Miller AUTOMATIC 1DA Owner's manual

Miller
Brand
Miller
Model
AUTOMATIC 1DA
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Miller
October
1989
FORM:
OM-1578
Effect
lye
With
S
erial
Numbe
r
JK697875
MODEL:
AUTOMATIC
1
DA
Gas/Current
Sensing
Control
Hub
&
Spindle
Assembly
Spool
Support
OWNERS
MANUAL
IMPORTANT:
Read
and
understand
the
entire
contents
of
both
this
manual
and
the
power
source
manual
used
with
this
unit,
with
special
emphasis
on
the
safety
material
throughout
both
manuals,
before
installing,
operating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equip
ment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
MILLER
ELECTRIC
Mfg.
Co.
A
Mifler
Group
Ltd.
Company
P.O.
Box
1079
Appleton,
WI
54912
USA
Tel.
414-734-9821
PRINTED
IN
U.S.A
LIMITED
WARRANTY
EFFECTIVE:
MARCH
15,
1989
L
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
7
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
fur
nished
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
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
trade
ac
cessories
and
other
items
are
sold
subject
to
the
warranties
of
their
respective
manufacturers,
if
any.
All
engines
are
war
ranted
by
their
manufacturer
for
one
year
from
date
of
original
purchase,
except
Tecumseh
and
Onan
engines
which
have
a
two
year
warranty.
Except
as
specified
below,
Millers
warranty
does
not
apply
to
components
having
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
MILLER
MATIC
parts
that
come
in
contact
with
the
welding
wire
includ
ing
nozzles
and
nozzle
insulators
where
failure
does
not
result
from
defect
in
workmanship
or
material.
Miller shall
be
required
to
honorwarrarity
claims
on
warranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
within
the
following
periods
from
the
date
of
delivery
of
Equipment
to
the
original
user:
-
1.
Arc
welders,
power
sources,
robots,
and
1
year
components
2.
Loadbanks
lyear
3.
Original
main
power
rectifiers
3
years
(labor
1
year
only)
4.
All
welding
guns,
feeder/guns
and
torches
..
90
days
5.
All
other
Millermatic
Feeders
1
year
6.
Replacement
or
repair
parts,
exclusive
of
labor
60
days
7.
Batteries
6
months
provided
that
Miller
is
notified
in
writing
within
thirty
(30)
days
of
the
date
of
such
failure.
As
a
matter
of
general
policy
only,
Miller
may
honor
daims
submitted
by
the
original
user
within
the
foregoing
periods.
In
the
case
of
Millers
breach
of
warranty
or
any
other
dutywith
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
therefore
shall
be,
at
Millers
option
(1)
repair
or
(2)
replacement
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
Miller
service
station
or(4)
payment
of
orcreditforthe
purchase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
Customers
risk
and
expense.
MILLERs
option
of
repairor
replacementwill
be
F.O.B.,
Factory
atAppleton,
Wisconsin,
or
F.O.
B.
at
a
MILLER
authorized
serv
ice
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
claimant
on
the
war
ranty
claim
procedures
to
be
followed.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRE
SENTATION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
FORTHIS
PRO
VISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHAN
TABILITY
OR
OF
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FUR
NISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
ULTI
MATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPE
RIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CON
SUMER
USE.
MILLERS
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
I
I
ERRATA
SHEET
July
19,
1990
FORM:
OM-1578
After
this
manual
was
printed,
refinements
in
equipment
design
occurred. This
sheet
lists
exceptions
to
data
appearing
iater
in
this
manual.
AMENDMENT
TO
SECTION
4INSTALLATiON
Amend
Section
4-3E.
INTERNAL
CONNECTIONS:
Flux
Valve
Connections
Connect
power
leads
for
115VAC
flux
valve
transformer
to
terminals
1TC
and
2TD
in
the
weld
control
(polarity
is
not
important).
The
flux
valve
energizes
when
the
weld
control
START
switch
is
pressed
and
deenergizes
at
the
end
of
post
flow.
AMENDMENT
TO
SECTION
8
ELECTRICAL
DIAGRAMS
Amend
Diagram
8-4.
Circuit
Diagram
For
Voltage
Control
Board
PCi
(see
Page
2
of
this
Errata
Sheet)
AMENDMENT
TO
SECTION
9
PARTS
LIST
Amend
Parts
List
as
follows:
Dia.
**
Mkgs.
Part
Replaced
No.
With
Description
Quantity
37-i
PCi
130
153
+137
693
CIRCUIT
CARD,
voltage
control
(Effw/KA743941)
1
39-
121
684
+121
684
CAPACITOR,
(qty
chg
added
C75)
2
39-
035
888
+035
888
RESISTOR,
(qty
chg
deleted
R78,93)
2
39-
035
826
+035
826
RESISTOR,
(qty
chg
deleted
R63,69)
5
39-
R63,78
Added
+097
110
RESISTOR,
MF
.25W
1K
ohm
2
39-
009
173
+009
173
POTENTIOMETER,
(qty
chg
added
R103)
3
39-
R69
Added
+108
437
RESISTOR,
MF
.25W
4.75
K
ohm
1
39-
R93
Added
+091
799
RESISTOR,
MF
.25W
8.25
K
ohm
1
39-
R103
082178
+Deleted
44-
070
183
137
152
CONTROL,
gas/current
sensing
(Eli
w/KA811372)
1
44-2
Reed
079687
136595
RELAY,current(Effw/KA8ii372)
1
44-3
057
091
Deleted
Eli
w/KA81
1372
44-4
604
525
Deleted
Eli
w/KA81
1372
44-11
602
934
602
934
FITTING,
(qty
chg)
(Eff
w/KA811372)
2
44-12
079
573
602
920
FITTING,
pipe
galv
nipple
L .250
NPT
x
2
(Eli
w/KA811372)
2
44-13
079
686
136
851
CASE
SECTION,
bottom/front/sides
(Eli
w/KA811372)
...
1
45-9
085
980
135
205
NUT,
stl slf
1kg
hex
reg
.625-11
1
**FirSt
digit
represents
page
no
-
digits
following
dash
represent
item
no.
+Circuit
card
components
(Fig
9-4)
remain
the
same
with
listed
exceptions.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Circuit
Diagram
No.
C-133
836
Diagram
8-4.
CIrcuit
Diagram
For
Voitage
Controi
Board
PCi
Effective
With
Serlai
No.
KA743941
OM-1
578
10/89
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam-
Use
the
following
spaces
to
record
the
Model
Designa
age
that
may
have
occurred
during
shipment.
File
any
tion
and
Serial
or
Style
Number
of
your
unit.
The
infor
claims
for
loss
or
damage
with
the
delIverIng
carrier.
mation
is
located
on
the
data
card
or
the
nameplate.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
the
distributor
and/or
the
equipment
manufactur-
Model
_______________________________
ers
Transportation
Department.
Senal
or
Style
No.
____________________
When
requesting
information
about
this
equipment,
al
ways
provide
the
Model
Description
and
Serial
or
Style
Date
of
Purchase
_____________________
Number.
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
5
SECTION
2
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
2-1.
General
Information
And
Safety
6
2-2.
Safety
Alert
Symbol
And
Signal
Words
6
SECTION
3
SPECIFICATIONS
3-1.
Description
7
SECTION
4
INSTALLATION
4-1.
Site
Selection
9
4-2.
Equipment
Installation
9
4-3.
Internal
Connections
10
4-4.
Wire
Drive
Motor
Speed
Calibration
Selection
12
4-5.
Weld
Control
Interconnections
13
4-6.
Gas/Current
Sensing
Control
Interconnections
14
4-7.
Welding
Wire
Installation
15
SECTION
5-
OPERATOR
CONTROLS
5-1.
Power
Switch
And
Pilot
Light
15
5-2.
Retract
-
Advance
Switch
And
Jog
Switch
15
5-3.
Purge
Switch
16
5-4.
Start
Switch
16
5-5.
Stop
Switch
16
5-6.
Error
Reset
Button
16
5-7.
Press
To
Set
Buttons
16
5-8.
Digital
Meters
17
5-9.
Run
In
Wire
Speed
Control
17
5-10.
Weld
Wire
Speed
Control
17
5-11.
Weld
Voltage
Control
17
Section
No.
Page
No.
SECTION
5
OPERATOR
CONTROLS
(Continued)
5-12.
Crater
&
Jog
Wire
Speed
Control
17
5-13.
Crater
Voltage
Control
17
5-14.
Pref
low
Time
Control
17
5-15.
Spot
-
Continuous
Switch
18
5-16.
Spot
Time
Control
18
5-17.
Crater
Time
Control
18
5-18.
Burnback
Control
18
5-19.
Postflow
Time
Control
18
5-20.
Optional
Run
In
Controls
18
SECTION
6
SEQUENCE
OF
OPERATION
6-1.
Gas
Metal
Arc
Welding
(GMAW)
And
Flux
Cored
Arc
Welding
(FCAW)
-
Continuous
19
6-2.
Gas
Metal
Arc
Welding
(GMAW)
And
Flux
Cored
Arc
Welding
(FCAW)
-
Spot
19
6-3.
Shutting
Down
19
SECTION
7
MAINTENANCE
&
TROUBLESHOOTING
7-1.
Routine
Maintenance
20
7-2.
Overload
Protection
20
7-3.
Hub
Reinstallation
20
7-4.
Circuit
Board
Handling
Precautions
21
7-5.
Troubleshooting
21
SECTION
8
ELECTRICAL
DIAGRAMS
Diagram
8-1.
Circuit
Diagram
23
Diagram
8-2.
Wiring
Diagram
24
Diagram
8-3.
Circuit
Diagram
For
Models
With
Run
In
Option
26
Diagram
8-4.
Circuit
Diagram
For
Voltage
Control
Board
PCi
27
Diagram
8-5.
Circuit
Diagram
For
Motor
Control
Board
PC2
28
Diagram
8-6.
Circuit
Diagram
For
Timer
Board
PC3
29
Diagram
8-7.
Circuit
Diagram
For
Tach
Board
PC4
30
Diagram
8-8.
Circuit
Diagram
For
Low
Speed
Calibration
Board
PC8
30
SECTION
9
PARTS
LIST
Figure
9-1.
Control
Box
32
Figure
9-2.
Meter,
Digital
Volt
35
Figure
9-3.
Panel,
W/Components
36
Figure
9-4.
Circuit
Card,
Voltage
Control
PCi
38
Figure
9-5.
Circuit
Card,
Motor
Speed
PC2
40
Figure
9-6.
Timer
PC3
42
Figure
9-7.
Circuit
Card
43
Figure
9-8.
Control,
Gas/Current
Sensing
44
Figure
9-9.
Hub
&
Spindle
Assembly
45
LIST
OF
CHARTS
AND
TABLES
Table
3-1.
Specifications
7
Table
3-2.
Weld
Parameters
7
Table
7-i.
Troubleshooting
21
to
atmospheres
containing
even
minute
amounts
of
trichioroethylene
or
perchloroethylene.
C.
Fire
and
Explosion
Prevention
Causes
of
fire
and
explosion
are:
combustibles
reached
by
the
arc,
flame,
flying
sparks,
hot
slag
or
heated
mate
rial;
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
tires
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,
venti
lators.
If
the
work
cannot
be
moved,
move
combustibles
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
extin
guishing
equipment
during
and
for
some
time
afterweld
ing
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
orwalls
within
35
feet
may
expose
combustibles
to
sparks
d.
combustibles
adjacent
to
walls,
ceilings,
roofs,
or
metal
partitions
can
be
ignited
by
radiant
or
conducted
heat.
Hot
work
permit
should
be
obtained
before
operation
to
ensure
supervisors
approval
that
adequate
precautions
have
been
taken.
After
work
is
done,
check
that
area
is
free
of
sparks,
glowing
embers,
and
flames.
An
empty
container
that
held
combustibles,
or
that
can
produce
flammable
or
toxic
vapors
when
heated,
must
never
be
welded
on
or
cut,
unless
container
has
first
been
cleaned
as
described
in
AWS
Standard
A6.O,
listed
7
in
Standards
Index.
This
includes:
a
thorough
steam
or
caustic
cleaning
(ora
solvent
or
water
washing,
depending
on
the
combusti
bles
solubility)
followed
by
purging
and
inerting
with
ni
trogen
or
carbon
dioxide,
and
using
protective
equip-
ment
as
recommended
in
A6.O.
Waterlilling
just
below
working
level
may
substitute
for
inerting.
A
container
with
unknown
contents
should
be
cleaned
(see
preceding
paragraph).
Do
NOT
depend
on
sense
of
smell
or
sight
to
determine
if
it
is
safe
to
weld
or
cut.
Hollow
castings
or
containers
must
be
vented
before
welding
or
cutting.
They
can
explode.
Explosive
atmospheres.
Never
weld
or
cut
where
the
air
may
contain
flammable
dust,
gas,
or
liquid
vapors
(such
as
gasoline).
D.
Compressed
Gas
EquIpment
Standard
precautions.
Comply
with
precautions
in
this
manual,
and
those
detailed
in
CGA
Standard
P-i,
SAFE
HANDLING
OF
COMPRESSED
GASES
IN
CYLIN
DERS,
listed
11
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
regulatorfrom
service
immediately
for
re
pair
(first
close
cylinder
valve).
The
following
symptoms
indicate
a
faulty
regulator:
Leaks-it
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
to
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
including
third
rails,
electrical
wires,
or
welding
circuits.
They
can
produce
short
circuit
arcs
that
may
lead
to
a
serious
acci
dent.
(See
1-3C.)
ICC
or
DOT
marking
must
be
on
each
cylinder.
It
is
an
assurance
of
safety
when
the
cylinder
is
properly
han
dled.
Identifying
gas
content.
Use
only
cylinders
with
name
of
gas
marked
on
them;
do
not
rely
on
color
to
identify
gas
content.
Notify
supplier
if
unmarked.
NEVER
DEFACE
or
alter
name,
number,
or
other
markings
on
a
cylinder,
It
is
illegal
and
hazardous.
Empties:
Keep
valves
closed,
replace
caps
securely;
mark
MI;
keep
them
separate
from
FULLS
and
return
promptly.
OM-1578
Page
2
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
orcradie.
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
al
low
contents
to
exceed
130F.
Cool
with
water
spray
where
such
exposure
exists.
Protect
cylinders
particularly
valves
from
bumps,
falls,
falling
objects,
and
weather.
Replace
caps
securely
when
moving
cylinders.
Stuck
valve.
Do
NOT
use
a
hammer
orwrench
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.
Never
refill
any
cylinder.
Cylinder
fittings
should
never
be
modified
or
exchanged.
3.
Hose
Prohibited
use.
Never
use
hose
other
than
that
designed
for
the
specified
gas.
A
general
hose
identification
rule
is:
red
for
fuel
gas,
green
for
oxygen,
and
black
for
inert
gases.
Use
ferrules
or
clamps
designed
for
the
hose
(not
ordi
nary
wire
or
other
substitute)
as a
binding
to
connect
hoses
to
fittings.
No
copper
tubing
splices.
Use
only
standard
brass
fit
tings
to
splice
hose.
Avoid
long
runs
to
prevent
kinks
and
abuse.
Suspend
hose
off
ground
to
keep
it
from
being
run
over,
stepped
on,
or
otherwise
damaged.
Coil
excess
hose
to
prevent
kinks
and
tangles.
Protect
hose
from
damage
by
sharp
edges,
and
by
sparks,
slag,
and
open
flame.
Examine
hose
regularly
for
leaks,
wear,
and
loose
con
nections.
Immerse
pressured
hose
in
water;
bubbles
in
dicate
leaks.
Repair
leaky
or
worn
hose
by
cutting
area
out
and
splic
ing
(1-2D3).
Do
NOT
tape.
4.
Proper
Connections
Clean
cylinder
valve
outlet
of
impurities
that
may
clog
orifices
and
damage
seats
before
connecting
regulator.
Except
for
hydrogen,
crack
valve
momentarily,
pointing
outlet
away
from
people
and
sources
of
ignition.
Wipe
with
a
clean
lintless
cloth.
Match
regulator
to
cylinder.
Before
connecting,
check
that
the
regulator
label
and
cylinder
marking
area,
and
thatthe
regulatorinlet
and
cylinderoutlet
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.
lighten.
If
connection
leaks,
disassemble,
clean,
and
retighten
using
property
fitting
wrench.
Adapters.
Use
a
CGA
adapter
(available
from
your
sup
plier)
between
cylinder
and
regulator,
if
one
is
required.
usetwowrenchestotighten
adaptermarked
RIGHTand
LEFT
HAND
threads.
Regulatoroutlet
(or
hose)
connections
may
be
identified
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
be
fore
opening
cylinder
(or
manifold
valve)
by
turning
ad
justing
screw
in
(clockwise).
Draining
prevents
exces
sive
compression
heat
at
high
pressure
seat
by
allowing
seat
to
open
on
pressurization.
Leave
adjusting
screw
engaged
slightly
on
single-stage
regulators.
Stand
to
side
of
regulator
while
opening
cylinder
valve.
Open
cylinder
valve
slowly
so
that
regulator
pressure
in
creases
slowly.
When
gauge
is
pressurized
(gauge
reaches
regulator
maximum)
leave
cylinder
valve
in
fol
lowing
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
(capfull
of
Ivory
Liq
uid*
or
equivalent
per
gallon
of
water).
Bubbles
indicate
leak.
Clean
off
soapy
water
after
test;
dried
soap
is
com
bustible.
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.
C.
Rope
Staging-Support
Rope
staging-support
should
not
be
used
for
welding
or
cutting
operation;
rope
may
burn.
*Trademark
of
Proctor
&
Gamble.
OM-1
578
Page
3
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
in
frared
energy
radiates,
weldments
are
hot,
and
com
pressed
gases
may
be
used.
The
wise
operator
avoids
unnecessary
risks
and
protects
himself
and
others
from
accidents.
Precautions
are
described
here
and
in
stan
dards
referenced
in
index.
A.
Burn
Protection
Comply
with
precautions
in
1-2.
The
welding
arc
is
intense
and
visibly
bright.
Its
radiation
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
PRECAUTIONS.
1.
Protective
Clothing
Wear
long-sleeve
clothing
(particularly
for
gas-shielded
arc)
in
addition
to
gloves,
hat,
and
shoes
(1
-2A).
As
nec
essary,
use
additional
protective
clothing
such
as
leatherjacket
or
sleeves,
flame-proof
apron,
and
fire-re
sistant
leggings.
Avoid
outer
garments
of
untreated
cot
ton.
Bare
skin
protection.
Wear
dark,
substantial
clothing.
Button
collar
to
protect
chest
and
neck
and
button
pock
ets
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
ordenser
must
be
used
when
welding.
Place
over
face
before
striking
arc.
Protect
filter
plate
with
a
clear
cover
plate.
Cracked
or
broken
helmet
or
shield
should
NOT
be
worn;
radiation
can
pass
through
to
cause
burns.
Cracked,
broken,
or
loose
filter
plates
must
be
replaced
IMMEDIATELY.
Replace
clear
cover
plate
when
broken,
pitted,
or
spattered.
Flash
goggles
with
side
shields
MUST
be
worn
under
the
helmet
to
give
some
protection
to
the
eyes
should
the
helmet
not
be
lowered
over
the
face
before
an
arc
is
struck.
Looking
at
an
arc
momentarily
with
unprotected
eyes
(particularly
a
high
intensity
gas-shielded
arc)
can
cause
a
retinal
burn
that
may
leave
a
permanent
dark
area
in
the
field
of
vision.
3.
Protection
of
Nearby
Personnel
Enclosed
welding
area.
For
production
welding,
a
sepa
rate
room
or
enclosed
bay
is
best.
In
open
areas,
sur
round
the
operation
with
low-reflective,
non-combusti
ble
screens
or
panels.
Allow
for
free
air
circulation,
par
ticularly
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
ves
sel.
It
creates
a
brittle
area
that
can
cause
a
violent
nip
ture
or
lead
to
such
a
rupture
under
rough
handling.
D.
Compressed
Gas
Equipment
Comply
with
precautions
in
1-2D.
E.
Shock
Prevention
Exposed
hot
conductors
or
other
bare
metal
in
the
weld
ing
circuit,
or
in
ungrounded,
electrically-HOT
equip
ment
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:
Wear
dry
insulating
gloves
and
body
protection.
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
dampness
or
sweat
can
not
be
avoided.
Sweat,
sea
water,
or
moisture
be
tween
body
and
an
electrically
HOT
part
or
grounded
metal
reduces
the
electrical
resistance,
and
could
en
able
dangerous
and
possibly
lethal
currents
to
flow
through
the
body.
A
voltage
will
exist
between
the
electrode
and
any
con
ducting
object
in
the
work
circuit.
Examples
of
conduct
ing
objects
include,
but
are
not
limited
to,
buildings,
elec
trical
tools,
work
benches,
welding
power
source
cases,
workpieces,
etc.
Never
touch
the
electrode
and
any
metal
object
unless
the
welding
power
source
Is
off.
1.
Grounding
the
Equipment
Arc
welding
equipment
must
be
grounded
according
to
the
National
Electrical
Code,
and
the
work
must
be
grounded
according
to
ANSI
Z49.1
Safety
In
Welding
And
Cutting.
When
installing,
connect
the
frames
of
each
unit
such
as
welding
power
source,
control,
worktable,
and
watercir
culatorto
the
building
ground.
Conductors
must
be
ade
quate
to
carry
ground
currents
safely.
Equipment
made
OM-1578
Page
4
electrically
HOT
by
stray
current
may
shock,
possibly
fa
tally.
Do
NOT
GROUND
to
electrical
conduit,
orto
a
pipe
carrying
ANY
gas
or
flammable
liquid
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
re
ceptacle,
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
receptacle.
Never
remove
the
ground
prong
from
a
plug,
or
use
a
plug
with
a
broken
off
ground
prong.
2.
Electrode
Holders
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
(contactor)
Welding
power
sources
for
use
with
the
gas
metal
arc
welding
(GMAW),
gas
tungsten
arc
welding
(GTAW)
and
similar
processes
nor
mally
are
equipped
with
devices
that
permit
on
off
control
of
the
welding
poweroutput.
When
so
equipped
the
electrode
wire
becomes
electri
cally
HOT
when
the
power
source
switch
is
ON
and
the
welding
gun
switch
is
closed.
Never
touch
the
electrode
wire
or
any
conducting
ob
ject
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
proc
esses
may
not
be
equipped
with
welding
power
output
on-off
control
devices.
With
such
equip
ment
the
electrode
is
electrically
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
equipment,
shut
OFF
all
power
and
remove
line
fuses
(or
lock
or
red-
tag
switches)
to
prevent
accidental
turning
ON
of
power.
Disconnect
all
cables
from
welding
power
source,
and
pull
all
115
volts
line-cord
plugs.
Do
not
open
power
circuit
or
change
polarity
while
weld
ing.
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.
F.
Protection
For
Wearers
of
Electronic
Life
Sup
port
Devices
(Pacemakers)
Magnetic
fields
from
high
currents
can
affect
pacemaker
operation.
Persons
wearing
electronic
life
support
equipment
(pacemaker)
should
consult
with
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
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
N.W.
LeJeune
Rd,
Miami,
FL
33126.
2.
NIOSH,
SAFETY
AND
HEALTH
IN
ARC
WELDING
AND
GAS
WELDING
AND
CUTTING
obtainable
from
the
Superintendent
of
Documents,
U.S.
Gov
ernment
Printing
Office,
Washington,
D.C.
20402.
3.
OSHA,
SAFETY
AND
HEALTH
STANDARDS,
29CFR
1910,
obtainable
from
the
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
4.
ANSI
Standard
Z87.1,
SAFE
PRACTICES
FOR
OCCUPATION
AND
EDUCATIONAL
EYE
AND
FACE
PROTECTION
obtainablefromthe
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
Broad
way,
New
York,
NY
10018.
6.
ANSi
Standard
Z49.2,
FIRE
PREVENTION
IN
THE
USE
OF
CUTTING
AND
WELDING
PROCESSES
OM-1578
Page
5
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
7.
AWS
Standard
A6.0,
WELDING
AND
CUTTING
CONTAINERS
WHICH
HAVE
HELD
COMBUS
TIBLES
obtainable
from
the
American
Welding
So
ciety,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126.
8.
NFPA
Standard
51,
OXYGEN-FUEL
GAS
SYS
TEMS
FOR
WELDING,
CUTTING,
AND
ALLIED
PROCESSES
obtainable
from
the
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
9.
NFPA
Standard
70,
NATIONAL
ELECTRICAL
CODE
obtainable
from
the
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
10.
NFPA
Standard
51B,
CUTTING
AND
WELDING
PROCESSES
obtainable
from
the
National
Fire
Protection
Association,
Batterymarch
Park,
Qul
ncy,
MA
02269.
11.
CGA
Pamphlet
P-i,
SAFE
HANDLING
OF
COM
PRESSED
GASES
IN
CYLINDERS
obtainable
fromthe
Compressed
Gas
Association,
1235
Jeffer
son
Davis
Highway,
Suite
501,
Arlington,
VA
22202.
12.
CSA
Standard
W117.2,
CODE
FOR
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from
the
Ca
nadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1R3.
13.
NWSA
booklet,
WELDING
SAFETY
BIBLIOGRA
PHY
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
PREPARATION
FOR
WELDING
AND
CUTTING
OF
CONTAINERS
AND
PIPING
THAT
HAVE
HELD
HAZARDOUS
SUBSTANCES,
obtainable
from
the
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126.
15.
ANSI
Standard
Z88.2,
PRACTICE
FOR
RESPIRA
TORY
PROTECTION,
obtainable
from
the
Ameri
can
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
SECTION
2-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
2-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
and
on
various
la
bels,
tags,
and
plates
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
equipment.
B
.
Safety
The
installation,
operation,
maintenance,
and
trouble
shooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be in
stalled,
operated,
and
maintained
only
by
qualified
per
sons
in
accordance
with
this
manual
and
all
applicable
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
Safety
Rules
For
Operation
Of
Arc
Weld
ing
Power
Source.
2-2.
SAFETY
ALERT
SYMBOL
AND
SIGNAL
WORDS
The
following
safety
alert
symbol
and
signal
words
are
used
throughout
this
manual
to
call
attention
to
and iden
tify
different
levels
of
hazard
and
special
instructions.
4~
This
safety
alert
symbol
is
used
with
the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
a
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
sen
ous
personal
injury
or
loss
of
life.
a
CAUTION
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
statements
identify
special
instructions
necessary
for
the
most
efficient
operation
of
this
equip
ment.
OM-1578
Page
6
SECTION
3-
SPECIFICATIONS
Table
3-1.
SpecIfications
Component
Dimensions
Weight
Height
Width
Depth
Net
Ship
Weld
Control
17-1/2
in.
(445
mm)
14
in.
(355
mm)
8in.
(203
mm)
32-1/2
lbs.
(14.7
kg)
Total
80
Ibs.*
(36
kg)
Gas/Current
Sensing
Control
4-1/2
in.
(108
mm)
5-1/2
in.
(140
mm)
10-1/2
in.
(267
mm)
4-1/2
lbs.
(2.0
kg)
Spool
Support
Assembly
13-31/2
in.
(343
mm)
8-3/4
in.
(222
mm)
8-1/2
in.
(216
mm)
6
lbs.
(2.7
kg)
Add
1
in.
(25
mm)
for
control
knobs.
+Spool
Support
without
optional
wire
reel.
*
Includes
weight
of
wire
drive
assembly.
Al
D-2
Al
D-4
50-780
ipm
(1.8-19.8
mpm)
.023-3/32
in.
wire
Wire
Feed
Speed
Range
(0.6-2.4
mm
wire)
Al
D-2L
Al
D-4L
.
15-200
ipm
(0.4-5.1
mpm)
5/64-5/32
in.
wire
(2.0-4.0
mm
wire)
Weld
Voltage
And
Amperage
Capacity
.
Limited
by welding
power
source.
3-1.
DESCRIPTION
This
weld
control
is
designed
to
automatically
cycle
welding
events
while
maintaining
constant
wire
feed
speed.
This
unit
is
to
be
used
with
a
DC
constant
voltage
(CV)
welding
power
source
having
remote
contactor
and
voltage
control
capabilities
for
Gas
Metal
Arc
Welding
(GMAW)
or
Submerged
Arc
Welding
(SAW).
The
standard
weld
control
has
provisions
to
set
weld
parameters
according
to
Table
3-2.
Spot
weld
controls
are
also
standard.
Normally-open
and
normally-closed
relay
contacts
that
work
in
conjunction
with
the
weld
cycle
are
available
to
interface
with
other
equipment
(such
as
fixtures).
Optional
controls
include
run
in
voltage
and
time,
and
water
valve.
Table
3-2.
Weld
Parameters
Weld
Cycle
Controls
Wire
Speed
Voltage.
Time
Pref
low
X
Run-In
X
Weld
X
X
Crater
(Jog)
X
X
X
Burnback
X
Postf
low
X
X
=
Standard
Optional
For
information
on
the
wire
drive
assembly,
see
Owners
Manual
supplied
with
the
wire
drive
assembly.
A
gas/current
sensing
control,
wire
spool
hub,
and
spindle
support
are
provided
with
the
weld
control.
The
wire
reel
is
optional.
OM-1578
Page
7
Overall
Dimensions
And
Mounting
Hole
Layout
Inches
Millimeters
A
21-7/8
556
B
13-3/4
349
C
3
76
D
2-1/2
63.5
E
3-1/2
88.9
F
4-1/2
114
G
10-11/16
275
Figure
3-1.
DImensional
Views
19-080
486-C
TA-080
485-A
*Add
1
in.
(25
mm)
for
front
panel
controls.
TC-070
484-E
AUTOMATIC
IDA
Weld
Control
Gas/Current
Sensing
Control
TA-080
429
OM-1578
Page
8
SECTION
4-INSTALLATION
4-1.
SITE
SELECTION
(Figure
3-1
And
Figure
4-1)
Select
an
installation
site
which
provides
the
following:
1.
Correct
input
power
supply
(see
unit
nameplate)
2.
Shielding
gas
supply
(if
applicable)
3.
Water
supply
(if
applicable)
4.
Adequate
ventilation
and
fresh
air
supply
5.
No
flammables
6.
A
clean
and
dry
area
7.
Proper
temperature
that
avoids
extremes
of
heat
or
cold
8.
Proper
airflow
around
unit
9.
Adequate
space
to
open
and
remove
cover
and
wrapper
for
installation,
maintenance,
and
repair
functions.
Mounting
holes
provide
the
capability
to
install
and
se
cure
the
system
components
in
a
permanent
location.
Figure
3-1
gives
overall
dimensions
and
mounting
hole
layout.
4-2.
EQUIPMENT
INSTALLATION
A.
Supplied
Equipment
The
following
equipment
is
supplied
as
standard
and
re
quires
installation
or
assembly:
1.
Weld
Control
2.
Gas/Current
Sensing
Control
3.
Hub
and
Spindle
Assembly
4.
Spindle
Support
5.
10
ft.
(3
m)
Weld
Control
Gas/Current
Sensing
Control
Interconnecting
Cord
~
,Weld
Control
Control
fl
I
~
L_J_~~~
1
J:1~..-wire
Drive
L
i
~j
Assembly
~
r
LI1
Welding
Ir~
Power
Source
I
Typical
Side
Beam
ApplicatIon
I
6.
25
ft.
(8
m)
Weld
Control
Welding
Power
Source
Interconnecting
Cord
7.
5ft.(1.5
m)
Motor
Cord
8.
25
ft.
(8
m)
Voltage
Sensing
Cord
9.
lOft.(3m)GasHose
B.
EquIpment
Location
(FIgure
4-1)
When
deciding
on
equipment
location,
consider
the fol
lowing:
1.
The
equipment
must
be
mounted
to
a
structure
ca
pable
of
supporting
the
weight
of
the
equipment.
2.
The
lead
lengths
of
the
cords
supplied
with
the
equipment
will
limit
the
area
in
which
the
equipment
can
be
located.
Some
cords
can
be
extended
by
us
ing
optional
extension
cords
(check
with
welding
equipment
distributor).
3.
The
interconnecting
cords
must
be
routed
so
that
they
are
not
caught,
pinched,
or
strained
during
welding
operations.
4.
One
weld
output
cable
must
be
routed
to
the
Gas/
Current
Sensing
control.
5.
Welding
wire
must
be
routed
so
that
it
does
not
con
tact
the
weld
control
or
any
other
grounded
equip
ment.
C.
EquIpment
InstallatIon
Obtain
appropriate
mounting
brackets
or
adapter
plates
as
necessary
and
mounting
hardware.
Prepare
struc
ture
for
equipment
installation.
Secure
weld
control,
Gas/Current
Sensing
control,
and
all
other
equipment
onto
structures
in
the
welding
area.
Weld
I
Welding
Power
Source
TC-131
138
Figure
4-1.
Equipment
Location
Diagram
OM-1578
Page
9
D.
Hub
And
Spindle
installation
To
Spindle
Sup
port
(Figure
4-2)
1.
Remove
hex
nut
from
spindle
support
shaft,
align
keyway,
and
insert
shaft
through
one
of
the
sets
of
holes
in
the
spindle
support.
Hole
selection
depends
on
wire
spool
size.
Be
sure
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
Section
4-6.
4-3.
INTERNAL
CONNECTIONS
There
are
fourtermi
nal
strips
in
the
weld
control
to
which
external
equipment
can
be
connected
or
at
which
inter
nal
reconnections
can
be
made.
The
use
of
these
termi
nal
strips
depends
on
the
welding
system
set-up
and
welding
application.
External
customer
supplied
remote
start/stop
devices
can
be
connected
to
the
weld
control.
External
customer
supplied
devices
(such
as
fixtures)
can
access
relay
contacts
that
change
state
in
conjunction
with
the
weld
cycle.
An
automatic
flux
valve
can
be
connected
to
the
weld
control
for
Submerged
Arc
Welding
(SAW).
The
op
tional
water
valve
can
be
reconnected
to
operate
simul
taneously
with
the
gas
valve.
(See
Section
4-6
for
nor
mal
operation
of
optional
water
valve.)
Determine
the
need
for
these
connections
based
on
the
welding
application,
and
proceed
as
follows:
4~
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
weld
control
and
welding
power
source,
and
disconnect
input
power
employing
lockout/ta
gging
procedures
before
inspecting
or
ins
falling.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
circuit
boards.
Put
on
properly
grounded
wrist
strap
BEFORE
working
near
circuit
boards.
Perform
work
only
at
a
static
safe
work
area.
To
access
the
terminal
strips,
open
control
panel
door.
Loosen
screws
from
cabinet
door
on
the
weld
control,
and
open
door.
Route
incoming
cables
through
strain
re
lief
provided
on
right
side
of
weld
control.
Close
and
se
cure
control
door,
and
tighten
strain
relief
when
installa
tion
is
complete.
A.
Remote
Start/Stop
Switch
Connections
(Figure
4-3)
Two
momentary-contact
push-button
switches
are
re
quired
for
remote
start/stop
control.
A
normally-open
switch
is
required
for
start
control
while
a
normally-
closed
switch
is
required
for
stop
control.
1.
Install
remote
switches
at
desired
location,
obtain
proper
length
cable,
and
make
connections
to
re
mote
switches.
3.
Connect
leads
from
normally-open
start
switch
to
1TF
(common)
and
1TH.
4.
Connect
leads
from
normally-closed
stop
switch
to
1TF
(common)
and
1TG.
B.
Remote
Start/Stop
Relay
(Maintained
Contact)
Connections
(Figure
4-3)
A
set
of
contacts
from
a
suitable
relay
can
be
used
for
start/stop
control
of
the
weld
cycle.
Closing
the
relay
contact
(energizing
the
relay)
starts
the
weld
cycle.
Opening
the
contact
stops
the
weld
event
and
crater
starts.
1.
Install
relay
at
desired
location,
obtain
proper
length
cable,
and
make
connections
to
the
normally-open
set
of
contacts.
2.
Locate
terminal
strip
1
Tin
the
weld
control,
and
re
move
jumper
link
between
1TE
and
1TF.
3.
Connect
leads
to
1TF
(common)
and
1TH.
Retaining
Ring
Wire
Retainer*
-Washer
Fiber
Was
her
*Optlonai
Washer
Figure
4-2.
Hub
And
Spindle
Installation
2.
Locate
terminal
strip
iT
in
weld
control,
and
remove
TD-045315-J
jumper
link
between
1TF
and
1TG.
OM-1578
Page
10
Welding
Start/Stop
Connections
And
Figure
4-4)
(Uses
Spot
Time
Con-
A
double-pole,
single-throw,
maintained-contact
switch
is
required
for
skip
welding.
Closing
the
switch
starts
the
spot
weld
cycle.
The
setting
of
the
pref
low
and
postf
low
timers
determines
the
skip
time
(time
between
weld
cycles).
The
spot
weld
cycle
repeats
until
the
switch
is
opened.
Double-Pole
Single-Throw
Switch
Figure
4-4.
Skip
Welding
Switch
Connections
1.
Install
switch
at
desired
location,
obtain
proper
length
cable,
and
make
connections
at
switch
(see
Figure
4-4).
2.
Locate
terminal
strips
1
T
and
2T
in
weld
control,
and
remove
jumper
link
between
1TE
and
1TF.
Motor
Speed
DIP
Switch
S50
3.
Connect
switch
common
to
1
TF.
4.
Connect
remaining
leads
to
lIE
and
2TA.
5.
Place
the
SPOT-CONTINUOUS
switch
inthe
SPOT
position
before
starting
skip
welding.
D.
Relay
Contact
Connections
For
Externai
Equip
ment
(Figure
4-3
And
Figure
4-5)
A
set
of
normally-open
and
normally-closed
contacts
are
provided
to
work
in
conjunction
with
the
weld
cycle
tim
ers.
Forexample,
if
a
fixture
needs
to
start
moving
at
arc
initiation
and
stop
when
the
STOP
switch
is
pressed,
the
normally-open
contacts
of
relay
CR51
(at
receptacle
RC4,
terminals
F
and
H)
would
be
used
to
control
fixture
movement.
Connections
can
be
made
to
the
3/16
in.
male
friction
terminals
on
timing
board
edge
connector
receptacles
RC4
and
RC1
0.
To
gain
access
to
these
receptacles,
the
timing
circuit
board
needs
to
be
removed.
1.
Remove
three
screws
securing
timer
panel.
2.
Gently
pull
timer
panel
part
way
out.
3.
Disconnect
plugs
PLG1
and
PLG2
from
the
timer
circuit
board.
4.
Remove
timer
panel
from
weld
control.
Terminal
Strip
iT
Board
PC8
Receptacle
RC1O
Receptacle
RC4
Timing
Circuit
Board
Assembly
liming
C.
Skip
(FIgure
43
tro
is)
Receptacle
RC1
Location
Figure
4-3.
Connection
Strip
Location
RC2
Location
Ret.
TC-112
519
To
Weld
Control
Terminal
Strips
2TA
1TE
1
TF
S-0280
OM-1578
Page
11
5.
Route
leads
from
external
equipment
to
desired
ter
minals
at
RC4
and
RC1O.
Leads
from
external
equipment
must
have
3/16
female
friction
terminals
to
connect
to
RC4
and
RC1
0.
6.
After
connections
are
made,
reverse
Steps
1
through
4
to
reinstall
timer
panel.
E.
Flux
Valve
Connections
(FIgure
4-3)
Connect
leads
from
flux
valve
to
terminals
1
TC
and
?TD
in
the
weld
control
(polarity
is
not
important).
The
flux
valve
energizes
when
the
weld
control
START
switch
is
pressed
and
deenergizes
at
the
end
of
post-
flow.
F.
Reconnecting
Water
Valve
Power
(Figure
4-3)
If
coolant
flow
is
desired
only
in
conjunction
with
shield
ing
gas
flow,
reconnect
power
to
the
water
valve
as
tot-
lows:
1.
Locate
terminal
strips
11
and
21.
2.
Locate
lead
1
from
gas/current
sensing
receptacle
RC9
at
2TB
and
disconnect
from
2TB.
3.
Reconnect
lead
1
at
1TC.
Start
Switch
Pressed
4-4.
WIRE
DRIVE
MOTOR
SPEED
CALIBRATION
SELECTION
(Figure
4-3)
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
weld
control
and
welding
power
source,
and
disconnect
input
power
employing
locko
ut/tagging
procedures
before
inspecting
or
installing.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
a
CAUTION:
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
circuit
boards.
Put
on
properly
grounded
wrist
strap
BEFORE
handling
circuit
boards.
Perform
work
only
at
a
static-safe
work
area.
The
weld
control
is
shipped
for
use
with
a
standard
speed
wire
drive
motor
(16.79:1
gear
ratio).
If
a
low
speed
motor
(65.5:1
gear
ratio)
is
used,
it
is
necessary
to
change
the
DIP
switch
position
on
the
Low
Speed
Cali
bration
board
PC8.
To
check
or
change
switch
position,
proceed
as
follows:
Weld
lime
Or
Spot
Time
0-Infinity
0-2.5
Sec.
Crater
lime
0-2.5
SeC
Burn
back
Time
.
0-0.25
Sec.
0.
~~R5Q~
tCR5~
~R5~
CR54
~R%
1CR5~
B
T0
LE
F
IH
~G
vM
TL
LK
p
yR
x
Iw
~v
CCTBB
LM
RCIO
Fixture
(Example
explained
in
Section
4-3D.)
I,
(
I
CR56
CR55*
CR54*
CR5O*
CR51*
CR52
i

-
I
I
II
J
;
II
.
F
H
i~
Run
in
lime
Run
In
Speed
PrefluxOr
I-
Pref
low
Tim
0-5
Sec.
I
11
lime
Switch
Pressed
*The
dotted
line
condition
indIcates
the
time
during
the
weld
cycle
that
the
control
relay
is
deenergized.
The
solid
line
condition
Indicates
the
time
during
the
weld
cycle
that
the
control
relay
Is
energized.
Ref.
S.0271
FIgure
4-5.
Weld
Control
Cycle
OM-1578
Page
12
1.
Loosen
screw
securing
door
on
upper
panel
of
the
weld
control,
and
open
door.
2.
Locate
switch
S50
on
PC8.
See
Figure
4-3
for
circuit
board
location.
3.
Place
S50
in
position
1
for
low
speed
motor
applica
tions.
4.
Close
and
secure
weld
control
door.
If
the
switch
is
in
the
wrong
position,
the
INCHES
PER
MINUTE
meter
display
is
not
accurate.
4-5.
WELD
CONTROL
INTERCONNECTIONS
(FIgure
4-6
and
FIgure
4-8)
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
weld
control
and
welding
power
source,
and
disconnect
input
power
employing
locko
uttagging
procedures
before
inspecting
or
installing.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
This
unit
is
supplied
with
the
necessary
interconnecting
cords.
Examine
and
select
the
proper
cord
for
each
of
the
following
connections.
A.
Drive
Motor
Connections
The
5
ft
(1.5
m)
motor
cord
has
a
14-pin
plug
and
14-socket
free-hanging
receptacle.
The
14-pin
plug
con
nects
to
the
weld
control.
The
14-socket
receptacle
con
nects
to
the
cord
coming
from
the
wire
drive
motor.
To
make
connections,
align
keyways,
insert
plugs
into
re
ceptacles,
and
rotate
threaded
collars
fully
clockwise.
B.
Gas/Current
SensIng
Control
Connections
The
10
ft.
(3
m)
interconnecting
cord
has
a
14-pin
plug
and
16-socket
plug.
The
14-pin
plug
connects
to
the
weld
control.
The
16-socket
plug
connects
to
the
Gas/
Current
Sensing
control.
To
make
connections,
align
keyways,
insert
plugs
into
receptacles,
and
rotate
threaded
collars
fully
clockwise.
C.
Voltage
Sensing
Connection
Connect
the
4-socket
plug
from
the
voltage
sensing
cord
to
the
matching
receptacle
on
the
weld
control
as
fol
lows:
align
keyway,
insert
plug
into
receptacle,
and
ro
tate
threaded
collar
fully
clockwise.
Connect
the
voltage
sensing
lead
with
ring
terminal
to
the
wire
drive
assembly
weld
cable
terminal.
See
wire
drive
assembly
Owners
Manual
for
terminal
location.
Connect
the
voltage
sensing
lead
with
clamp
to
the
workpiece.
Be
sure
the
clamp
is
connected
to
bare,
dry
metal.
D.
ElectrIcal
Input/Contactor
ControlNoltage
Con
trol
Connections
The
25
ft.
(8
m)
interconnecting
cord
has
14-socket
and
14-pin
plugs.
The
14-socket
plug
connects
to
the
weld
control.
The
14-pin
plug
connects
to
the
welding
power
source.
To
make
connections,
align
keyway,
insert
plugs
into
receptacles,
and
rotate
threaded
collars
fully
clock
wise.
Be
sure
remote
contactor
and
voltage
control
switches
on
the
welding
power
source
are
in
the
correct
position
to
allow
use
of
a
remote
control
device.
FIgure
4-6.
Cord
Connections
IMPORTANT:
If
the
supplied
electrical
input/contactor
control/voltage
control
cord
does
not
match
the
welding
power
source
remote
control
receptacle,
obtain
the
nec
essary
adapter
cord from
your
welding
equipment
dis
tributor.
The
following
socket
information
is
included
in
case
the
supplied
cord
is
not
suitable,
and
it
is
necessary
to
wire
a
plug
or
cord
to
interface
with
the
welding
power
source
REMOTE
14
receptacle.
Socket
C:
+10
volts
dc
with
respect
to
Socket
D
re
quired
from
external
source.
Socket
D:
Control
circuit
common
for
remote
control
device
from
external
source.
Socket
E:
Output
Signal;
0
volts
equals
machine
mini
mum;
+10
volts
equals
machine
maximum.
Socket
G:
115
volts
ac
circuit
common.
Socket
I:
Requires
115
volts
ac,
60
Hz,
with
respect
to
socket
G
(circuit
common).
Socket
J:
A
contact
closure
from
socket
Ito
socket
J
completes
the
115
volt
circuit
to
the
welding
power
source.
Socket
K:
Chassis
ground.
IMPORTANT:
The
remaining
sockets
in
the
receptacle
are
not
used.
Voltage
SensIng
Receptacle
~bIe
Clamp
~WIre
Drive
Sensing
Control
Receptacle
Electrical
lnput/
Contactor
Controi/
Voltage
Control
Receptacle
TC-070
484-E
OM-1578
Page
13
4-6.
GAS/CURRENT
SENSING
CONTROL
INTER
CONNECTIONS
(FIgure
4-6)
A.
Weld
Output
Connections
a
WARNING:
ELECTRIC
SHOCK
can
kIll.
Do
not
touch
live
electrical
parts.
Shut
down
weld
control
and
welding
power
source,
and
disconnect
input
power
employing
locko
ut/tagging
procedures
before
inspecting
or
installing.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tag9ing
circuit
breaker
or
other
disconnect
ing
device.
Select
and
prepare
proper
size
and
length
weld
cables
according
to
the
welding
power
source
Owners
Manual.
Remove
cover
from
Gas/Current
Sensing
control.
1.
Electrode
Positive/Reverse
Polarity
Connections
a.
Connectaweldcabletothepositiveweld
output
terminal
on
the
welding
power
source.
b.
Route
cable
through
weld
cable
opening
on
gas/current
sensing
control
IN
panel,
and
through
reed
relay.
c.
Connect end
of
cable
coming
from
Gas/Current
Sensing
control
to
weld
cable
terminal
on
wire
drive
assembly.
See
wire
drive
assembly
Own
ers
Manual
for
terminal
location.
d.
Connect
a
weld
cable
from
the
negative
weld
output
terminal
on
the
welding
power
source
to
the
workpiece.
e.
Reinstall
and
secure
Gas/Current
Sensing
con
trol
cover.
2.
Electrode
Negative/Straight
Polarity
Connections
Follow
directions
for
Electrode
Positive/Reverse
Polarity
with
the
following
exceptions:
a.
Route
weld
cable
from
welding
power
source
negative
weld
output
terminal
through
Gas/
Current
Sensing
control
to
wire
drive
assembly.
b.
Connect
weld
cable
from
welding
power
source
positive
weld
output
terminal
to
workpiece.
B.
Shielding
Gas
Connections
The
shielding
gas
fittings
at
the
Gas/Current
Sensing
control
have
5/8-18
right-hand
threads.
IMPORTANT:
The
gas
flow
must
be
accurately
con
trolled
by
a
regulator/flowmeter
at
the
source.
1.
Select
and
obtain
shielding
gas
hose
of
suitable
length
and
type
for
connection
between
the
shield
ing
gas
source
and
the
Gas/Current
Sensing
con
trol.
TA-080
484-B
Figure
4-7.
Gas/Current
Sensing
Control
2.
Connect
gas
hose
from
source
to
gas
fitting
on
IN
panel
of
Gas/Current
Sensing
control.
3.
Connect
supplied
10
ft.
(3
m)
gas
hose
to
remaining
fitting
on
gas/current
sensing
control.
Push
remain
ing
end
of
hose
onto
barbed
fitting
on
wire
drive
as
sembly.
See
wire
drive
assembly
Owners
Manual
for
location
of
barbed
fitting.
Shielding
gas
flow
is
controlled
by
the
pref
low
and
post-
flow
timers
in
the
weld
control.
C.
OptIonal
Water
Connections
4~
CAUTION:
OVERHEATING
Gas
Metal
Arc
Welding
(GMAW)
gun
can
damage
gun.
Do
not
use
water
connections
on
the
Gas!
Current
Sensing
control
if
a
recirculating
coolant
system
is
used.
If
using
a
water-cooled
gun
and
recirculating
coolant
system,
make
connections
from
gun
directly
to
recirculating
coolant
system.
The
water
fittings
at
the
Gas/Current
Sensing
control
have
5/8-18
left-hand
threads.
1.
Select
and
obtain
water
hose
of
suitable
length
and
type
for
connection
between
the
water
supply
and
Gas/Current
Sensing
control.
2.
Connect
water
hose
from
source
to
water
fitting
on
IN
panel
of
Gas/Current
Sensing
control.
3.
Connect
water
in
fitting
from
welding
gun
hose
to
re
maining
fitting
on
Gas/Current
Sensing
control.
4.
Route
hose
from
gun
water
out
fitting
to
a
proper
drain.
Water
flows
as
soon
as
the
weld
control
POWER
switch
is
placed
in
the
ON
position.
Check
system
for
proper
water
flow
before
welding.
OM-1578
Page
14
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Miller AUTOMATIC 1DA Owner's manual

Miller
Brand
Miller
Model
AUTOMATIC 1DA
Category
Welding System
Type
Owner's manual
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