Miller SYSTEM 9 Owner's manual

January

1983

FORM:

OM-1

537;

Effective

With

Serial

No.

JC658847

MODEL

SYSTEM

9

~

~1

/C

r

~

~

I

~O

i~k

OWNERS

MANUAL

fullER

MILLER

ELECTRIC

MFG.

CO.

718

S.

BOUNDS

ST,

P.O.

Box

1079

APPLETON.

WI

54912

USA

ADDITiONAL

COPY

PRICE

$1.55

NWSA

CODE

NO.

4579

PRINTED

IN

U.S.A.

Ot

LIMITED

WARRANTY

EFFECTIVE:

JUNE

1,

1979

This

warranty

supersedes

all

warranties

and

is

ex

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

submitted

by

the

original

user

within

the

foregoing

periods.

to

its

Distributor/Dealer

that

all

new

and

unused

Equipment

(

furnished

by

Miller

is

free

from

defect

in

workmanship

and

In

the

case

of

Millers

breach

of

warranty

or

any

other

duty

material

as

of

the

time

and

place

of

delivery

by

Miller.

No

war-

with

respect

to

the

quality

of

any

goods,

the

exclusive

remedies

ranty

is

made

by

Miller

with

respect

to

engines,

trade

ac-

therefore

shall

be,

at

Millers

option

Ii)

repair

or

12)

replacement

cessories

or

othef

items

manufactured

by

others.

Such

or,

where

authorized

in

writing

by

Miller

in

appropriate

cases,

(31

engines,

tradeaccessories

and

other

items

are

sold

sublect

to

the

reasonable

cost

of

repair

or

replacement

at

an

authorized

the

warranties

of

their

respective

manufacturers,

if

any

.

All

Miller

service

station

or

141

payment

of

or

credit

for

the

purchase

engines

are

warranted

by

their

manufacturer

for

one

year

from

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

date

of

original

purchase.

return

of

the

goods

at

Customers

risk

and

expense.

Upon

receipt

of

notice

of

apparent

defect

or

failure,

Miller

shall

instruct

the

clai-

Except

as

specified

below,

Millers

warranty

does

not

apply

mant

on

the

warranty

claim

procedures

to

be

followed.

to

components

having

normal

useful

life

of

less

than

one

Ill

year,

such

as

spot

welder

tips,

relay

and

contactor

points,

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

MILLERMATIC

parts

that

come

in

contact

with

the

welding

ANY

IMPLIED

WARRANTY,

GUARANTY

OR

REPRESENTA-

?

wire

including

nozzles

and

nozzle

insulators

where

failure

does

TION

AS

TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

not

result

from

defect

in

workmanship

or

material.

BREACH

OF

CONTRACT

WHICH,

BUT

FOR

THIS

PROVISION,

k~

MIGHT

ARISE

BY

IMPLICATION,

OPERATION

OF

LAW,

Miller

shall

be

required

to

honor

warranty

claims

on

war-

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

INCLUDING

ranted

Equipment

in

the

event

of

failure

resulting

from

a

defect

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

OF

within

the

following

periods

from

the

date

of

delivery

of

Equip-

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

TO

t

ment

to

the

original

user:

ANY

AND

ALL

EQUIPMENT

FURNISHED

BY

MILLER

IS

EX

CLUDED

AND

DISCLAIMED

BY

MILLER.

1.

Arc

welders,

power

sources

and

components

.

1

year

2.

Original

main

power

rectifiers

3

years

EXCEPT

AS

EXPRESSLY

PROVIDED

BY

MILLER

IN

(labor

-

1

year

onlyl

WRITING,

MILLER

PRODUCTS

ARE

INTENDED

FOR

3.

All

welding

guns

and

feeder/guns

90

days

ULTIMATE

PURCHASE

BY

COMMERCIAL/INDUSTRIAL

r

4.

All

other

Millermatic

Feeders

1

year

USERS

AND

FOR

OPERATION

BY

PERSONS

TRAINED

AND

5.

Replacement

or

repair

parts,

exclusive

of

labor

.

60

days

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

6.

Batteries

6months

WELDING

EQUIPMENT

AND

NOT

FOR

CONSUMERS

OR

CONSUMER

USE.

MILLER

WARRANTIES

DO

NOT

EXTEND

provided

that

Miller

is

notified

in

writing

within

thirty

130)

days

TO,

AND

NO

RESELLER

IS

AUTHORIZED

TO

EXTEND

of

the

date

of

such

failure

MILLERS

WARRANTIES

TO,

ANY

CONSUMER.

~

~.

~

.,~

~

~,

~

.

~,

~r

August11,

1983

FORM:

OM-1537A

ERRATA

SHEET

After

this

manu~

was

printed,

refinements

in

equipment

design

occurred.

This

sheet

lists

exceptions

to

data

appearing

later

in

this

manual.

AMENDMENT

TO

SECTION

3

-

INSTALLATION

Add

the

following

IMPORTANT

at

beginning

of

entire

Section:

iMPORTANT

If

an

optional

motorized

slide

is

to

be

used

with

this

unit,

install

and

connect

slide

as

instructed

in

FIILE

COPY

RETURN

TO

FOLDER

Part

No.

Description

Quantity

084

170

RELAY,

24

volts

dc

DPDT

pickup

18

volts

dc

(description

chg)

1

088

638

CIRCUIT

CARD,

display

(Eff

w/JD668503)

1

074

127

POTENTIOMETER,

carbon

1

turn

2

watt

10K

ohm

1

079

737

RECEPTACLE

W/

PINS

(consisting

of)

1

TERMINAL,

male

9

RESISTOR,

carbon

film

0.25

watt

27K

ohm

1

RESISTOR,

carbon

film

0.25

watt

2200

ohm

4

CORD,

motor

(consisting

of)

1

HOUSING

PLUG

&

PINS

(consisting

of)

1

TERMINAL,

male

14

CORD,

No.

166/c

(order

byft)

lOft

CLAMP,

cable

1

RECEPTACLE,

w/sockets

(consisting

of)

1

TERMINAL,

female

14

Owners

Manual

1096.

AMENDMENT

TO

SECTION

7

-

MAINTENANCE

&

TROUBLESHOOTING

Dia.

Replaced

**

Mkgs.

With

5-11

CR1

084

170

16-4

PC2

091

752

16-10

R4

073 562

17-

RC53

090 246

079 535

17-

R50

039332

039334

17-

R55-63

039 330

035

888

t071

006

047

636

079

535

073

139

079

739

071

892

079

534

**First

digit

represents

page

no.

-

digits

following

dash

represents

item

no.

tOptional

Parts

(Part

of

MHA-2).

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

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Serial

No.

JD668503

TABLE

OF

CONTENTS

Section

No.

Page

No.

SECTION

1

-

SAFETY

RULES

FOR

OPERATION

OF

ARC

WELDING

POWER

SOURCE

1

-

1.

Introduction

1

-

2.

General

Precautions

1

-3.

Arc

Welding

4

1

-

4.

Standards

Booklet

Index

5

SECTION

2

-

INTRODUCTION

2

-

1.

General

Information

And

Safety

7

2

-

2.

Receiving-Handling

7

2

-

3.

Description

7

SECTION

3

-

INSTALLATION

3-1.

Location

7

3

-

2.

Shielding

Gas

Connections

8

3

-

3.

Water

Connections

8

3

-

4.

Limit

Switch

Connections

8

3

-5.

Auxiliary

Output

Connections

10

3

-

6.

Weld

Contro.l

Interconnections

10

3

-

7.

Field

Installation

of

MHA-2

11

SECTION

4

-

DEFINITIONS

OF

PROGRAM

TERMS

4

-

1.

Program

Definitions

13

4

-

2.

Alpha

Numeric

Display

Definitions

14

SECTION

5

-

OPERATOR

CONTROLS

5

-

1.

Power

Emergency

Stop

Button

15

5-2.

Run/SetUpSwitch

15

5

-

3.

Jogging

Controls

16

5

-4.

Auxiliary

Output

Indicators

16

5

-

5.

Alpha-Numeric

Display

16

5

-

6.

Weld

Program

Indicators

16

5

-

7.

Voltage

Reset

Button

17

5

-

8.

Purge

Push

Button

17

5

-

9.

Program

Select

Push

Button

17

5-10.

ProgramRunPushButton

17

5-11.

Sequence

Advance

Push

Button

18

5-12.

Halt/ResumePush

Button

18

SECTION

6

-

PROGRAMMING

6

-

1.

Mini-Cassette

Tape

Operation

18

6

-2.

Programming

Module

Operation

19

6

-

3.

Programming

Examples

20

6

-

4.

Running

A

Program

21

SECTION

7

-

MAINTENANCE

&

TROUBLESHOOTING

7

-

1.

Running

The

Diagnostic

Program

32

7

-

2.

Inspection

And

Upkeep

32

7

-

3.

Memory

Batteries

32

7

-

4.

Troubleshooting

32

SECTION

1

-

SAFETY

RULES

FOR

OPERATION

OF

ARC

WELDING

POWER

SOURCE

1-1.

INTRODUCTION

-

We

learn

by

experience.

Learning

safety

through

personal

experience,

like

a

child

touching

a

hot

stove

is

harmful,

wasteful,

and

un

wise.

Let

the

experience

of

others

teach

you.

Safe

practices

developed

from

experience

in

the

use

of

welding

and

cutting

are

described

in

this

manual.

Research,

development,

and

field

experience

have

evolved

reliable

equipment

and

safe

installation,

opera-

tion,

and

servicing

practices.

Accidents

occur

when

equipment

is

improperly

used

or

maintained.

The

reason

for

the

safe

practices

may

not

always

be

given.

Some

are

based

on

common

sense,

others

may

require

technical

volumes

to

explain,

It

is

wiser

to

follow

the

rules.

Read

and

understand

these

safe

practices

before

at

tempting

to

install,

operate,

or

service

the

equipment.

Comply

with

these

procedures

as

applicable

to

the

par

ticular

equipment

used

and

their

instruction

manuals,

for

personal

safety

and

for

the

safety

of

others.

Failure

to

observe

these

safe

practices

may

cause

serious

injury

or

death.

When

safety

becomes

a

habit,

the

equipment

can

be

used

with

confidence.

These

safe

practices

are

divided

into

two

Sections:

1

-

General

Precautions,

common

to

arc

welding

and

cutting;

and

2

-

Arc

Welding

(and

Cutting)

(only).

Reference

standards:

Published

Standards

on

safety

are

also

available

for

additional

and

more

complete

pro

cedures

than

those

given

in

this

manual.

They

are

listed

in

the

Standards

Index

in

this

manual.

ANSI

Z49.1

is

the

most

complete.

The

National

Electrical

Code,

Occupational

Safety

and

Health

Administration,

local

industrial

codes,

and

local

inspection

requirements

also

provide

a

basis

for

equip

ment

installation,

use,

and

service.

1-2.

GENERAL

PRECAUTIONS

Different

arc

welding

processes,

electrode

alloys,

and

fluxes

can

produce

different

fumes,

gases,

and

radiation

levels.

%n

addition

to

the

information

in

this

manual,

be

sure

to

consult

flux

and

elec

trode

manufacturers

for

specific

technical

data

and

precautionary

measures

concerning

their

material.

A.

Burn

Prevention

Wear

protective

clothing

-

gauntlet

gloves

designed

for

use

in

welding,

hat,

and

high

safety-toe

shoes.

Button

shirt

collar

and

pocket

flaps,

and

wear

cuffless

trousers

to

avoid

entry

of

sparks

and

slag.

Wear

helmet

with

safety

goggles

or

glasses

with

side

shields

underneath,

appropriate

filter

lenses

or

plates

(protected

by

clear

cover

glass).

This

is

a

MUST

for

welding

or

cutting,

(and

chipping)

to

protect

the

eyes

from

radiant

energy

and

flying

metal.

Replace

cover

glass

when

broken,

pitted,

or

spattered.

See

1-3A.2.

Avoid

oily

or

greasy

clothing.

A

spark

may

ignite

them.

Hot

metal

such

as

electrode

stubs

and

workpieces

should

never

be

handled

without

gloves.

Medical

first

aid

and

eye

treatment.

First

aid

facilities

and

a

qualified

first

aid

person

should

be

available

for

each

shift

unless

medical

facilities

are

close

by

for

im

mediate

treatment

of

flash

burns

of

the

eyes

and

skin

burns.

Ear

plugs

should

be

worn

when

working

on

overhead

or

in

a

confined

space.

A

hard

hat

should

be

worn

when

others

work

overhead.

Flammable

hair

preparations

should

not

be

used

by

per

sons

intending

to

weld

or

cut.

B.

Toxic

Fume

Prevention

Severe

discomfort,

illness

or

death

can

result

from

fumes,

vapors,

heat,

or

oxygen

enrichment

or

depletion

that

welding

(or

cutting)

may

produce.

Prevent

them

with

adequate

ventilation

as

described

in

ANSI Stan

dard

Z49.1

listed

1

in

Standards

index.

NEVER

ventilate

with

oxygen.

Lead

-,

cadmium

-,

zinc

-,

mercury

-,

and

beryllium

-

bearing

and

similar

materials,

when

welded

(or

cut)

may

produce

harmful

concentrations

of

toxic

fumes.

Ade

quate

local

exhaust

ventilation

must

be

used,

or

each

person

in

the

area

as

well

as

the

operator

must

wear

an

air-supplied

respirator.

For

beryllium,

both

must

be

us

ed.

Metals

coated

with

or

containing

materials

that

emit

toxic

fumes

should

not

be

heated

unless

coating

is

removed

from

the

work

surface,

the

area

is

well

ven

tilated,

or

the

operator

wears

an

air-supplied

respirator.

Work

in

a

confined

space

only

while

it

is

being

ven

tilated

and,

if

necessary,

while

wearing

an

air-supplied

respirator.

Gas

leaks

in

a

confined

space

should

be

avoided.

Leaked

gas

in

large

quantities

can

change

oxygen

con

centration

dangerously.

Do

not

bring

gas

cylinders

into

a

confined

space.

Leaving

confined

space,

shut

OFF

gas

supply

at

source

to

prevent

possible

accumulation

of

gases

in

the

space

if

downstream

valves

have

been

accidently

opened

or

left

open.

Check

to

be

sure

that

the

space

is

safe

before

re-entering

it.

Vapors

from

chlorinated

solvents

can

be

decomposed

by

the

heat

of

the

arc

(or

flame)

to

form

PHOSGENE,

a

OM-1537

Page

1

highly

toxic

gas,

and

other

lung

and

eye

irritating

pro

ducts.

The

ultraviolet

(radiant)

energy

of

the

arc

can

also

decompose

trichloroethylene

and

per

chioroethylene

vapors

to

form

phosgene.

DO

NOT

WELD

or

cut

where

solvent

vapors

can

be

drawn

into

the

welding

or

cutting

atmosphere

or

where

the

radiant

energy

can

penetrate

to

atmospheres

containing

even

minute

amounts

of

trichloroethylene

or

per

chloroethylene.

C.

Fire

and

Explosion

Prevention

Causes

of

fire

and

explosion

are:

combustibles

reached

by

the

arc,

flame,

flying

sparks,

hot

slag

or

heated

material;

misuse

of

compressed

gases

and

cylinders;

and

short

Circuits.

BE

AWARE

THAT

flying

sparks

or

falling

slag

can

pass

through

cracks,

along

pipes,

through

windows

or

doors,

and

through

wall

or

floor

openings,

out

of

sight

of

the

goggled

operator.

Sparks

and

slag

can

fly

35

feet.

To

prevent

fires

and

explosion:

Keep

equipment

clean

and

operable,

free of

oil,

grease,

and

(in

electrical

parts)

of

metallic

particles

that

can

cause

short

circuits.

If

combustibles

are

in

area,

do

NOT

weld

or

cut.

Move

the

work

if

practicable,

to

an

area

free

of

combustibles.

Avoid

paint

spray

rooms,

dip

tanks,

storage

areas,

yen

tilators.

If

the

work

cannot

be

moved,

move

com

bustibles

at

least

35

feet

away

out

of

reach

of

sparks

and

heat;

or

protect

against

ignition

with

suitable

and

snug-fitting,

fire-resistant

covers

or

shields.

Walls

touching

combustibles

on

opposite

sides

should

not

be

welded

on

(or

cut).

Walls,

ceilings,

and

floor

near

work

should

be

protected

by

heat-resistant

covers

or

shields.

Fire

watcher

must

be

standing

by

with

suitable

fire

ex

tinguishing

equipment

during

and

for

some

time

after

welding

or

cutting

if:

a.

appreciable

combustibles

(including

building

construction)

are

within

35

feet

b.

appreciable

combustibles

are

further

than

35

feet

but

can

be

ignited

by

sparks

c.

openings

(concealed

or

visible)

in

floors

or

walls

within

35

feet

may

expose

com

bustibles

to

sparks

d.

combustibles

adjacent

to

walls,

ceilings,

roofs,

or

metal

partitions

can

be

ignited

by

radiant

orconducted

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

3

in

Standards

index.

This

includes:

a

thorough

steam

or

caustic

cleaning

(or

a

solvent

or

water

washing,

depending

on

the

com

bustibles

solubility)

followed

by

purging

and

inerting

with

nitrogen

or

carbon

dioxide,

and

using

protective

equipment

as

recommended

in

A6.O.

Waterfilling

just

below

working

level

may

substitute

for

inerting.

A

container

with

unknown

contents

should

be

cleaned

(see

paragraph

above).

Do

NOT

depend

on

sense

of

smell

or

sight

to

determine

if

it

is

safe

to

weld

or

cut.

Hollow

castings

or

containers

must

be

vented

before

-

welding

or

cutting.

They

can

explode.

Explosive

atmospheres.

Never

weld

or

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,

PRECAUTIONS

FOR

SAFE

HANDLING

Of

COMPRESSED

GASES

IN

CYLINDERS,

listed

6

in

Standards

index.

1.

Pressure

Regulators

Regulator

relief

valve

is

designed

to

protect

only

the

regulator

from

overpressure;

it

is

not

intended

to

protect

any

downstream

equipment.

Provide

such

protection

with

one

or

more

relief

devices.

Never

connect

a

regulator

to

a

cylinder

containing

gas

other

than

that

for

which

the

regulator

was

designed.

Remove

faulty

regulator

from

service

immediately

for

repair

(first

close

cylinder

valve).

The

following

symptoms

indicate

a

faulty

regulator:

Leaks

-

if

gas

leaks

externally.

Excessive

Creep

-

if

delivery

pressure

continues

to

rise

with

downstream

valve

closed.

Faulty

Gauge

-

if

gauge

pointer

does

not

move

off

stop

when

pressurized,

nor

returns

to

stop

after

pressure

release.

Repair.

Do

NOT

attempt

repair.

Send

faulty

regulators

for

repair

to

manufacturers

designated

repair

center,

where

special

techniques

and

tools

-

are

used

by

trained

personnel.

2.

Cylinders

must

be

handled

carefully

to

prevent

leaks

and

damage

to

their

walls,

valves,

or

safety

devices:

Avoid

electrical

circuit

contact

with

cylinders

in

cluding

third

rails,

electrical

wires,

or

welding

cir

cuits.

They

can

produce

short

circuit

arcs

that

may

lead

to

a

serious

accident.

(See

1-3G.)

Page

2

Coil

excess

hose

to

prevent

kinks

and

tangles.

ICC

or

DOT

marking

must

be

on

each

cylinder.

It

is

an

assurance

of

safety

when

the

cylinder

is

properly

handled.

Identifying

gas

content.

Use

only

cylinders

with

name

of

gas

mark~d

on

them;

do

not

rely

on

color

to

identify

gas

content.

Notify

supplier

if

unmarked.

NEVER

DEFACE

or

alter

name,

number,

or

other

markings

on

a

cylinder.

It

is

illegal

and

hazardous.

Empties:

Keep

valves

closed,

replace

caps

securely;

mark

MT;

keep

them

separate

from

FULLS

and

return

promptly.

Prohibited

use.

Never

use

a

cylinder

or

its

contents

for

other

than

its

intended

use,

NEVER

as

a

support

or

roller.

Locate

or

secure

cylinders

so

they

cannot

be

knocked

over.

Passageways

and

work

areas.

Keep

cylinders

clear

of

areas

where

they

may

be

struck.

Transporting

cylinders.

With

a

crane,

use

a

secure

sup

port

such

as

a

platform

or

cradle.

Do

NOT

lift

cylinders

off

the

ground

by

their

valves

or

caps,

or

by

chains,

slings,

or

magnets.

Do

NOT

expose

cylinders

to

excessive

heat,

sparks,

slag,

and

flame,

etc.

that

may

cause

rupture.

Do

not

allow

contents

to

exceed

130F.

Cool

with

water

spray

where

such

exposure

exists.

Protect

cylinders

particularly

valves

from

bumps,

falls,

falling

objects,

and

weather.

Replace

caps

securely

when

moving

cylinders.

Stuck

valve.

Do

NOT

use

a

hammer

or

wrench

to

open

a

cylinder

valve

that

can

not

be

opened

by

hand.

Notify

your

supplier.

Mixing

gases.

Never

try

to

mix

any

gases

in

a

cylinder.

Never

refill

any

cylinder.

Cylinder

fittings

should

never

be

modified

or

exchang

ed.

Protect

hose

from

damage

by

sharp

edges,

and

by

sparks,

slag,

and

open

flame.

Examine

hose

regularly

for

leaks,

wear,

and

loose

con

nections.

Immerse

pressured

hose

in

water;

bubbles

in

dicate

leaks.

Repair

leaky

or

worn

hose

by

cutting

area

out

and

splic

ing

(1-2D3).

Do

NOT

use

tape.

4.

Proper

Connections

Clean

cylinder

valve

outlet of

impurities

that

may

clog

orifices

and

damage

seats

before

connecting

regulator.

Except

for

hydrogen,

crack

valve

momentarily,

pointing

outlet

away

from

people

and

sources

of

ignition.

Wipe

with

a

clean

lintless

cloth.

Match

regulator

to

cylinder.

Before

connecting,

check

that

the

regulator

label

and

cylinder

marking

agree,

and

that

the

regulator

inlet

and

cylinder

outlet

match.

NEVER

CONNECT

a

regulator

designed

for

a

particular

gas

or

gases

to

a

cylinder

containing

any

other

gas..

Tighten

connections.

When

assembling

threaded

con

nections,

clean

and

smooth

seats

where

necessary.

Tighten.

If

connection

leaks,

disassemble,

clean,

and

retighten

using

properly

fitting

wrench.

Adapters.

Use

a

CGA

adapter

(available

from

your

sup

plier)

between

cylinder

and

regulator,

if

one

is

required.

Use

two

wrenches

to

tighten

adapter

marked

RIGHT

and

LEFT

HAND

threads.

Regulator

outlet

(or

hose)

connections

may

be

iden

tified

by

right

hand

threads

for

oxygen

and

left

hand

threads

(with

grooved

hex

on

nut

or

shank)

for

fuel

gas.

5.

Pressurizing

Steps:

Drain

regulator

of

residual

gas

through

suitable

vent

before

opening

cylinder

(or

manifold

valve)

by

turning

adjusting

screw

in

(clockwise).

Draining

prevents

ex

cessive

compression

heat

at

high

pressure

seat

by

allowing

seat

to

open

on

pressurization.

Leave

adjusting

screw

engaged

slightly

on

single-stage

regulators.

3.

Hose

Stand

to

side

of

regulator

while

opening

cylinder

valve.

Prohibited

use.

Never

use

hose

other

than

that

designed

for

the

specified

gas.

A

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

or

dinary

wire

or

other

substitute)

as

a

binding

to

connect

hoses

to

fittings.

No

copper

tubing

splices.

Use

only

standard

brass

f

it

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.

Open

cylinder

valve

slowly

so

that

regulator

pressure

in

creases

slowly.

When

gauge

is

pressurized

(gauge

reaches

regulator

maximum)

leave

cylinder

valve

in

following

position:

For

oxygen,

and

inert

gases,

open

fully

to

seal

stem

against

possible

leak.

For

fuel

gas,

open

to

less

than

one

turn

to

permit

quick

emergency

shutoff.

Use

pressure

charts

(available

from

your

supplier)

for

safe

and

efficient,

recommended

pressure

settings

on

regulators.

Check

for

leaks

on

first

pressurization

and

regularly

there-after.

Brush

with

soap

solution

(capful

of

Ivory

OM-1537

Page

3

Liquid*

or

equivalent

per

gallon

of

water).

Bubbles

in

dicate

leak.

Clean

off

soapy

water

after

test;

dried

soap

is

combustible.

E.

User

Responsibilities

Remove

leaky

or

defective

equipment

from

service

im

mediately

for

repair.

See

User

Responsibility

statement

in

equipment

manual.

F.

Leaving

Equipment

Unattended

Close

gas

supply

at

source

and

drain

gas.

G.

Rope

Staging-Support

Rope

staging-support

should

not

be

used

for

welding

or

cutting

operation;

rope

may

burn.

1-3.

ARC

WELDING

-

Comply

with

precautions

in

1-1,

1-2,

and

this

section.

Arc

Welding,

properly

done,

is

a

safe

process,

but

a

careless

operator

invites

trouble.

The

equipment

carries

high

currents

at

significant

voltages.

The

arc

is

very

bright

and

hot.

Sparks

fly,

fumes

rise,

ultraviolet

and

infrared

energy

radiates,

weldments

are

hot,

and

compressed

gases

may

be

us

ed.

The

wise

operator

avoids

unnecessary

risks

and

pro

tects

himself

and

others

from

accidents.

Precautions

are

described

here

and

in

standards

referenced

in

index.

A.

Burn

Protection

Comply

with

precautions

in

1-2.

The

welding

arc

is

intense

and

visibly

bright.

Its

radia

tion

can

damage

eyes,

penetrate

lightweight

clothing,

reflect

from

light-colored

surfaces,

and

burn

the

skin

and

eyes.

Skin

burns resemble

acute

sunburn,

those

from

gas-shielded

arcs

are

more

severe

and

painful.

DONT

GET

BURNED;

COMPLY

WITH

PRECAU

TIONS.

1.

Protective

Clothing

Wear

long-sleeve

clothing

(particularly

for

gas-shielded

arc)

in

addition

to

gloves,

hat,

and

shoes

(1-2A).

As

necessary,

use

additional

protective

clothing

such

as

leather

jacket

or

sleeves,

flame-proof

apron,

and

fire-

resistant

leggings.

Avoid

outergarments

of

untreated

cotton.

Bare

skin

protection.

Wear

dark,

substantial

clothing.

Button

collar

to

protect

chest

and

neck

and

button

pockets

to

prevent

entry

of

sparks.

2.

Eye

and

Head

Protection

Protect

eyes

from

exposure

to

arc.

NEVER

look

at

an

electric

arc

without

protection.

Welding

helmet

or

shield

containing

a

filter

plate

shade

no.

12

or

denser

must

be

used

when

welding.

Place

over

face

before

striking

arc.

*Trademark

of

Proctor

&

Gamble.

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

separate

room

or

enclosed

bay

is

best.

In

open

areas,

surround

the

operation

with

low-reflective,

non-

combustible

screens

or

panels.

Allow

for

free

air

circula

tion,

particularly

at

floor

level.

Viewing

the

weld.

Provide

face

shields

for

all

persons

who

will

be

looking

directly

at

the

weld.

Others

working

in

area.

See

that

all

persons

are

wearing

flash

goggles.

Before

starting

to

weld,

make

sure

that

screen

flaps

or

bay

doors

are

closed.

B.

Toxic

Fume

Prevention

Comply

with

precautions

in

1-2B.

Generator

engine

exhaust

must

be

vented

to

the

outside

air.

Carbon

monoxide

can

kill.

C.

Fire

and

Explosion

Prevention

Comply

with

precautions

in

1

-2C.

Equipments

rated

capacity.

Do

not

overload

arc

welding

equipment.

It

may

overheat

cables

and

cause

a

fire.

Loose

cable

connections

may

overheat

or

flash

and

cause

a

fire.

Never

strike

an

arc

on

a

cylinder

or

other

pressure

vessel.

It

creates

a

brittle

area

that

can

cause

a

violent

rupture

or

lead

to

such

a

rupture

later

under

rough

handling.

D.

Compressed

Gas

Equipment

Comply

with

precautions

in

I

-2D.

Page

4

E.

Shock

Prevention

2.

Electrode

Holders

Exposed

hot

conductors

or

other

bare metal

in

the

welding

circuit,

or

in

ungrounded,

electrically-HOT

equipment

can

fatally

shock

a

person

whose

body

becomes

a

conductor.

DO

NOT

STAND,

SIT,

LIE,

LEAN

ON,

OR

TOUCH

a

wet

surface

when

welding,

without

suitable

protection.

To

protect

against

shock:

Keep body

and

clothing

dry.

Never

work

in

damp

area

without

adequate

insulation

against

electrical

shock.

Stay

on

a

dry

duckboard,

or

rubber

mat

when

damp

ness

or

sweat

can

not

be

avoided.

Sweat,

sea

water,

or

moisture

between

body

and

an

electrically

HOT

part

-

or

grounded

metal

-

reduces

the

body

surface

electrical

resistance,

enabling

dangerous

and

possibly

lethal

currents

to

flow

through

the

body.

1.

Grounding

the

Equipment

When

arc

welding

equipment

is

grounded

according

to

the

National

Electrical

Code,

and

the

work

is

grounded

according

to

ANSI

Z49.1

Safety

In

Welding

And

Cut

ting,

a

voltage

may

exist

between

the

electrode

and

any

conducting

object.

Examples

of

conducting

objects

include,

but

are

not

limited

to,

buildings,

electrical

tools,

work

benches,

welding

power

source

cases,

workpieces,

etc.

Never

touch

the

electrode

and

any

metal

object

unless

the

welding

power

source

is

off.

When

installing,

connect

the

frames

of

each

unit

such

as

welding

power

source,

control,

work

table,

and

water

circulator

to

the

building

ground.

Conductors

must

be

adequate

to

carry

ground

currents

safely.

Equipment

made

electrically

HOT

by

stray

current

may

shock,

possibly

fatally.

Do

NOT

GROUND

to

electrical

conduit,

or

to

a

pipe

carrying

ANY

gas

or

a

flammable

li

quid

such

as

oil

or

fuel.

Three-phase

connection.

Check

phase

requirements

of

equipment

before

installing.

If

only

3-phase

power

is

available,

connect

single-phase

equipment

to

only

two

wires

of

the

3-phase

line.

Do

NOT

connect

the

equip

ment

ground

lead

to

the

third

(live)

wire,

or

the

equip

ment

will

become

electrically

HOT

-

a

dangerous

condi

tion

that

can

shock,

possibly

fatally.

Before

welding,

check

ground

for

continuity.

Be

sure

conductors

are

touching

bare

metal

of

equipment

frames

at

connections.

If

a

line

cord

with

a

ground

lead

is

provided

with

the

equipment

for

connection

to

a

switchbox,

connect

the

ground

lead

to

the

grounded

switchbox.

If

a

three-

prong

plug

is

added

for

connection

to

a

grounded

mating

receptacle,

the

ground

lead

must

be

connected

to

the

ground

prong

only.

If

the

line

cord

comes

with

a

three-prong

plug,

connect

to

a

grounded

mating

recep

tacle.

Never

remove

the

ground

prong

from

a

plug,

or

use

a

plug

with

a

broken

off

ground

prong.

Fully

insulated

electrode

holders

should

be

used.

Do

NOT

use

holders

with

protruding

screws.

3.

Connectors

Fully

insulated

lock-type

connectors

should

be

used

to

join

welding

cable

lengths.

4.

Cables

Frequently

inspect

cables

for

wear,

cracks

and

damage.

IMMEDIATELY

REPLACE

those

with

excessively

worn

or

damaged

insulation

to

avoid

possibly

-

lethal

shock

from

bared

cable.

Cables

with

damaged

areas

may

be

taped

to

give

resistance

equivalent

to

original

cable.

Keep

cable

dry,

free

of

oil

and

grease,

and

protected

from

hot metal

and

sparks.

5.

Terminals

And

Other

Exposed

Parts

Terminals

and

other

exposed

parts

of

electrical

units

should

have

insulating

covers

secured

before

operation.

6.

Electrode

Wire

Electrode

wire

becomes

electricalty

HOT

when

the

power

switch

of

gas

metal-arc

welding

equipment

is

ON

and

welding

gun

trigger

is

pressed.

Keep

hands

and

body

clear

of

wire

and

other

HOT

parts.

7.

Safety

Devices

Safety

devices

such

as

interlocks

and

circuit

breakers

should

not

be

disconnected

or

shunted

out.

Before

installation,

inspection,

or

service,

of

equip

ment,

shut

OFF

all

power

and

remove

line

fuses

(or

lock

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

welding.

If,

in

an

emergency,

it

must

be

disconnected,

guard

against

shock

burns,

or

flash

from

switch

arcing.

Leaving

equipment

unattended.

Always

shut

OFF

and

disconnect

all

power

to

equipment.

Power

disconnect

switch

must

be

available

near

the

welding

power

source.

1-4.

STANDARDS

BOOKLET

INDEX

For

more

information,

refer

to

the

following

standards

or

their

latest

revisions

and

comply

as

applicable:

1.

ANSI

Standard

Z49.1,

SAFETY

IN

WELDING

AND

CUTTING

obtainable

from

the

American

Welding

Society,

550

Le

Jeune

Rd,

P.O.

Box

351040,

Miami,

FL

33135.

OM-1537

Page

5

2.

NIOSH,

SAFETY

AND

HEALTH

IN

ARC

WELDING

AND

GAS

WELDING

AND

CUTTING

obtainable

from

the

Superintendent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

3.

OSHA,

SAFETY

AND

HEALTH

STANDARDS,

29CFR

1910,

obtainable

from

the

U.S.

Govern

ment

Printing

Office,

Washington,

D.C.

20402.

4.

ANSI

Standard

Z87.1,

SAFE

PRACTICES

FOR

OCCUPATION

AND

EDUCATIONAL

EYE

AND

FACE

PROTECTION

obtainable

from

the

American

Nationai

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

5.

ANSI

Standard

Z41

.1,

STANDARD

FOR MENS

SAFETY-TOE

FOOTWEAR

obtainable

from

the

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

6.

ANSI

Standard

Z49.2,

FIRE

PREVENTION

IN

THE

USE

OF

CUTTING

AND

WELDING

PRO

CESSES

obtainable

from

the

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

7.

AWS

Standard

A6.0,

WELDING

AND

CUT

.TING

CONTAINERS

WHICH

HAVE

HELD

COM

BUSTIBLES

obtainable

from

the

American

Welding

Society,

550

Le

Jeune

Rd.,

P.O.

Box

351040,

Miami,

FL

33135.

8.

NFPA

Standard

51,

OXYGEN

-

FUEL

GAS

SYSTEMS

FOR

WELDING

AND

CUTTING

ob

tainable

from

the

National

Fire

Protection

Association,

470

Atlantic

Avenue,

Boston,

MA

02210.

9.

NFPA

Standard

70-1978,

NATIONAL

ELEC

TRICAL

CODE

obtainable

from

the

National

Fire

Protection

Association,

470

Atlantic

Avenue,

Boston,

MA

02210.

10.

NFPA

Standard

51

B,

CUTTING

AND

WELDING

PROCESSES

obtainable

from

the

National

Fire

Protection

Association,

470

Atlantic

Avenue,

Boston,

MA

02210.

11.

CGA

Pamphlet

P-i,

SAFE

HANDLING

OF

COM

PRESSED

GASES

IN

CYLINDERS

obtainable

from

the

Compressed

Gas

Association,

500

Fifth

Avenue,

New

York,

NY

10036.

12.

CSA

Standard

Wi

17.2,

CODE

FOR

SAFETY

IN

WELDING

AND

CUTTING

obtainable

from

the

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Boulevard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

13.

NWSA

booklet,

WELDING

SAFETY

BIBLIOGRAPHY

obtainable

from

the

National

Welding

Supply

Association,

1900

Arch

Street,

Philadelphia,

PA

19103.

14.

American

Welding

Society

Standard

AWSF4.i

Recommended

Safe

Practices

for

the

Prepara

tion

for

Welding

and

Cutting

of

Containers

and

Piping

That

Have

Held

Hazardous

Substances,

obtainable

from

the

American

Welding

Society,

550

Le

Jeune

Rd.,

P.O.

Box

351040,

Miami,

FL

33135.

15.

ANSI

Standard

Z88.2

Practice

for

Respiratory

Protection

obtainable

from

the

American

Na

tional

Standards

institute,

1430

Broadway,

New

York,

NY

10018.

Page

6

SECTION

2

-

INTRODUCTION

Wire

Feed

Speed

Open-Circuit

Voltage

Control

Input

Power

Requirements

Weight

50-800

pm

(1.3-20.3

mpm)

Depends

On

Welding

Power

Source

Open-Circuit

Voltage

115

Volts

AC

83

lbs.

4

Amperes

(37.6

kg.)

Figure

2-1.

Specifications

2

-

2.

RECEIVING-HANDLING

-

Prior

to

installing

this

equipment,

clean

all

packing

material

from

around

the

unit

and

carefuUy

inspect

for

any

damage

that

may

have

occurred

during

shipment.

Any

claims

for

loss

or

damage

that

may

have

occurred

in

transit

must

be

filed

by

the

purchaser

with

the

carrier.

A

copy

of

the

bill

of

lading

will

be

furnished

by

the

manufacturer

on

re

quest

if

occasion

to

file

claim

arises.

When

requesting

information

concerning

this

equip

ment,

it

is

essential

that

Model

Description

and

Serial

(or

Style)

Numbers

of

the

equipment

be

supplied.

2

-

3.

DESCRIPTION

-

The

System

9

programmable

weld

control

is

designed

for

use

with

a

Deltaweld

welding

power

source

to

provide

automated

Gas

Metal-

Arc

Welding

(GMAW).

The

System

9

consists

of

a

weld

control

and

gas

control

assembly.

The

programmable

weld

control

has

a

microprocessor

which

receives

and

interprets

input

commands

and

sup

plies

output

commands

necessary

for

making

the

weld.

________

The

weld

control

can

be

programmed

for

nine

weld

pro

grams,

each

of

which

contain

several

sequences.

____________

The

weld

control

will

start,

stop,

and

set

the

feed

rate

of

the

welding

wire;

start,

stop,

and

set

the

output

voltage

of

the

welding

power

source

(arc

voltage);

sequence

the

shielding

gas

and/or

water

valves;

time

each

se

quence

as

required,

and

operate

four

auxiliary

outputs

___________

that

can

turn

on

and

off

with

each

sequence

as

re

quired.

The

gas

control

assembly

contains

the

gas

(and

optional

water)

valve

which

allows

gas

flow

as

programmed

on

_____________

the

weld

control.

The

gas

control

assembly

also

con

tains

a

reed

switch

through

which

one

weld

output

cable

is

routed

to

provide

current

sensing

feedback.

SECTION

3

-

INSTALLATION



3

-

1.

LOCATION

(Figure

3-1)

-

The

location

should

Mounting

holes

have

been

provided

in

each

component

allow

room

to

open

and

remove

covers

and

wrappers

for

mounting

purposes.

Figure

3-1

gives

unit

dimen

for

installation,

maintenance

and

repair.

Lead

lengths

sions.

must

be

considered

when

locating

individual

com

ponents

of

the

system.

The

service

life

and

efficiency

of

the

system

are

reduced

when

it

is

subjected

to

high

levels

of

dust,

dirt,

moisture,

corrosive

vapors,

and

extreme

heat.

2

-

1.

GENERAL

INFORMATION

AND

SAFETY

A.

General

Information

presented

in

this

manual

and

on

various

labels,

tags,

and

plates

provided

on

the

unit

pertains

to

equipment

design,

installation,

operation,

maintenance,

and

troubleshooting

which

should

be

read,

understood,

and

followed

for

the

safe

and

effective

use

of

this

equip

ment.

B.

Safety

The

installation,

operation,

maintenance,

and

troubleshooting

of

arc

welding

equipment

requires

practices

and

procedures

which

ensure

personal

safety

and

the

safety

of

others.

Therefore,

this

equipment

is

to

be

installed,

operated,

and

maintained

only

by

qualified

persons

in

accordance

with

this

manual

and

all

ap

plicable

codes

such

as,

but

not

limited

to,

those

listed

at

the

end

of

Section

1

-

Safety

Rules

For

Operation

Of

Arc

Welding

Power

Source.

Safety

instructions

specifically

pertaining

to

this

unit

ap

pear

throughout

this

manual

highlighted

by

the

signal

words

____________

and

___________

which

identify

different

levels

of

hazard.

I~L~

:

I

I~

Eel

statements

include

installation,

operating,

and

maintenance

procedures

or

practices

which

if

not

carefully

could

result

in

serious

personal

injury

or

loss

of

life.

statements

include

installation,

operating,

and

maintenance

procedures

or

practices

which

if

not

carefully

followed

could

result

in

minor

personal

injury

or

damage

to

this

equipment.

A

third

signal

word,

,

highlights

instruc

tions

which

need

special

emphasis

to

obtain

the

most

efficient

operation

of

this

equipment.

WARNING

CAUTION

IMPORTANT

OM-1537

Page

7

4-1/8

in.

f

!

5/18

in.

(7.9

mm)

(105

mm)

Diameter

2

Holes

L

_

(251

mm)

~

9-7/8

in.

10-1/2

in.

(267

mm)

TA-080

429

Add

1

in.

(25.4

mm)

for

connectors.

Add

1/2

in.

(12.7

mm)

for

front

panel

knob.

TC085

225-A

Figure

3-1.

Dimensional

Views

3

-

2.

SHIELDING

GAS

CONNECTIONS

(Figure

3-4)

-

The

gas

in

and

gas

out

fittings

have

5/8-18

right

hand

threads.

Connect

a

hose

from

the

shielding

gas

supply

to

the

gas

in

fitting

on

the

gas

control

assembly.

The

gas

flow

must

be

controlled

by

a

regulator

and

flowmeter.

Connect

a

hose

from

the

gas

out

fitting

to

the

barbed

fitting

on

the

wire

drive

housing.

3

-

3.

WATER

CONNECTIONS

(Optional)

may

be

used

to

end

sequence

and

allow

the

unit

to

ad

vance

to

the

IMPORTANT

______________

A

limit

switch

must

be

used

when

codes

5

or

6

are

used

(see

Table

4-2).

Terminal

strip

2T

is

located

on

the

component

panel.

Loosen

the

screws

from

the

front

door

and

open

door

to

gain

access

to

2T.

Route

leads

from

limit

switches

through

strain

relief

on

right

side

panel

to

2T.

Leads

must

be

shielded

twisted

pair

wire.

CAUTION:

OVERHEATING

of

Gas

Metal-Arc

Welding

(GMAW)

gun

can

damage

gun.



If

using

a

water-cooled

gun

and

recirculating

coo/ant

system,

make

connections

from

the

coo/ant

system

directly

to

the

gun

hoses.

Do

not

make

water

connections

to

the

gas

control

assembly.

Check

system

periodically

for

proper

coolant

f/ow.

The

water

in

and

water

out

fittings

have

5/8-18

left

hand

threads.

Connect

a

hose

from

the

water

supply

to

the

water

in

fitting

on

gas

control

assembly.

Connect

the

water

hose

from

the

torch

to

the

water

Out

fitting

on

the

gas

control

assembly.

Connect

and

route

a

hose

from

the

torch

output

hose

to

a

proper

drain.

3

-

4.

LIMIT

SWITCH

CONNECTIONS

(Figure

3-2)

-

When

an

untimed

sequence

is

programmed,

an

external

limit

switch,

connected

to

terminal

strip

2T,

WARNING

__________

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

the

weld

control

and

disconnect

input

power

(115

vac)

before

making

any

terminal

strip

connections.

Make

connections

as

follows:

1.

Connect

insulated

wires

from

shielded

twisted

pair

wire

(Belden

8760

or

equivalent)

to

contacts

of

normally-open

momentary-contact

switch.

Cut

off

shielding

wire.

Repeat

for

each

limit

switch

required.

2.

Route

leads

from

switch(es)

through

strain

relief

clamp

(Figure

3-3)

to

terminal

strip

2T.

3.

Open

weld

control

door.

26-112

in.

(673.1

mm)

TA-080

485

22

in.

(558.8

mm)

9-1/2

in.

.3

mm)

Page

8

if

~,,

~

.5..

Remove

Jumper

Link

For

MHA-2

~

Jumper

I-

r

,-

,~



,_

~

\,,Wire~

-~-.

Customer

Supplied

Limit

Switches

A

B

CD

E

F

GHJ

Customer

Supplied

Switches

K/L-J-Remote

Halt/Resume

K/L.M-Remote

Program

Run

K

L

M

iT

A

B

C

0

E

F

G

H

J

K

2T

A/B-C

Weld

1

-

Weld

2

limit

switch

A/B-0

Weld

2

-

Weld

3

limit

switch

A/B-E

Weld

3

-

Pause

limit

switch

A/B-F

Pause

-

Preflow

of

limit

switch

ir

Lg~

~t,

U

C..)

U

~

A

B

C

D

E

F

G

H

4T

Remote

Aux.

Control

A-C

-

Aux.

C

A-B

-

Aux.

0

Figure

3-2.

Terminal

Strip

Connections

14-086

213-A

4.

Connect

shielding

drain

wire(s)

to

control

chassis.

5.

To

advance

from

Weld

1

to

Weld

2

using

a

limit

switch,

make

switch

connections

between

2TA

and

2TC.

6.

To

advance

from

Weld

2

to

Weld

3

using

a

limit

switch,

make

switch

connections

between

2TA

and

2TD.

7.

To

advance

from

Weld

3

to

Crater

using

a

limit

switch,

make

switch

connections

between

2TA

and

2TE.

8.

To

advance

from

Pause

to

Preflow

of

the

using

a

limit

switch,

make

connections

between

2TA

and

2TF.

9.

Close

and

secure

weld

control

door.

x

ci

x

Customer

Supplied

Switches

OM-1537

Page

9

3

-

5.

AUXILIARY

OUTPUT

CONNECTIONS

(Figure

3-2)

-

Terminal

strips

iT

and

3T

allow

the

user

access

to

relay

contacts

that

are

controlled

(on/off)

by

the

settings

of

the

auxiliary

outputs.

Terminal

strip

4T

allows

the

user

to

remotely

control

the

energizing

of

C

and

D

auxiliary

output

relay

contacts.

~

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

the

weld

control

and

disconnect

input

power

(115

vac)

before

making

any

terminal

strip

connections.

1.

Open

weld

control

door.

2.

Route

leads

from

equipment

through

strain

relief

clamp

on

right

side

of

weld

control

to

terminal

strip(s)

iT,

3T,

or

4T.

TC-085

225-A

3.

Connect

equipment

leads

to

terminal

strip(s)

as

desired

according

to

program

needs

and

data

entered.

Figure

3-3.

Weld

Control

Interconnections

D.

Gas

Control

Connections

IMPORTANT

A

snubber

circuit

with

an

impedance

of

25K

ohms

at

60

Hertz

is

connected

across

each

of

the

auxiliary

output

contacts.

4.

Close

and

secure

weld

control

door.

3

-

6.

WELD

CONTROL

INTERCONNECTIONS

(Figures

3-3

and

3-5)

Lifl:h~lh~cf

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

welding

power

source

and

be

sure

it

cannot

be

accidentally

energized

before

making

interconnections.

This

unit

is

supplied

with

the

necessary

interconnecting

cords.

Examine

and

select

the

proper

cord

for

each

of

the

following

connections.

A.

Voltage

Sensing

Connections

Connect

the

14-pin

plug

from

the

gas

control

cord

to

weld

control

receptacle

D

(see

Figure

3-3).

Connect

re

maining

end

to

receptacle

on

gas

control

assembly

(see

Figure

3-4).

E.

Weld

Output

Connections

(Figure

3-4)

1.

Select,

prepare

and

attach

to

weld

output

ter

minals

proper

size

weld

cables

according

to

in

structions

in

welding

power

source

Owners

Manual.

2.

Remove

cover

from

gas

control

assembly.

3.

For

Reverse

Polarity,

route

positive

(+)

weld

cable

through

grommet

on

IN

panel

of

gas

assembly,

through

reed

switch

bracket,

and

out

grommet

on

opposite

end

(see

Figure

3-4).

For

Straight

Polarity,

route

negative

(-)

weld

cable

through

reed

switch.

Connect

the

4-pin

plug

from

the

voltage

sensing

cord

to

weld

control

receptacle

A

(see

Figure

3-3).

Connect

re

maining

ends

as

follows:

Connect

leads

with

ring

ter

minals

to

weld

output

terminals

on

welding

power

source

(polarity

is

not

important).

B.

Voltage

Control

Connections

Connect

the

4-pin

plug

from

the

voltage

control

cord

to

weld

control

receptacle

B

(see

Figure

3-3).

Connect

re

maining

end

to

VOLTAGE

CONTROL

receptacle

on

welding

power

source.

Welding

power

source

VOLTAGE

CONTROL

switch

must

be

in

REMOTE

posi

tion.

C.

Motor

Control

Connections

Connect

the

14-pin

plug

from

the

motor

control

cord

to

weld

control

receptacle

C

(see

Figure

3-3).

Connect

re

maining

end

to

plug

from

drive

motor.

4.

Route

and

connect

weld

cable

from

gas

control

assembly

to

weld

cable

terminal

on

wire

drive

housing

(see

OM-1

538).

5.

Connect

remaining

weld

cable

from

the

welding

power

source

to

the

work.

6.

Reinstall

cover

onto

gas

control

assembly.

F.

115

VAC

And

Contactor

Control

Connec

tions

Connect

the

4-pin

plug

from

the

115

volts

ac

and

con

tactor

control

cord

to

weld

control

receptacle

E

(see

Figure

3-3).

Connect

remaining

ends

to

welding

power

source

as

follows:

Connect

2-prong

twistlock

plug

to

CONTACTOR

CONTROL

receptacle,

and

connect

3-prong

plug

to

115

VOLTS

AC

twistlock

receptacle.

CONTACTOR

switch

on

welding

power

source

must

be

in

REMOTE

position.

Page

10

Gase

Control

Receptacle

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

the

weld

control

and

disconnect

input

power

(115

vac)

before

beginning

this

installation.

IMPORTANT

______________

Depending

on

its

location,

the

weld

control

(System

9)

may

have

to

be

removed

from

its

mounting

to

accomplish

this

installation.

Retain

all

hardware

removed

for

reinsta/lation

unless

specifically

told

otherwise.

1.

Open

weld

control

door.

2.

Remove

snap-in

blank

and

the

4

nearby

sheet

metal

screws

from

top

panel

of

weld

control

case.

3.

Remove

cover

from

MHA-2.

4.

Route

MHA-2

wiring

harness

with

edge

connec

tor

attached

through

opening

in

case

top

panel.

5.

Using

location

and

the

4

sheet

metal

screws

from

Step

2,

install

and

secure

MHA-2

to

case

top

panel

with

two-receptacle

end

to

the

right.

6.

Using

supplied

spacers,

lock

washers,

and

four

6-32

x

5/8

screws,

install

supplied

MHA-2

circuit

card

assembly

onto

door

shield

between

wiring

harnesses

with

18-pin

edge

connector

to

the

left.

7.

Install

MHA-2

wiring

harness

connector

(routed

in

Step

4)

into

18-pin

edge

connector

on

MHA-2

circuit

card

assembly

installed

in

Step

6;

connec

tOrs

only

fit

together

one

way.

IMPORTANT:

_______

Locate

and

examine

supplied

loose

wiring

harness

with

connectors

on

both

ends

of

leads.

The

8-pin

connector

is

PL

G5

1,

and

the

6-pin

connector

is

PLG9.

Figure

3-5.

Interconnection

Diagram

8.

Connect

PLG51

to

MHA-2

circuit

card

assembly.

9.

Disconnect

PLG9

from

microprocessor

board

PCi.

Turn

plug

so

that

keying

fingers

are

on

the

bottom

when

holding

plug

in

hand.

Slide

the

flat

tened

end

of

a

20

or

22

gauge

wire

over

the

right

side

of

the

contact

to

release

the

contact

catch.

Pull

wire

from

plug

and

discard

plug.

Push

wire

into

empty

space

on

PLG9

from

MHA-2.

Con

nect

PLG9

to

PCi

through

slot

in

door

shield.

Be

sure

connection

is

secure.

10.

Locate

one

lead

No.

31

at

A

of

relay

CR1

in

weld

control.

CR1

is

enclosed

relay

to

left

of

other

relays.

Cut

cable

ties

as

necessary

to

gain

access

to

this

lead

No.

31.

II

~

1

~I.] ~I

(

~t

~

Install

supplied

adhesive

back

wiring

retainers

onto

case

as

necessary,

and

route

leads

pro

perly

through

retainers

before

making

connections.

11.

Using

supplied

tab

connector,

splice

lead

No.

31

from

PLG51

1

to

lead

No.

31

near

CR1.

12.

Locate

terminal

A

on

terminal

strip

2T

inside

weld

control.

13.

Connect

lead

No.

42

from

PLG51

2

to

ter

minal

A

on

strip

2T.

14.

Locate

lead

No.

54

that

goes

to

7

of

recep

tacle

RC18.

RC1

8

is

the

motor

control

receptacle

(third

from

top)

on

side

of

weld

control

as

shown

in

Figure

3-3.

The

numbers

can

be

identified

from

the

outside

of

the

receptacle.

Cut

cable

ties

as

necessary

to

gain

access

to

lead

No.

54.

115

VAC/Contactor

Control

Cord

Weld

Control

(System

9)

Weld

Cable

In

Opening

Deltaweld

WeldIng

Power

Source

Motor

Control

Cord

TA-070

483

Figure

3-4.

Gas

Control

Assembly

3-7.

FIELD

INSTALLATION

OF

MHA-2

(Figure

3-6)

Gas

Control

Assembly

Work

Wire

Drive

Assembly

TA-087

275

OM-1537

Page

11

Figure

3-6.

Interconnection

Diagram

With

MHA-2

TA-087

275

15.

Using

supplied

tab

connector,

splice

lead

No.

54

from

PLG51

6

to

lead

No.

54

near

rear

of

RC18.

16.

Disconnect

lead

from

terminal

K

on

strip

iT

and

remove

jumper

link

between

terminals

K

and

L

on

1

T;

reconnect

removed

lead

back

Onto

ter

minal

K

on

iT.

17.

Disconnect

lead

from

terminal

L

on

iT

and

reconnect

it

to

terminal

K

on

iT.

18.

Connect

one

end

of

supplied

19

in.

(483

mm)

long

to

terminal

L

on

terminal

strip

iT.

19.

Connect

remaining

end

of

lead

from

Step

18

to

12

on

receptacle

RC1

8

(see

Step

14

for

loca

tion

method

of

numbers).

20.

Connect

supplied

10

in.

(254

mm)

long

lead

bet

ween

terminal

L

on

terminal

strip

iT

and

male

friction

terminal

No.

3

on

SCR

network

circuit

card

PC7.

21.

Connect

supplied

7.5

in.

(191

mm)

long

lead

bet

ween

male

friction

terminals

No.

4

and

13

on

PC7.

22.

Locate

lead

that

goes

from

male

friction

terminal

No.

14

on

PC7

to

terminal

G

on

terminal

strip

2T.

23.

Disconnect

end

of

lead

located

in

Step

22

from

2TG

and

cut

off

ring

terminal.

24.

Using

supplied

tab

connector,

splice

lead

(from

Step

23)

to

one

end

of

supplied

22

in.

(559

mm)

long

lead.

25.

Connect

remaining

end

of

new

lead

(from

Step

24)

into

14

of

receptacle

RC18.

26.

Connect

one

end

of

supplied

5

in.

(127

mm)

long

lead

into

11

of

receptacle

RC18.

27.

Connect

remaining

end

of

lead

from

Step

26

to

terminal

G

on

strip

2T.

28.

Using

supplied

cable

ties

and

clips,

secure

new

leads

to

existing

wiring

harnesses

where

possi

ble.

29.

Connect

one

end

of

supplied

cord

with

amp

plugs

on

both

ends

to

single

(left

end)

receptacle

on

MHA-2.

30.

Connect

remaining

end

to

motor

control

recep

tacle

on

side

of

weld

control

as

shown

in

Figure

3-3

and

3-6.

31.

Connect

one

motor

control

cord

to

one

drive

motor

and

connect

remaining

end

to

HEAD

NO.

1

receptacle

on

MHA-2

(see

Figure

3-6).

32.

Connect

another

(not

supplied)

motor

control

cord

to

remaining

drive

motor

and

connect

re

maining

end

to

HEAD

NO.

2

receptacle

on

MHA-2

(see

Figure

3-6).

33.

Connect

a

jumper

cable

of

adequate

size

(see

Welding

Power

Source

Owners

Manual)

bet

ween

the

two

wire

drive

assemblies

(see

Figure

3-6).

The

MHA-2

is

shipped

so

that

HEAD

NO.

1

is

activated

during

programs

1-5,

and

HEAD

NO.

2

is

activated

dur

ing

programs

6-9.

If

the

operation

requires

a

different

setup,

the

jumper

links

on

terminal

strips

1

T

and

2T

in

the

MHA-2

unit

can

be

changed.

If

HEAD

NO.

1

is

to

be

115

VAC/Contactor

Control

Cord,

Welding

Power

Source

Motor

Cords

Wire

Drive

Gas

Control

Assembly

(HEAD

NO.

21

Page

12

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