

the

boom

may

be

held

in

any

desired

position.

Rotating

the

Locking

Knob

in

a

counterclockwise

direction

will

permit

the

boom

to

free

travel.

Changing

the

position

of

the

Locking

Knob

to

the

other

threaded

holes

provided

along

the

side

of

the

swivel

plate,

limits

the

lift

of

the

boom

to

50

degrees

or

40

degrees

respectively

during

free

travel.

2-11.

MOTOR

CONTROL

CONNECTION

(Figure

2-7)

115

Volt

Contactdr

Receptacle

Figure

2-7.

Rear

Panel

Connections

m

TA.049

731

I

Examine

the

motor

control

plug

and

connector

carefully

to

determine

proper

alignment

of

the



arrangement

with

the

contacts.

A

receptacle

is

provided

for

connecting

the

motor

control

plug

to

the

control.

Align

keyways

and

insert

the

plug

from

the

control

end

of

the

boom

into

the

receptacle

and

rotate

the

plug

threaded

collar

clockwise

as

far

as

possible.

2-12.

SWITCH

CONTROL

CONNECTION

(Figure

3-1)

A

receptacle

is

provided

for

making

switch

control

con

nections.

Align

keyways

and

insert

the

plug

from

the

control

end

of

the

boom

into

the

receptacle

and

rotate

the

plug

threaded

collar

clockwise

as

far

as

possible.

Nut

Justment

Rod

Locking

The

amount

of

weight

which

the

boom

can

retract

into

the

upright

position

when

released

can

be

varied

by

ad

justing

the

jam

nut

and

adjustment

rod

located

at

the

base

of

the

boom.

If

a

heavier

gun

is

installed

on

the

end

of

the

boom

thereby

making

it

necessary

to

increase

the

OM-1522

Page

5

2-13.

WELD

CABLE

CONNECTION

2-it

ADJUSTMENT

OF

HUB

TENSION

(Figure

2-2)

A

weld

cable

extends

out

of

the

wire

support

end

of

the

boom

for

making

secondary

connections

to

the

welding

power

source.

The

end

of

the

weld

cable

is

equipped

with

a

terminal

for

a

1/2

stud.

2-14.

115

VOLT

AND

CONTACTOR

CONNECTION

(Fig

ure

2-7)

A

10

ft.

cable

is

provided

for

115

volts

ac

power

and

contactor

control

connections

between

control

and

welding

power

source.

Align

keyways

and

insert

the

plug

into

receptacle

on

the

control

and

rotate

the

threaded

collar

clockwise

as

far

as

possible.

Insert

the

115

volts

power

plug

into

the

115

volts

ac

receptacle

on

the

welding

power

source

and

rotate

clockwise

to

lock

in

place.

Insert

contactor

control

plug

into

the

contactor

control

receptacle

on

the

welding

power

source

and

rotate

clockwise

to

lock

in

place.

~n~olv

I

be

electrically

h~ternally

and

ready

to

operate

as

soon

as

the

115

volts

power

plug

is

connected

to

the

115

volts

ac

source

and

the

welding



power

source

is

energized.



It~TANT

I

The

contactor

control

circuitry

that

is

to

be

used

in

I

conjunction

with

this

control/feeder

must

be

of

the

type

that

operates

on

115

volts

60

Hertz

power.

This

is

necessary

because

the

control

will

supply

115

volts

ac

through

the

contactor

control

cable

whenever

the



gun

switch

is

closed.

2-15.

REMOTE

CONTROL

CONNECTION

(Figure

3-1)

A

receptacle

is

provided

for

connecting

a

remote

control

to

the

unit.

Align

keyways

and

insert

the

plug

from

the

remote

control

into

the

receptacle

and

rotate

the

threaded

collar

clockwise

as

far

as

possible.

2-16.

INSTALLATION

OF

SPOOL-TYPE

WIRE

(Figure

2-2)

1.

Remove

the

retaining

ring

(12).

2.

Slide

the

spool

of

wire

onto

the

hub

(4)

so

that

the

wire

will

feed

off

the

top

of

the

spool.

The

spool

turns

in

a

clockwise

direction.

3.

Rotate

the

spool

until

the

hole

in

the

spool

aligns

with

the

in

the

hub

(4).

Slide

the

spool

onto

the

hub

until

it

seats

against

the

back

flange

of

the

hub.

4.

Depress

the

two

spring-loaded

stops

(11)

on

the

retaining

ring

(12)

and

slide

the

retaining

ring

(12)

into

proper

position

on

the

hub

(4).

Release

the

two

stops

(11).

2-17.

INSTALLATION

OF

REEL-TYPE

WIRE

(Figure

2-3)

1.

Loosen

the

four

wing

nuts

(3)

on

the

fingers

(2)

of

the

wire

reel

(1).

2.

Pull

the

four

fingers

(2)

out

until

they

can

be

rotated

toward

the

center

of

the

reel

(1).

3.

Install

the

wire

onto

the

reel

(1)

over

the four

fingers

(2).

Ensure

that

the

wire

feeds

off

the

top

of

the

reel

(1).

The

reel

(1)

turns

in

a

clockwise

direction.

4.

Rotate

the

four

fingers

(2)

back

to

their

proper

position.

Tighten

the

four

wing

nuts

(3).

Check

the

hub

tension

by

slowly

pulling

the

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

feeding

ceases.

If

adjustment

is

required,

loosen

or

tighten

the

hex

nut

(10)

on

the

end

of

the

spindle

support

shaft

(1)

accordingly.

2-19.

WELDING

WIRE

THREADING

CAUTION

I

Prior

to

threading

the

welding

wire

~gh

the

gun,

ensure

that

weld

power

is

not

available

at

the

weld



head.

-I

1.

Install

the

wire

(reel-type

or

spool-type)

as

instructed

in

Section

2-16

or

2-17.

2.

Cut

off

any

portion

of

the

free

end

of

the

wire

which

is

not

straight.

Ensure

that

the

cut

end

is

free

from

rough

surfaces

to

permit

proper

feeding.

3.

Route

the

wire

through

the

wire

guide

tube

on

the

side

of

the

boom,

over

the

wire

pulley,

and

to

the

drive

assembly.

4.

Loosen

the

wing

nut

on

the

drive

roll

pressure

adjustment,

pivot

the

pressure

adjustment

free

of

the

cover,

and

pivot

the

pressure gear

assembly

away

until

it is

in

an

open

position.

5.

Feed

the

wire

through

the

inlet

wire

guide,

past

the

drive

rolls,

and

on

into

the

outlet

wire

guide.

Feed

approximately

4

inches

of

wire

into

the

outlet

wire

guide.

m



If

when

the

gear

cover

is

closed

the

U-Cog

drive

rolls

U

are

not

aligned

properly

(see

Section

2-6),

pivot

the

gear

cover

away

from

the

drive

gear

and

rotate

the



pressure

gear

one

tooth.

6.

Pivot

the

gear

cover

closed

making

sure

the

teeth

on

the

pressure

gear

mesh

with

the

teeth

on

the

drive

gear.

The

welding

wire

must

also

be

in

the

grooves

of

the

drive

rolls.

7,

Pivot

the

pressure

adjustment

wing

nut

until

the

washer

on

the

pressure

adjustment

is

seated

on

top

of

the

gear

cover.

8.

Turn

the

pressure

adjustment

wing

nut

in

a

clockwise

direction

until

the

drive

rolls

are

tight

against

the

welding

wire.

Do

not

overtighten.

Further

adjustment

to

attain

desired

clamping

pressure

can

be

made

after

the

welding

power

source

and

the

control/feeder

are

put

into

operation:

9.

Draw

the

gun

cable

out

straight.

10.

Energize

the

welding

power

source

(if

the

115

Volts

AC

receptacle

on

the

welding

power

source

is

uti

lized).

11.

Place

the

control

POWER

switch

in

the

ON

position.

12.

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

when

the

welding

wire

extends

approximately

one

inch

out

of

the

gun

tip.

Page

6

SECTION

3

-

FUNCTION

OF

CONTROLS

3-1.

POWER

SWITCH

(Figure

3-1)

Placing

the

POWER

switch

on

the

control

in

the

ON

position

will

apply

115

volts

ac

to

the

unit

and

thereby

place

it

in

an

operational

condition,

ready

to

feed

wire

and

permit

shielding

gas

to

flow.

Placing

the

POWER

switch

in

the

OFF

position

will

shut

the

control/feeder

down.

~ng

the

P0

WER

switch

in

the

OFF

pos

ition

d

oes

not

remove

power

from

all

of

the

controls

internal

circuitry.

Completely

terminate

all

electrical

power

to

the

control

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

inspec

~ion

or

work

inside

the

unit.

p

3-2.

REMOTE

CONTROL

RECEPTACLE

AND

SWITCH

(Figure

3-1)

The

remote

control

receptacle

is

provided

for

use

in

conjunction

with

Certain

optional

controls.

If

a

remote

control

is

to

be

used,

make

connections

as

instructed

in

Section

2-15

and

place

the

Remote

Control

switch

in

the

REMOTE

position.

When

changing

the

position

of

the

switch

it is

necessary

to

pull

out

on

the

toggle.

If

a

remote

control

is

not

to

be

used,

place

the

Remote

Control

switch

in

the

STANDARD

position.

SECTION

4

-

SEQUENCE

4-1.

GAS

METAL-ARC

WELDING

(GMAW)

1.

Make

all

necessary

connections

as

instructed

in

Section

2.

Place

the

control

unit

Remote

Control

switch

in

the

STANDARD

position.

3.

Energize

the

welding

power

source.

4.

Place

the

POWER

switch

on

the

control

in

the

ON

position,

5.

Rotate

the

WIRE

SPEED

control

until

the

desired

wire

speed

is

displayed

on

the

INCHES

PER

MINUTE

meter.

6.

Turn

on

the

shielding

gas

at

the

source.

7.

Depress

the

PURGE

button

for

one

minute.

3-3.

PURGE

BUTTON

(Figure

3-1)

The

PURGE

button

is

a

momentary

contact

switch.

This

switch

will

energize

the

gas

solenoid

and

purge

the

shielding

gas

line

of

the

gun.

The

PURGE

button

also

allows

the

shielding

gas

regulator

to

be

adjusted

without

energizing

the

welding

circuit.

3-4.

INCH

SWITCH

(Figure

3-1)

The

INCH

switch

is

a

spring

loaded

toggle

switch.

When

actuated

it

completes

the

circuit

to

the

motor

without

having

to

depress

the

gun

trigger

switch.

This

switch

will

permit

inching

of

the

wire

at

whatever

setting

the

WIRE

SPEED

control

is

at,

without

energizing

the

welding

circuit

or

the

shielding

gas

valve,

3-5.

WIRE

SPEED

CONTROL

(Figure

3-1)

A

ten

turn

WIRE

SPEED

control

provides

a

means

of

determining

the

rate

at

which

welding

wire

will

be

fed

into

the

weld.

Rotating

the

WIRE

SPEED

control

in

a

clockwise

direction

will

increase

the

rate

of

the

wire

feed.

3-6.

INCHES

PER

MINUTE

METER

(Figure

3-1)

This

meter

displays

the

wire

speed

in

inches

per

minute.

Before

the

gun

trigger

is

depressed,

the

meter

displays

wire

speed

as

set

by

the

WIRE

SPEED

control.

During

welding

the

meter

displays

actual

wire

speed

as

set

by

the

WIRE

SPEED

control.

3-7.

RESET

CIRCUIT

BREAKER

(Figure

3-1)

A

circuit

breaker

provides protection

to

the

feeder

motor.

In

the

event

the

motor

should

be

placed

in

an

overload

condition,

the

breaker

would

trip

and

suspend

all

output.

Should

this

breaker

trip,

the

RESET

button

would

have

to

be

manually

depressed

in

order

to

reset

the

circuit

breaker,

3-8.

BURNBACK

CONTROL

(OptionaU

The

burnback

circuitry

in

this

control

provides

a

means

of

keeping

the

welding

wire

from

sticking

to

the

workpiece

after

the

gun

switch

is

released.

The

burnback

capability

in

this

control/feeder

will,

depending

upon

the

setting

of

the

BURNBACK

control,

keep

weld

current

present

on

the

welding

wire

from

0

to

15

cycles

after

the

wire

has

stopped

feeding.

This

delay

action

will

permit

the

welding

wire

to

burn

back

to

a

point

where

it

will

neither

stick

to

the

workpiece

nor

the

contact

tube.

If

the

welding

wire

sticks

to

the

contact

tube,

rotate

the

BURNBACK

control

to

a

more

counterclockwise

position.

If

the

welding

wire

sticks

to

the

workpiece,

rotate

the

BURNBACK

control

to

a

more

clockwise

position.

OF

OPERATION

8.

Hold

the

tip

of

the

gun

approximately

1/2

inch

from

the

workpiece.

9.

Depress

the

trigger

on

the

gun

handle.

Gas

will

start

to

flow

and

wire

will

start

to

feed

if

drive

roll

pressure

is

properly

adjusted

to

prevent

slippage.

If

wire

slippage

is

noticed,

tighten

the

drive

roll

pressure

adjustment

wing

nut

1/2

turn

clockwise.

Repeat

until

slippage

stops.

Do

not

overtighten

wing

nut.

~lding

wire

and

all

me

ta

I

pa

rts

in

con

tact

w

ith

it

are

energized

while

welding.

Do

not

touch

the

welding

wire

or

any

metal

part

making

contact

with

it.

4-2.

SHUTTING

DOWN

1.

Turn

off

the

shielding

gas

at

the

source.

2.

Place

the

POWER

switch

on

the

control

in

the

OFF

position.

3.

Turn

off

all

associated

equipment.

Fuse

inches

Per

Minute

Purge

Meter

Button

Inch

Switch

I

~/

Circuit

H



LIIIIIIIJ;?

Breaker~l~'

Power

Switch

II

I

Wire

Speed



Control



Remote

Control

Switch

Control

Receptacle

Remote

Control

Receptacle

TA-049

732

Figure

3-1.

Control

Components

I

Prior

to

welding,

it

is

imperative

that

proper

protective

I

clothing

(welding

coat

and

gloves)

and

eye

protection

(glasses

and

welding

helmet)

be

put

on.

Failure

to

comply

may

result

in

serious

or

permanent

bodily



damage.

OM-1522

Page

7

I

If

welding

is

performed

in

a

confined

area,

failure

to

turn

off

the

shielding

gas

Supply

could

result

in

a

build-up

of

gas

fumes,

thereby

endangering

personnel



reentering

the

welding

area.

I

SECTION

5-MAINTENANCE



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

hos.e

and

cable;

give

particular

attention

to

frayed

and

cracked

insulation

and

areas

where

it

enters

equipment.

5-2.

CLEANING

OF

DRIVE

ROLLS

Occasionally

it

will

become

necessary

to

clean

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

2-6

for

removal

and

installation

instructions).

~uretoproperlymai~:fhedriverolIscanresult

in

a

build-up

of

wire

particles

which

will

decrease

the

~

efficiency

of

the

wire

feeding

operation.

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.

~dous

voltages

are

present

on

~nternalcir

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



personnel

only.

It

is

assumed

that

proper

installation

has

been

made,

according

to

Section

2 of

this

manual,

and

that

the

unit

has

been

functioning

properly

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

malfunction,

the

manufacturers

recommendations

should

be

strictly

followed.

The

following

chart

is

designed

to

diagnose

and

provide

remedies

for

some

of

the

troubles

that

may

develop

in

this

unit.

TROUBLE

PROBABLE

CAUSE

REMEDY

Depressing

gun

switch

will

not

energize

control/feeder.

Electrode

wire

is

not

energized

and

shielding

gas

does

not

flow.

Control

POWER

switch

in

wrong

position

or

defective.

Place

switch

to

ON

position.

Replace

defective

POWER

switch.

115

volts

input

fuse

Fl

open.

Replace

fuse

Fl.

115

volts

contactor

control

plug

is

not

secure

in

receptacle.

Secure

plug

in

receptacle.

Plug

from

gun

switch

is

not

secure

in

switch

control

cable

on

boom,

Insert

plug

fully

into

switch

control

cable

and

rotate

locking

ring.

Plug

from

switch

control

cable

is

not

secure

in

Switch

Control

receptacle.

Secure

plug

in

Switch

Control

receptacle.

Coil

of

relay

CR1

defective.

Replace

relay

CR1.

Circuit

breaker

CB1

tripped.

Manually

reset

circuit

breaker

by

depressing

the

button

on

the

front

panel

of

the

control

labeled

RESET.

Wire

feeds,

shielding

gas

flows,

but

electrode

wire

is

not

energized.

~

115

volts

contactor

control

plug

is

not

secure

in

contactor

receptacle

on

welding

power

source.

Secure

plug

in

receptacle.

Defect

in

welding

power

source.

.

See

TROUBLESHOOTING

Section

in

welding

power

source

instruction

manual.

5-3.

FUSE

(Figure

3-1)

The

control

is

protected

from

damage

due

to

an

internal

short

or

excessive

overload

by

fuse

Fl.

Should

Fl

open,

the

control

would

be

completely

inoperative.

SECTION

6

-

TROUBLESHOOTING

Page

8

Wire

feeds

erratically.

Pressure

on

drive

rolls

is

insufficient,

Rotate

pressure

adjustment

wing

nuts

clockwise

in

1/4

turn

increments

until

wire

slippage

stops.

Drive

roll

is

too

large

for

wire

size

Change

to

proper

size

drive

roll.

See

Section

2-6.

being

used.

Worn

drive

roll.

Replace

drive

roll.

See

Section

2.6.

Dirt

in

drive

roll.

Clean

drive

roll

as

instructed

in

Section

5-2.

if

it

becomes

necessary

to

replace

any

fuse

in

the

control/feeder,

ensure

that

a

fuse

of

the

proper

size

is

used.

OM-1522

Page

9

38

~rok

PURGE

Circuit

Diagram

No.

C-081

944-A

Figure

6-1.

Circuit

Diagram

April

1979

FORM:

OM-1522

PARTS

LIST

Effective

With

Serial

No.

HK270136

MODEL

SWINGARC

DIGITAL

-

1

12

SWINGARC

DIGITAL

-

1

16

Figure

A



Main

Assembly

TD-049

746

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