Miller JB500222 Owner's manual
- Category
- Welding System
- Type
- Owner's manual
This manual is also suitable for
May
1981
FORM:
OM-1536
OWN
E
RS
MANUAL
1!I1,lI!rI!
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k
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON,
WI
54912
USA
ADDITIONAL
COPY
PRICE
90
CENTS
NWSA
CODE
NO.
4579
PRINTED
IN
U.S.A.
Effective
With
Serial
No.
JE1500222
MODEL
AUTOMATIC
1
D
L
~
~.
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t~m
LIMITED
WARRANTY
EFFECTIVE:
JUNE
1.
1979
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
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
Millers
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
Millers
option
11)
repair
or
(2)
replacement
cessories
or
other
items
manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of
their
respective
manufacturers,
if
any
.
All
Miller
service
station
or
(4)
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
Customers
risk
and
expense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
clai-
Except
as
specified
below,
Millers
warranty
does
not
apply
mant
on
the
warranty
claim
procedures
to
be
followed.
to
components
having
normal
useful
life
of
less
than
one
lii
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
MILLERMATIC
parts
that
come
in
contact
with
the
welding
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA-
?
wire
including
nozzles
and
nozzle
insulators
where
failure
does
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
not
result
from
defect
in
workmanship
or
material.
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
Miller
shall
be
required
to
honor
warranty
claims
on
war-
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
within
the
following
periods
from
the
date
of
delivery
of
Equip-
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ment
to
the
original
user:
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EX
CLUDED
AND
DISCLAIMED
BY
MILLER.
1.
Arc
welders,
power
sources
and
components
. .
1
year
2.
Original
main
power
rectifiers
3
years
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
(labor
-
1
year
only)
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
3.
All
welding
guns
and
feeder/guns
90
days
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
4.
All
other
Millermatic
Feeders
1
year
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
5.
Replacement
or
repair
parts,
exclusive
of
labor
.
60
days
EXPERIENCED
IN
THE USE
AND
MAINTENANCE
OF
d
6.
Batteries
6
months
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER
WARRANTIES
DO
NOT
EXTEND
provided
that
Miller
is
notified
in
writing
within
thirty
(30)
days
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
of
the
date
of
such
failure.
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
j
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
3
1
-
4.
Standards
Booklet
Index
4
SECTION
2
-
INTRODUCTION
2
-
1.
General
Information
And
Safety
5
2
-
2.
Receiving-Handling
5
2
-
3.
Description
5
SECTION
3
-
INSTALLATION
3-1.
Location
6
3
-
2.
Shielding
Gas
Connections
6
3
-3.
Water
Connections
6
3
-
4.
Remote
Start
And
Stop
Connections
7
3
-
5.
Normally-Open
And
Normally-Closed
Contacts
Available
For
Control
Of
Weld
Fixtures
7
3
-
6.
Weld
Control
Interconnections
8
SECTION
4
-
FUNCTION
OF
CONTROLS
4
-
1.
Power
Switch
10
4
-
2.
Retract-Advance
Switch
And
Inch
Switch
10
4
-
3.
Purge
Push-Button
Switch
10
4
-
4.
Start
Push-Button
Switch
10
4
-
5.
Stop
Push-Button
Switch
11
4
-
6.
Error
Reset
Button
11
4-7.
PressTo
Set
Buttons
11
4
-
8.
Digital
Voltmeter
11
4
-
9.
Digital
Inches
Per
Minute
Meter
11
4-10.
Weld
Voltage
Control
11
4-11.
WeldWireSpeedControl
11
4-12.
Run-In
Wire
Speed
Control
11
4-13.
Run-In
Voltage
Control
11
4-14.
RunlnlimeControl
12
4-15.
Crater
&
Inch
Wire
Speed
Control
12
4-16.
Crater
Voltage
Control
12
4-17.
Pre-FIow
Time
Control
12
4-18.
Spot-Continuous
Switch
12
4-19.
SpotlimeControl
12
4-20.
Crater
Time
Control
12
4-21.
BurnbackControl
12
4-22.
Post-Flow
Time
Control
12
4-23.
Overload
Protection
12
SECTION
5
-
SEQUENCE
OF
OPERATION
5
-
1.
Gas
Metal-Arc
Welding
&
Flux
Cored
Arc
Welding
-
Continuous
13
5-2.
Gas
Metal-Arc
Welding&Flux
Cored
Arc
Welding-Spot
13
5
-
3.
Shutting
Down
13
SECTION
6
-
MAINTENANCE
&
TROUBLESHOOTING
6-1.
Inspection
And
Upkeep
13
6-2.
General
14
6
-
3.
Troubleshooting
Chart
14
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
unwise.
Let
the
experience
of
others
teach
you.
Safe
practices
developed
from
experience
in
the
use
of
weld
ing
and
cutting
are
described
in
this
manual.
Research,
devel
opment.
and
field
experience
have
evolved
reliable
equipment
and
safe
installation,
operation,
and
servicing
practices.
Acci
dents
occur
when
equipment
is
improperly
used
or
main
tained.
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
so
follow
the
rules.
Read
and
understand
these
safe
practices
before
attempting
so
install,
operate,
or
service
the
equipment.
Comply
with
shese
procedures
es
applicable
to
she
particular
equipment
used
and
their
instruction
manuals,
for
personal
safety
and
for
she
safety
of
others.
Failure
so
observe
these
safe
practices
may
cause
serious
in
jury
or
death.
When
safety
becomes
a
habit,
the
equipment
can
be
used
wish
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
procedures
than
those
given
in
this
manual.
They
are
listed
in
she
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
in
spection
requirements
also
provide
a
basis
for
equipment
in
stallation,
use,
and
service.
GENERAL
PRECAUTIONS
Burn
Prevention
Wear
protective
clothing
-
leather
(or
esbestos(
gaunsles
gloves,
has,
and
high
safesy-soe
shoes.
Button
shirt
collar
and
pocket
flaps,
and
wear
cuffless
trousers
to
avoid
entry
of
sparks
and
slag.
Wear
helmet
wish
safety
goggles
or
glasses
with
side
shields
underneath,
appropriate
filter
lenses
or
plates
(prorected
by
clear
cover
glass(.
This
is
a
MUST
for
welding
or
cutting,
(and
chipping(
to
protect
the
eyes
from
radiant
energy
and
flying
mesal.
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
end
eye
treatment.
First
aid
facilities
and
a
qualified
first
aid
person
should
be
available
for
each
shift
unless
medical
facilities
are
close
by
for
immediate
treatment
of
flash
burns
of
she
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
persons
inrending
to
weld
or
cut.
B.
Toxic
Fume
Prevention
Adequate
ventilation.
Severe
discomfort,
illness
ordeath
can
result
from
fumes,
vapors,
heat
or
oxygen
enrichment
or
depletion
that
welding
(or
cutsing(
may
produce.
Prevent
them
with
adequate
ventilation
aa
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
cus(
may
produce
harmful
concentrations
of
toxic
fumes.
Adequate
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
used.
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
ventilated,
or
she
operator
wears
an
air-supplied
respirator.
Work
in
a
confined
space
only
while
it
is
being
ventilated
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
concentration
danger
ously.
Do
not
bring
gas
cylinders
into
a
confined
space.
Leaving
confined
space,
shut
OFF
gas
supply
as
source
to
prevent
possible
accumulation
of
gases
in
the
space
if
down
stream
valves
have
been
accidently
opened
or
left
open.
Check
to
be
sure
that
the
space
is
safe
before
re-entering
it.
Vapors
from
chlorinated
solvenrs
can
be
decomposed
by
the
heat
of
the
arc
(or
flame(
to
form
PHOSGENE,
a
highly
toxic
gas,
and
other
lung
and
eye
irritating
products.
The
ultra
violet
(radiant(
energy
of
the
arc
can
also
decompose
tn
chloroeshylene
and
perchioroethylene
vapors
to
form
phos
gene.
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
tnichioroethylene
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
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,
ventilators.
If
the
work
cannot
be
moved,
move
combustibles
as
least
35
lees
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
sh
ould
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
weld
ing
or
cutting
if:
a.
appreciable
combustibles
(including
building
construc
sion(
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
combustibles
to
sparks
d.
combustibles
adjacent
to
walls,
ceilings,
roofs,
or
motel
partitions
can
be
ignited
by
radiant
or
conducted
heat.
Hot
work
permit
should
be
obtained
before
operation
to
ensure
supervisors
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
pro
duce
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.
1-2.
A.
OM-1536
Page
1
This
includes:
a
thorough
steam
or
caustic
cleaning
(or
a
solvent
or
water
washing,
depending
on
the
combustibles
solubility)
followed
by
purging
and
inerting
with
nitrogen
or
carbon
dioxide,
and
using
protective
equipment
at
recom
mended
in
A6,0.
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
gaso
line)
-
D.
Compressed
Gas
Equipment
Standard
precautions.
Comply
with
precautions
in
this
manual,
and
those
detailed
in
CGA
Standard
P-i,
PRECAU
TIONS
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
regula
tor
from
overpressure;
it is
not
intended
to
protect
any
downstream
equipment.
Provide
such
protection
with
one
or
more
relief
devices.
Never
connect
a
regulator
to
a
cylinder
containing
gas
other
than
that
for
which
the
regulator
was
designed.
Remove
faulty
regulator
from
service
immediately
for
repair
(first
close
cylinder
valve).
The
following
symptoms
indicate
a
faulty
regulator:
Leaks
-
if
gas
leaks
externally,
Excessive
Creep
-
if
delivery
pressure
continues
to
rise
with
downstream
valve
closed.
Faulty
Gauge
-
if
gauge
pointer
does
not
move
off
stop
pin
when
pressurized,
nor
returns
to
stop
pin
after
pressure
release.
Repair.
Do
NOT
attempt
repair.
Send
faulty
regulators
for
repair
to
manufacturers
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
accident.
(See
i-3C.)
ICC
or
DOT
marking
must
be
on
each
cylinder.
It
is
an
assurance
of
safety
when
the
cylinder
is
properly
handled.
Identifying
gas
content
Use
only
cylinders
with
name
of
gas
marked
on
them;
do
not
rely
on
color
to
identify
gas
con
tent.
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
support
such
as
a
platform
or
cradle.
Do
NOT
lift
cylinders
off
the
ground
by
their
valves
or
caps,
or
by
chains,
slings,
or
mag
nets.
Do
NOT
expose
cylinders
to
excessive
heat,
sparks,
slag,
and
flame,
etc.
that
may
cause
rupture.
Do
not
allow
contents
to
exceed
130F.
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
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
ordinary
wire
or
other
substitute)
as
a
binding
so
connect
hoses
to
fittings.
No
copper
tubing
splices.
Use
only
standard
brass
fittings
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
other
wise
damaged.
Coil
excess
hose
to
prevent
kinks
and
tangles.
Protect
hose
from
damage
by
sham
edges,
and
by
sparks,
slag,
and
open
flame.
Examine
hose
regularly
for
leaks,
wear,
and
loose
connec
tions,
Immerse
pressured
hose
in
water;
bubbles
indicate
leaks.
Repair
leaky
or
worn
hose
by
cutting
area
out
and
splicing
)i-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
lint-
less
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
CON
NECT
a
regulator
designed
for
a
particular
gas
or
gases
to
a
cylinder
containing
any
other
gas.
Tighten
connections,
When
assembling
threaded
connections,
clean
and
smooth
seats
where
necessary.
Tighten.
If
connec
tion
leaks,
disassemble,
clean,
and
retighten
using
properly
fitting
wrench.
Adapters.
Use
a
CGA
adapter
(available
from
your
supplier)
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
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
before
opening
cylinder
(or
manifold
valve)
by
turning
adjusting
screw
in
(clockwise).
Draining
prevents
excessive
compression
heat
at
high
pressure
seat
by
allowing
seat
to
open
on
pressur
ization.
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
regu
lator
maximum)
leave
cylinder
valve
in
following
position:
For
oxygen,
and
inert
gases,
open
fully
so
seal
stem
against
possible
leak.
For
fuel
gas,
open
to
less
than
one
turn
to
permit
quick
emergency
shutoff.
Page
2
Use
pressure
charts
(available
from
your
supplier)
for
safe
and
efficient,
recommended
pressure
sestings
on
regulators.
Check
for
leaks
on
first
pressurization
and
regularly
there
after.
Brush
with
soap
solution
(capful
of
Ivory
Liquid
or
equivalent
per
gallon
of
water).
Bubbles
indicate
leak.
Clean
off
soapy
water
after
test;
dried
soap
is
combustible.
E.
User
Responsibilities
Remove
leaky
or
defective
equipment
from
service
immed
iately
for
repair.
See
User
Responsibility
statement
in
equip
ment
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
cut
ting
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
opera
tor
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,
weld
ments
are
hot,
and
compressed
gases
may
be
used.
The
wise
operator
avoids
unnecessary
risks
and
protects
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
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.
DONT
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
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
pre
vent
entry
of
sparks.
2.
Eye
and
Head
Protection
Protect
eyes
from
exposure
to
arc.
NEVER
look
at
an
elec
tric
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.
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
IM
MEDIATELY.
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
she
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
circulation,
particularly
at
floor
level.
Viewing
the
weld.
Provide
face
shields
for
all
persons
who
will
be
looking
direÆtly
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.
Equipments
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
1-2D.
E.
Shock
Prevention
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
sur
face
when
welding,
without
suitable
protection.
To
protect
against
shock:
Keep
body
and
clothing
dry,
Never
work
in
damp
area
with
out
adequate
insulation
against
electrical
shock.
Stay
on
a
dry
duckboard,
or
rubber
met
when
dampness
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
installing,
connect
the
frames
of
each
unit
such
as
welding
power
source,
control,
work
table,
and
watr
circula
tor
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
liquid
such
as
oil
or
fuel.
Three-phase
connection,
Check
phase
requirement
of
equip
ment
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
equipment
ground
lead
to
the
third
(live)
wire,
or
the
equipment
will
become
electri
cally
HOT
-
a
dangerous
condition
that
can
shock,
possibly
fatally.
Before
welding,
check
ground
for
continuity.
Be
sure
conduc
tors
are
touching
bare
metal
of
equipment
frames
at
connec
tions.
If
a
line
cord
with
a
ground
lead
is
provided
with
the
equip
ment
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
receptacle.
Never
remove
the
ground
prong
from
a
plug,
or
use
a
plug
with
a
broken
off
ground
prong.
Trademark
of
Proctor
&
Gamble.
OM-1536
Page
3
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
Wire
Electrode
wire
becomes
electrically
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
equipment,
shut
OFF
all
power
and
remove
line
fuses
(or
lock
or
red-tag
switches)
to
prevent
accidental
turning
ON
of
power.
Discon
nect
all
cables
from
welding
power
source,
and
pull
all
115
volts
line-cord
pIu~.
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
dis
connect
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,
2501
NW
7th
St..
Miami,
Fla.
33125.
2.
ANSI
Standard
Z87.1,
SAFE
PRACTICE
FOR
OCCUPA
TION
AND
EDUCATIONAL
EYE
AND
FACE
PROTEC
TION,
obtainable
from
American
National
Standards
institute,
1430
Broadway,
New
York,
N.Y.
10018.
3.
American
Welding
Society
Standard
A6.0,
WELDING
AND
CUTTING
CONTAINERS
WHICH
HAVE
HELD
COMBUSTIBLES,
obtainable
same
as
item
1.
4.
NFPA
Standard
51.
OXYGEN-FUEL
GAS
SYSTEMS
FOR
WELDING
AND
CUTTING.
obtainable
from
the
National
Fire
Protection
Association,
470
AtlantIc
Avenue,
Boston,
Mass.
02210.
5.
NFPA
Standard
51B,
CUTTING
AND
WELDING
PRO
CESSES,
obtainable
same
as
item
4.
6.
CGA
Pamphlet
P-i.
SAFE
HANDLING
OF
COM
PRESSED
GASES
IN
CYLINDERS,
obtain~,Ie
from
the
Compressed
Gas
Association,
500
Fifth
Avenue,
New
York,
N.
Y.
10036.
7.
OSHA
Standard
29
CFR,
Part
1910,
Subpart
0,
WELD
ING,
CUTTING
AND
BRAZING.
8.
Code
for
Safety
in
Welding
and
Cutting,
CSA
Standard
W117.2.
Page
4
SECTION
2
-
INTRODUCTION
Dimensions
Weight
Height
Width
Depth
Weld
Control
17-1/2
in.
(445
mm)
13-7/8
in.
(352
mm)
8
in.~
(203
mm)
32-1/2
lbs.
(14.7
kg)
Gas
Control
4-1/8
in.
(105
mm)
5-1/8
in.
(130
mm)
10-1/2
in.
(267
mm)
4-1/2
lbs.
(2.0
kg)
Wire
Feed
Speed
Range
50
in.
(1.3
m)
to
780
in.
(19.8
m)
per
minute
*Add
1
in.
(25.4
mm)
for
front
panel
controls.
Figure
2-1.
Specifications
2
-
1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
IMPORTANT
A
third
signal
word,
______________,
highlights
instruc
tions
which
need
special
emphasis
to
obtain
the
most
efficient
operation
of
this
equipment.
WARNING
CAUTION
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.
~
:
statements
include
installation,
operating,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
serious
personal
injury
or
loss
of
life.
~UIl.1~I
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.
2
-
2.
RECEIVING-HANDLING
-
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
and
freight
bill
will
be
furnished
by
the
carrier
Ofl
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
it
is
essential
that
Model
Description
and
Serial
(or
Style)
Number
of
the
equipment
be
supplied.
2
-
3.
DESCRIPTION
-
This
weld
control
provides
digital
meter
display
of
voltage
and
wire
speed
and
allows
preselection
and
meter
display
of
welding
condi
tions
before
operation
begins
as
well
as
continuous
display
during
the
weld
cycle.
This
unit
is
also
designed
to
automatically
cycle
preprogrammed
welding
events
and
provide
a
constant
wire
feed
speed
and
arc
voltage
regardless
of
conditions.
This
unit
is
to
be
used
with
the
Deltaweld
series
of
power
sources.
The
standard
weld
control
has
provisions
to
select
the
PREFLOW
TIME,
RUN-IN
WIRE
SPEED,
WELD
VOLTAGE,
WELD
WIRE
SPEED,
CRATER
&
INCH
WIRE
SPEED,
CRATER
VOLTAGE,
CRATER
TIME,
SPOT
TIME,
BURNBACK
TIME,
and
POSTFLOW
TIME,
with
RUN-IN
VOLTAGE
and
RUN
IN
TIME
con
trols
optional.
Normally-open
and
normally-closed
con
tacts
are
provided
on
each
time
control
to
interface
with
other
equipment
(for
example,
starting
and
stopping
a
welding
fixture).
For
information
on
the
wire
drive
and
spool
support
assemblies,
see
Owners
Manual
1538.
OM-1
536
Page
5
SECTION
3
-
INSTALLATION
4-1/8
in.
5/16
in.
(7.9
mm)
(105
mm)
~LI
ameter
2
Holes
li
~
9-7/8
in.
-
(251
mm)
10-1/2
in.
__________
(267
mm)
3
-
1.
LOCATION
(Figure
3-1)
-
The
service
life
and
efficiency
of
this
unit
and
associated
components
will
be
reduced
when
they
are
subjected
to
high
levels
of
dust,
dirt,
moisture,
corrosive
vapors,
and
extreme
heat.
The
location
should
allow
room
to
open
the
front
panel
and
to
remove
wrapper(s)
for
installation,
inspection,
maintenance,
and
repair
functions.
Provisions
have
been
made
for
mounting
the
gas
con
trol
assembly
on
the
bottom
of
the
weld
control.
The
gas
control
assembly
may
also
be
mounted
anywhere
in
line
with
the
welding
gun
thereby
avoiding
routing
the
weld
cables
and
gas
hoses
back
to
the
weld
control.
Lead
lengths
must
be
considered
when
locating
all
com
ponents
of
the
weld
control.
Mounting
holes
are
provided
in
the
gas
assembly
and
weld
control.
Figure
3-1
gives
overall
dimensions
and
mounting
hole
layout.
3
-2.
SHIELDING
GAS
CONNECTIONS
(Figure
3-5)
-
Connect
a
hose
(not
supplied)
of
proper
length
and
construction
from
shielding
gas
supply
(regulator
flowmeter)
to
fitting
on
the
IN
panel
of
gas
control
assembly.
The
gas
fitting
is
a
5/8-18
connector
with
right-hand
threads.
The
gas
flow
must
be
accurately
controlled
by
a
regulator
and
flowmeter
at
the
source.
Connect
supplied
gas
hose
from
remaining
fitting
on
gas
control
assembly
to
barbed
fitting
on
wire
drive
housing.
3
-
3.
WATER
CONNECTIONS
(Optional)
C
MJTIION
_________
OVERHEATING
Gas
Metal-Arc
Welding
(GMAW)
gun
can
damage
gun.
If
using
a
water-cooled
gun
and
recirculating
coolant
system,
make
connections
from
the
coolant
system
directly
to
the
gun
hoses.
Do
not
use
water
connections
on
the
gas
control
assembly.
Check
system
periodically
for
proper
coolant
flow.
When
a
recirculating
coolant
system
is
not
employed,
and
use
of
the
provided
solenoid
valve
is
desired,
make
TA-080
485
water
connections
at
gas
control
assembly.
The
water
fittings
are
5/8-18
connectors
with
left-hand
threads.
Connect
water
hose
from
supply
to
fitting
on
IN
pane)
of
gas
control
assembly.
Connect
another
hose
bet
ween
remaining
fitting
on
gas
control
and
gun
IN
fitting.
Connect
and
route
a
hose
from
gun
OUT
fitting
to
a
proper
drain.
Check
system
periodically
for
proper
coolant
flow.
7-3/4
in.
(197
mm)
(130
mm)
Coolant
will
flow
as
soon
as
the
POWER
switch
on
the
weld
control
is
placed
in
the
ON
position.
If
coolant
flow
is
desired
only
in
conjunction
with
shielding
gas
flow,
1~A-O8O
429
proceed
as
follows:
Locate
the
lead
connected
from
pin
8
of
receptacle
RC9
to
terminal
B
on
terminal
strip
2T.
Figure
3-1.
Overall
Dimensions
And
Mounting
Disconnect
this
lead
from
terminal
B
on
2T,
and
recon
Hole
Layout
nect
it
to
terminal
C
on
terminal
strip
iT.
Page6
~j~V1PORTANT
For
in
formation
on
the
wire
drive
and
spool
support
assemblies,
see
Owners
Manual
1538.
5.
Connect
remaining
lead
to
terminal
A
on
terminal
strip
2T.
3
-4.
REMOTE
START
AND
STOP
CONNEC
TIONS
6.
Place
the
SPOT-CONTINUOUS
switch
in
the
SPOT
position.
I~tVARNlNG:
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.
For
remote
control
of
starting
and
stopping,
connec
tions
must
be
made
to
terminal
strips
iT
and
2T
in
the
weld
control.
Loosen
screw
from
door
on
upper
panel
of
the
weld
control
and
open
door.
Terminal
strips
1
T
and
2T
are
located
on
the
right
side of
the
control.
A.
Momentary-Contact
Push-Button
Switch
1.
Route
cord
from
switch(es)
through
strain
relief
clamp
on
right
side
of
weld
control
(see
Figure
3-4).
2.
Remove
jumper
link
between
terminals
G
and
F
on
terminal
strip
iT.
3.
Connect
the
two
leads
from
the
normally-open
start
switch
to
terminals
F
and
H
on
1
T.
4.
Connect
the
two
leads
from
the
normally-closed
stop
switch
to
terminals
G
and
F
on
iT.
B.
Maintained-Contact
(Relay)
Switch
1.
Route
cord
from
relay
through
strain
relief
clamp
on
right
side
of
weld
control
(see
Figure
3-4).
2.
Remove
jumper
link
between
terminals
F
and
E
on
terminal
strip
iT.
7.
Closing
the
switch
will
start
weld
cycle
and
unit
will
weld
for
the
time
set
on
the
SPOT
TIME
con
trol.
The
setting
of
the
pre-flow
and
post-flow
timers
determines
how
long
weld
current
is
not
present
and
thereby
determines
the
skip
time.
The
unit
will
automatically
recycle
through
the
weld
cycle
until
the
switch
is
opened.
After
all
connections
are
secured,
close
door
on
upper
panel
of
weld
control
and
tighten
screw.
(
To
Terminal
A
_________
On
2T
To
Weld
J
To
Terminal
E
Control
On
iT
I
To
Terminal
F
is,.
OniT
Figure
3-2.
Skip
Welding
Switch
Connections
3
-
5.
NORMALLY-OPEN
AND
NORMALLY-
CLOSED
CONTACTS
AVAILABLE
FOR
CONTROL
OF
WELD
FIXTURES
(Figure
3-3)
-
A
set
of
normally-open
and
normally-closed
contacts
are
provid
ed
to
work
in
conjunction
with
each weld
cycle
timing
circuit.
These
contacts
may
be
used
to
determine
fix
ture
movement
in
conjunction
with
the
weld
cycle.
For
example:
If
the
operator
wants
the
fixture
to
start
mov
ing
at
arc
initiation
and
stop
when
the
STOP
push
but
ton
is
depressed,
the
normally-open
contacts
of
CR51
(at
receptacle
RC4,
terminals
F
and
H)
would
be
used
to
control
fixture
movement.
3.
Connect
the
normally-open
maintained
contact
of
the
relay
to
terminals
F
and
H
on
1
T.
4.
Closing
relay
contact
will
start
unit
and
opening
relay
contact
will
stop
unit.
C.
Skip
Welding
(Figure
3-2)
1.
Route
a
3-conductor
cord
from
a
single-pole,
double-throw
switch
through
strain
relief
clamp
on
right
side of
weld
control
(see
Figure
3-4).
2.
Remove
jumper
link
between
terminals
F
and
E
on
terminal
strip
iT.
3.
The
switch
commons
of
the
single-pole,
double-
throw
switch
should
be
tied
together
to
one
lead
of
the
3-conductor
cord.
Connect
this
lead of
the
3-conductor
cord
to
terminal
F
on
terminal
strip
1
T.
4.
Connect
one
of
the
two
remaining
leads
to
ter
minal
E
on
terminal
strip
iT.
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
internal
con
nections.
Connections
can
be
made
to
the
3/16
male
friction
connectors
on
receptacles
RC4
and
RC1O
located
behind
the
timing
circuit
card
assembly
in
the
weld
con
trol.
To
gain
access
to
these
receptacles,
the
timing
cir
cuit
card
assembly
may
be
removed
as
follows:
1.
Loosen
screw
from
door
on
upper
panel
of
the
weld
control
and
open
door.
2.
Remove
three
screws
securing
timer
panel.
3.
Gently
pull
timer
panel
part
way
out.
4.
Remove
plugs
PLG1
and
PLG2
from
the
printed
circuit
card
assembly.
5.
Remove
timer
panel.
Single-Pole,
Double-Throw
Switch
TA-044
484-A
OM-1
536
Page
7
I
I
CR54
F-
U
a
UI
a
C
U
a
*The
dotted
line
condition
indicates
the
time
during
the
weld
cycle
that
the
control
relay
is
deenergized.
The
solid
line
condi
tion
Indicates
the
time
during
the
weld
cycle
that
the
control
relay
is
energized.
Route
leads
from
the
receptacles
through
the
strain
relief
clamp
provided
on
the
side of
the
weld
control.
After
connections
are
made
to
the
receptacles,
reverse
the
steps
to
install
the
timer
panel.
3
-
6.
WELD
CONTROL
INTERCONNECTIONS
(Figure
3-4)
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
five
electrical
parts.
Shut
down
we/ding
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
4-pin
plug
from
the
voltage
sensing
cord
to
weld
control
receptacle
A
(see
Figure
3-4).
Connect
re
maining
ends
as
follows:
Connect
lead
with
clamp
at
tached
to
workpiece.
Connect
lead
with
ring
terminal
attached
to
weld
cable
terminal
on
wire
drive
housing
(see
Owners
Manual
1538
for
location of
weld
cable
terminal).
B.
Voltage
Control
Connections
Connect
the
4-pin
plug
from
the
voltage
control
cord
to
weld
control
receptacle
B
(see
Figure
3-4).
Connect
re
maining
end
to
VOLTAGE
CONTROL
receptacle
on
welding
power
source.
Place
VOLTAGE
CONTROL
switch
on
welding
power
source
in
the
REMOTE
posI
C.
Motor
Control
Connections
Connect
the
9-pin
plug
from
the
motor
control
cord
to
weld
control
receptacle
C
(see
Figure
3-4).
Connect
re
maining
end
to
plug
from
drive
motor.
D.
Gas
Control
Connections
Connect
the
14-pin
plug
from
the
gas
control
cord
to
weld
control
receptacle
D
(see
Figure
3-4).
Connect
re
maining
end
to
receptacle
on
gas
control
assembly
(see
Figure
3-5).
J~i~
J~R5~~
J~R54
CR~,
~
~R5s4
4~
~D
~
F
kR
L
~
CC
-i
I
--
-~
Fixture
(Example
explained
in
Section
3-5.)
CR56*
CRS5
~
I!
II
ii
I
CR50
CR51
CR52
I,
I
I,
H
--it-----H-~
-
I,
I
Run
In
Speed
Pre-Flow
Time
~
0.5
Sec.
Weld
Time
Spot
Time
0-
Infinity
Or
0-2.5
Sec.
Crater
Time
0-2.5 Sec.
START
Arc
Initiation
Burnback
Time
0-025
STOP
Time
Figure
3-3.
Weld
Control
Cycle
TB-080
432
tion.
Page8
1.
Select
and
prepare
proper
size
weld
cables
ac
cording
to
welding
power
source
Owners
Manual.
2.
Remove
cover
from
gas
control
assembly.
3.
Connect
a
weld
cable
to
the
positive
(+)
weld
output
terminal
on
welding
power
source.
IMPORTANT
Instructions
are
given
for
DC
Reverse
Polarity
connections.
For
DC
Straight
Polarity
connec
tions,
connect
a
weld
cable
to
the
negative
(-1
weld
out
put
terminal
on
welding
power
source,
route
cable
through
gas
control~,
and
connect
to
weld
cable
terminal
on
wire
drive
housing.
Connect
another
weld
cable
from
positive
(+1
weld
output
terminal
on
welding
power
source
to
the
work.
E.
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
3-4).
Connect
remaining
ends
to
welding
power
source
as
follows:
Connect
2-prong
plug
to
CONTAC
TOR
CONTROL
receptacle,
and
connect
3-prong
plug
to
115
VOLTS
AC
twistlock
receptacle.
Place
CON
TACTOR
CONTROL
switch
on
welding
power
source
in
the
REMOTE
position.
F.
Weld
Output
Connections
(Figure
3-5)
~~1:1~II~Ief
ELECTRIC
SHOCK
can
kill.
o
Do
not
touch
five
electrical
parts.
o
Shut
down
the
welding
power
source
and
be
sure
it
cannot
be
accidentally
energized
before
making
weld
output
connections.
4.
Route
positive
(+)
weld
cable
through
grommet
on
IN
panel
of
gas
assembly,
through
reed
switch
bracket,
and
out
grommet
on
opposite
end
(see
Figure
3-5).
5.
Route
and
connect
positive
(+)
weld
cable
to
weld
cable
terminal
on
wire
drive
housing
(see
Owners
Manual
1538).
6.
Connect
a
weld
cable
from
the
negative
(-)
weld
output
terminal
on
welding
power
source
to
the
work.
7.
Reinstall
cover
onto
gas
control
assembly.
14-Pin;
Gas
Control
Assembly-D
Figure
3-4.
Interconnection
Points
On
Weld
Con
trol
TA-071)
483
Figure
3-5.
Gas
Control
Assembly
OM-1536
Page
9
SECTION
4
-
FUNCTION
OF
CONTROLS
Inch
Circuit
Purge
Button
TC-070 484
4
-
1.
POWER
SWITCH
(Figure
4-1)
-
Placing
the
POWER
switch
on
the
weld
control
in
the
ON
position
will
apply
115
volts
ac
to
the
unit
and
thereby
place
it
in
an
operational
condition,
permitting
the
preprogramm
ed
welding
cycle
to
start
when
the
START
button
is
depressed,
or
gas
to
flow
when
the
PURGE
button
is
depressed,
or
welding
wire
to
feed
if
the
INCH
switch
is
depressed.
The
meters
will
illuminate
showing
the
selected
WELD
VOLTAGE
and
WELD
WIRE
SPEED.
Placing
the
POWER
switch
in
the
OFF
position
wilI
shut
the
weld
control
and
associated
components
down.
This
switch
must
be
in
the
ON
position
to
preprogram
the
desired
weld
cycle.
4
-2.
RETRACT-ADVANCE
SWITCH
AND
INCH
SWITCH
(Figure
4-1)
-
With
the
RETRACT-
ADVANCE
switch
in
the
RETRACT
position,
the
welding
wire
will
retract
into
the
gun
at
the
speed
set
by
the
CRATER
&
INCH
WIRE
SPEED
control
only
while
the
INCH
switch
is
activated.
With
the
RETRACT-ADVANCE
switch
in
the
AD
VANCE
position,
the
welding
wire
will
advance
from
the
gun
at
the
speed
set
by
the
CRATER
&
INCH
WIRE
SPEED
control
only
while
the
INCH
switch
is
activated.
The
INCH
switch
is
a
normally-open,
momentary-
contact,
toggle
switch.
Activating
the
switch
will
energize
the
drive
motor
without
energizing
the
welding
power
source
contactor
or
the
gas
control
circuitry.
4
-
3.
PURGE
PUSH-BUTTON
SWITCH
(Figure
4-1)
-
The
PURGE
push-button
switch
is
a
normally-
open,
momentary-contact
switch.
Depressing
the
push
button
will
energize
the
gas
solenoid
and
thereby
purge
the
shielding
gas
line
to
the
gun.
4
-
4.
START
PUSH-BUTTON
SWITCH
(Figures
4-1
&
3-3)
-
Depressing
the
START
push-button
switch
will
start
the
preprogrammed
weld
cycle.
See
Figure
3-3
for
weld
cycle
events.
The
weld
cycle
will
continue
until
the
STOP
push-button
switch
is
depress
ed
or
the
SPOT
TIME
control
times
out.
Figure
4-1.
Front
Panel
Controls
Page
10
4
-
5.
STOP
PUSH-BUTTON
SWITCH
(Figures
4-1
&
3-3)
-
Depressing
the
STOP
push-button
switch
will
initiate
the
preprogrammed
crater
fill,
burnback,
and
post-flow
time.
See
Figure
3-3
for
weld
cycle
events.
4
-6.
ERROR
RESET
BUTTON
(Figure
4-1)
-
The
Voltage
Reset
button,
labeled
ERROR
RESET,
is
provid
ed
to
reset
the
Voltmeter
if
the
preset
voltage
is
beyond
the
limitations
of
the
welding
power
source.
If
the
load
voltage
remains
lower
or
higher
than
the
preset
voltage
for
more
than
1
.5
seconds,
the
Voltmeter
display
will
begin
to
flash.
Once
the
display
begins
to
flash,
it
will
continue
to
do
so
even
if
the
preset
voltage
can
be
ob
tained
by
the
welding
power
source
or
welding
opera
tions
cease.
Depress
the
ERROR
RESET
button
to
stop
the
Voltmeter
display
from
flashing.
During
normal
equipment
operation,
the
condition
which
would
cause
the
display
to
flash
would
be
a
preset
voltage
which
is
out
of
the
range
of
the
welding
power
source
(at
a
particular
line
voltage
and
load
cur
rent)
or
improper
connection
of
voltage
sensing
leads.
Ensure
that
leads
are
properly
connected
(see
Section
3-6A)
and
that
connections
are
clean
and
tight.
Read
just
the
preset
voltage
before
resuming
operation.
4-7.
PRESS
TO
SET
BUTTONS
(Figure4-1)
-
Two
white
push-button
switches
are
provided
for
presetting
weld
cycle
conditions.
Each
button
governs
the
two
controls
directly
below
it.
Pressing
(and
holding)
the
RUN-IN
button
allows
presetting
of
the
RUN-IN
WIRE
SPEED
and
optional
RUN-IN
VOLTAGE
(if
applicable).
Pressing
the
CRATER
&
INCH
button
allows
presetting
of
the
CRATER
VOLTAGE
and
CRATER
&
INCH
WIRE
SPEED.
When
either
of
these
buttons
is
pressed,
the
values
selected
on
the
applicable
controls
will
appear
on
the
meter
displays.
The
POWER
switch
must
be
in
the
ON
position
for
these
buttons
to
be
functional.
When
the
buttons
are
released,
the
meters
will
display
the
selected
WELD
VOLTAGE
and
WELD
WIRE
SPEED.
(See
Sections
4-8
and
4-9
for
additional
meter
display
information.)
4
-
8.
DIGITAL
VOLTMETER
(Figure
4-1)
-
This
meter
displays
voltage
to
the
nearest
tenth
of
a
volt.
The
POWER
switch
must
be
in
the
ON
position
for
the
meter
to
function.
With
the
POWER
switch
in
the
ON
position,
but
before
the
START
button
is
depressed,
this
meter
will
display
WELD
voltage.
In
all
cases,
regardless
of
options,
WELD
voltage
as
selected
by
the
WELD
VOLTAGE
control
is
displayed
during
preflow,
weld,
burnback,
and
postflow
times.
Crater
voltage,
as
selected
by
the
CRATER
VOLTAGE
control,
is
displayed
during
CRATER
TIME.
If
the
optional
RUN-IN
VOLTAGE
and
RUN
IN
TIME
controls
are
present,
Run-
In
Voltage,
as
selected
by
the
RUN-IN
VOLTAGE
con
trol,
is
displayed
during
Run-In
and
until
the
RUN
IN
TIME
control
times
out
after
arc
initiation.
II
~
I
~s
.
fit
I
~
If
voltmeter
display
is
erratic
during
run
in
and
crater
time,
no
malfunction
is
present.
The
meter
does
not
have
sufficient
time
to
change
and
stabilize
the
display.
Regardless,
the
unit
will
still
pro
vide
the
preset
values
if
within
its
capability.
IMPORTANT
4
-
9.
DIGITAL
INCHES
PER
MINUTE
METER
(Figure
4-1)
-
This
meter
displays
wire
speed
in
inches
per
minute.
The
POWER
switch
must
be
in
the
ON
posi
tion
for
the
meter
to
function.
With
the
POWER
switch
in
the
ON
position,
but
before
the
START
button
is
depressed,
this
meter
will
display
WELD
wire
speed.
In
all
cases,
regardless
of
options,
wire
speed
as
selected
by
the
WELD
WIRE
SPEED
control
is
displayed
during
preflow,
weld,
burnback,
and
postflow
time.
Crater
speed,
as
selected
by
the
CRATER
&
INCH
SPEED
CONTROL,
is
displayed
during
CRATER
TIME.
Run-In
speed,
as
selected
by
the
RUN-IN
SPEED
control,
is
displayed
during
Run
In
time
(after
preflow
until
arc
in
itiation).
If
the
optional
RUN-IN
VOLTAGE
and
RUN
IN
TIME
controls
are
present,
Run-In
speed,
as
selected
by
the
RUN-IN
SPEED
control,
is
displayed
during
Run-In
time
(after
preflow
until
arc
initiation).
If
the
optional
RUN-IN
VOLTAGE
and
RUN
IN
TIME
controls
are
pre
sent,
Run-In
speed,
as
selected
by
the
RUN-IN
SPEED
control,
is
displayed
during
Run-In
and
until
the
RUN
IN
TIME
control
times
out
after
arc
initiation.
______________
If
meter
display
is
erratic
during
run
in
and
crater
time,
no
maffunction
is
present.
The
meter
does
not
have
sufficient
time
to
change
and
stabilize
the
display.
Regardless,
the
unit
will
still
provide
the
preset
values
if
within
its
capability.
4-10.
WELD
VOLTAGE
CONTROL
(Figuire
4-1)
-
The
WELD
VOLTAGE
control
provides
a
means
of
selecting
the
desired
voltage
during
the
Weld
portion
of
the
cycle
(see
Section
4-8).
Rotating
this
control
clockwise
increases
the
WELD
voltage.
This
control
is
a
10-turn
potentiometer.
4-11.
WELD
WIRE
SPEED
CONTROL
(Figure
4-1)
-
The
WELD
WIRE
SPEED
control
provides
a
means
of
selecting
the
rate
at
which
welding
wire
will
feed
into
the
weld
during
the
Weld
portion
of
the
cycle
(see
Section
4-9).
Rotating
this
control
clockwise
increases
the
WELD
wire
feed
speed.
This
control
is
a
10-turn
poten
tiometer.
4-12.
RUN-IN
WIRE
SPEED
CONTROL
(Figure
4-1)
-
The
RUN-IN
WIRE
SPEED
control
provides
a
means
of
selecting
the
rate
at
which
welding
wire
will
feed
after
preflow
and
prior
to
arc
initiation
(or
until
the
optional
RUN
IN
TIME
control
times
out
after
arc
initia
tion,
if
applicable).
After
arc
initiation
(or
after
optional
RUN
IN
TIME
control
times
out,
if
applicable),
the
wire
feed
speed
is
governed
by
the
WELD
WIRE
SPEED
con
trol.
The
selected
Run-In
Wire
Speed
will
be
displayed
by
the
INCHES
PER
MINUTE
meter
during
the
Run-In
period.
Rotating
this
control
clockwise
increases
the
wire
feed
speed
during
the
Run-In
portion
of
the
cycle.
This
con-
trolls
a
10-turn
potentiometer.
4-13.
RUN-IN
VOLTAGE
CONTROL
(Optional)
-
The
Optional
RUN-IN
VOLTAGE
control,
located
directly
above
the
RUN-IN
WIRE
SPEED
con-
OM-1536
Page
11
trol,
provides
a
means
of
selecting
the
voltage
during
the
Run-In
portion
of
the
welding
cycle
(see
Section
4-12
for
explanation).
The
selected
voltage
will
be
displayed
by
the
voltmeter
during
the
Run-In
period.
Rotating
this
control
clockwise
increases
the
Run-In
voltage.
This
control
is
a
10-turn
potentiometer
and
is
provided
as
an
optional
package
which
includes
the
RUN
IN
TIME
control.
4-14.
RUN
IN
TIME
CONTROL
(Optional)
-
The
Optional
RUN
IN
TIME
control,
located
to
the
right
of
the
CRATER
WIRE
SPEED
and
CRATER
VOLTAGE
controls,
provides
a
means
of
selecting
the
length
of
time
for
the
Run-In
portion
of
the
cycle
after
arc
initia
tion.
This
adjustable
0
to
2.5
seconds
control
begins
timing
out
the
selected
value
upon
arc
initiation.
When
the
selected
time
has
elapsed,
the
unit
goes
to
the
weld
portion
of
the
cycle.
4-15.
CRATER
&
INCH
WIRE
SPEED
CONTROL
(Figure
4-1)
-
The
CRATER
&
INCH
WIRE
SPEED
control
provides
a
means
of
selecting
the
rate
at
which
wire
will
feed
into
the
weld
during
the
Crater
Time
and
the
rate
at
which
wire
will
advance
or
retract
when
the
INCH
switch
is
depressed.
The
selected
speed
will
be
displayed
by
the
INCHES
PER
MINUTE
meter
during
the
Crater
Time
period.
Rotating
this
control
clockwise
increases
the
wire
feed
speed
during
the
Crater
Time
portion
of
the
cycle.
This
control
is
a
10-turn
potentiometer.
4-16.
CRATER
VOLTAGE
CONTROL
(Figure
4-1)
-
The
CRATER
VOLTAGE
control
provides
a
means
of
selecting
the
voltage
during
the
Crater
Time
portion
of
the
welding
cycle.
The
selected
voltage
will
be
displayed
on
the
voltmeter
during
the
Crater
Time
period.
Rotating
this
control
clockwise
increases
the
voltage
during
the
Crater
Time
portion
of
the
cycle.
This
control
is
a
10-turn
potentiometer.
4-17.
PRE-FLOW
TIME
CONTROL
(Figure
4-1)
-
An
adjustable
0
to
5
seconds
PRE-FLOW
TIME
control
is
provided
for
selecting
the
period
of
time
shielding
gas
flows
before
arc
initiation.
The
PRE
FLOW
TIME
control
starts
to
time
when
the
START
switch
is
depressed.
Rotating
this
control
clockwise
increases
the
pre-flow
time.
The
scale
surrounding
the
PRE-FLOW
TIME
con
trol
is
calibrated
in
seconds
to
aid
in
the
selection
of
a
pre-flow
time
period
suited
to
the
individual
welding
operation.
4-18.
SPOT-CONTINUOUS
SWITCH
(Figure
4-1)
-
The
SPOT-CONTINUOUS
switch
provides
the
means
to
select
either
normal
weld
cycle
or
a
timed
weld
cycle.
Placing
the
SPOT-CONTINUOUS
switch
in
the
SPOT
position
will
provide
a
timed
weld
as
deter
mined
by
the
SPOT
TIME
control.
Placing
the
SPOT-
CONTINUOUS
switch
in
the
CONTINUOUS
position
will
cause
the
weld
control
to
operate
normally.
4-19.
SPOT
TIME
CONTROL
(Figure
4-1)
-
An
ad
justable
0
to
2.5
seconds
SPOT
TIME
control
is
provid
ed
for
selecting
the
time
welding
wire
will
feed
into
the
weld
at
the
speed
selected
by
the
WELD
WIRE
SPEED
control.
The
SPOT
TIME
control
starts
to
time
out
at
arc
initiation.
Rotating
this
control
clockwise
increases
the
spot
time.
The
scale
surrounding
the.
SPOT
TIME
control
is
calibrated
in
seconds
to
aid
in
the
selection
of
a
spot
time
suited
to
the
individual
welding
operation.
4-20.
CRATER
TIME
CO~JTROL
(Figure
4-1)
-
An
adjustable
0
to
2.5
seconds
CRATER
TIME
control
is
provided
for
selecting
the
time
welding
wire
will
feed
in
to
the
weld
at
the
rate
set
by
the
CRATER
&
INCH
WIRE
SPEED
control.
The
CRATER
TIME
control
starts
to
time
out
when
the
STOP
switch
is
depressed
or
when
the
SPOT
TIME
control
times
out.
Rotating
this
control
clockwise
increases
the
Crater
Time.
The
scale
surrounding
the
CRATER
TIME
control
is
calibrated
in
seconds
to
aid
in
the
selection
of
a
Crater
Time
period
suited
to
the
individual
welding
operation.
4-21.
BURNBACK
CONTROL
(Figure
4-1)
-
An
ad
justable
0
to
0.25
seconds
BURNBACK
control
is
pro
vided
for
selecting
the
time
the
welding
wire
will
remain
electrically
energized
after
the
drive
motor
stops.
The
BURNBACK
control
starts
to
time
out
after
the
CRATER
TIME
control
has
timed
out.
Rotating
this
control
clockwise
increases
the
burnback
time.
The
scale
surrounding
the
BURNBACK
control
is
calibrated
in
seconds.
By
adjusting
this
control
proper
ly,
the
welding
wire
will
neither
freeze
in
the
weld
pud
dle
nor
in
the
contact
tube
of
the
gun.
If
the
welding
wire
freezes
to
the
work,
increase
the
burnback
time.
If
the
welding
wire
burns
back
into
the
contact
tube,
decrease
the
burnback
time.
4-22.
POST-FLOW
TIME
CONTROL
(Figure
4-1)
-
An
adjustable
0-5
seconds
POST-FLOW
TIME
control
is
provided
for
selecting
the
time
shielding
gas
will
flow
after
the
BURNBACK
control
has
timed
out.
Rotating
this
control
clockwise
increases
the
post-flow
time.
The
scale
surrounding
the
POST-FLOW
TIME
control
is
calibrated
in
seconds
to
aid
in
the
selection
of
a
post-flow
time
period
suited
to
the
individual
welding
operation.
4-23.
OVERLOAD
PROTECTION
(Figure
4-1)
-
The
weld
control
is
protected
from
damage
due
to
an
internal
short
or
excessive
overload,
by
fuse
Fl.
Fuse
Fl
is
located
on
the
front
panel.
If
fuse
Fl
should
open,
the
weld
control
would
completely
shut
down.
The
drive
motor
is
protected
from
damage
due
to
overload
by
circuit
breaker
CB1
.
Circuit
breaker
CB1
is
located
on
the
front
panel
of
the
weld
control.
If
circuit
breaker
CB1
should
open,
the
weld
control
would
com
pletely
shut
down.
The
reset
button
would
have
to
be
manually
depressed
to
reset
the
circuit
breaker.
Page
12
SECTION
5
-
SEQUENCE
OF
OPERATION
ELECTRIC
SHOCK
can
kill;
MOVING
PARTS
can
cause
serious
injury.
o
Do
not
touch
live
electrical
parts.
o
Keep
clear
of
moving
parts.
The
welding
wire
and
all
metal
parts
in
contact
with
it
are
energized
while
welding.
ARC
RAYS,
SPARKS,
AND
HOT
SURFACES
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
'
Wear
correct
eye,
ear,
and
body
protection.
FUMES
AND
GASES
can
seriously
harm
your
health.
o
Use
enough
ventilation
to
keep
fumes
and
gases
from
the
breathing
zone.
See
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source
for
basic
welding
safety
infor
mation.
S
-
1.
GAS
METAL-ARC
WELDING
(GMAW)
&
FLUX
CORED
ARC
WELDING
(FCAW)
-
CON
TO~UOUS
1.
Mount
and
position
all
components.
2.
Make
all
connections
as
instructed
in
Section
3.
3.
Place
the
SPOT-CONTINUOUS
switch
in
the
CONTINUOUS
position
(see
Section
4-18).
4.
Turn
on
shielding
gas
at
the
source.
5.
Energize
the
welding
power
source.
6.
Place
the
weld
control
POWER
switch
in
the
ON
position
(see
Section
4-1).
7.
Program
the
desired
weld
cycle
by
setting
the
controls
as
instructed
in
Section
4.
8.
Purge
the
gas
line
by
depressing
the
PURGE
but
ton
for
one
minute
(see
Section
4-3).
9.
Depress
the
weld
control
START
button
(see
Section
4-4).
10.
To
terminate
the
weld
cycle,
depress
the
weld
control
STOP
button
(see
Section
4-5).
5
-
2.
GAS
METAL-ARC
WELDING
(GMAW)
&
FLUX
CORED
ARC
WELDING
(FCAW)
-
SPOT
1.
Mount
and
position
all
components.
2.
Make
all
connections
as
instructed
in
Section
:3.
3.
Place
the
SPOT-CONTINUOUS
switch
in
the
SPOT
position
(see
Section
4-18).
4.
Rotate
the
SPOT
TIME
control
to
the
desired
position
(see
Section
4-19).
5.
Turn
on
shielding
gas
at
the
source.
6.
Energize
the
welding
power
source.
7.
Place
the
weld
control
POWER
switch
in
the
ON
position
(see
Section
4-1).
8.
Program
the
desired
weld
cycle
by
setting~
the
controls
as
instructed
in
Section
4.
9.
Purge
the
gas
line
by
depressing
the
PURGE
but
ton
for
one
minute
(see
Section
4-3).
10.
Depress
the
weld
control
START
button
(see
Section
4-4).
11.
The
weld
cycle
will
automatically
terminate
when
the
SPOT
TIME
control
times
out.
5
-
3.
SHUTFING
DOWN
1.
Place
the
weld
control
POWER
switch
in
the
OFF
position.
2.
Turn
off
all
associated
equipment.
3.
Turn
off
the
shielding
gas
at
the
source.
~
HIGH
CONCENTRATION
OF
SHIELDING
GAS
can
harm
health
or
kill.
S
Shut
off
gas
supply
when
not
in
use.
SECTION
6
-
MAINTENANCE
&
TROUBLESHOOTING
~jj~J1~c~
ELECTRIC
SHOCK
can
kill.
S
Do
not
touch
live
electrical
parts.
S
Disconnect
unit
from
input
power
and
shut
down
welding
power
source
before
internally
inspecting
or
servicing.
Troubleshooting
of
internal
parts
to
be
performed
only
by
qualified
persons.
6
-
1.
INSPECTION
AND
UPKEEP
_______________
Periodically
inspect
the
labels
on
this
unit
for
legibility.
All
labels
must
be
maintained
in
a
c/early
readable
state
and
replaced
when
necessary.
See
the
Parts
List
for
part
number
of
labels.
IMPORTANT
OM-1536
Page
13
Usage
and
shop
conditions
will
determine
the
frequency
and
type
of
maintenance.
Inspect
equipment
as
follows:
1.
Repair
or
replace,
as
required,
all
hose
and
cable;
give
particular
attention
to
frayed
and
cracked
in
sulation
and
areas
where
it
enters
equipment.
2.
Remove
grease
and
grime
from
components;
moisture
from
electrical
parts
and
cable.
6
2.
GENERAL
-
It
is
assumed
that
proper
installa
tion
has
been
made,
according
to
Section 3
of
this
manual,
and
that
the
unit
has
been
functioning
properly
until
this
trouble
developed.
IMPORTANT:
_____
Be
sure
that
all
connections
on
side
of
weld
control
and
at
components
are
correct
and
secure
according
to
Section
3,
and
that
all
controls
and
swit
ches
are
in
proper
positions
according
to
Section
4,
before
proceeding
with
troubleshooting.
6
-
3.
TROUBLESHOOTING
CHART
-
The
follow
ing
chart
is
designed
to
diagnose
and
provide
remedies
for
some
of
the
troubles
that
may
develop
in
this
unit.
Use
this
chart
in
conjunction
with
the
circuit
diagram
while
performing
troubleshooting
procedures.
If
the
trouble
is
not
remedied
after
performing
these
pro
cedures,
the
nearest
Factory
Authorized
Service
Sta
tion
should
be
contacted.
In
all
cases
of
equipment
malfunction,
the
manufacturers
recommendations
should
be
strictly
followed.
TROUBLE
PROBABLE
CAUSE
REMEDY
Depressing
START
button
will
not
start
weld
cycle,
Electrode
wire
is
not
energized
and
shielding
gas
does
not
flow.
POWER
switch
Si
in
wrong
position
or
defec
tive.
Place
POWER
switch
Si
to
ON
position.
Replace
defective
POWER
switch
Si.
Circuit
breaker
CBi
tripped.
Manually
reset
circuit
breaker
CBi
by
depressing
button
on
front
panel
labeled
PRESS
TO
RESET.
115
volts
ac
input
power
plug
is
not
secure
in
recep-
tacle
on
welding
power
source.
Insert
plug
fully
into
ii
5
VAC
twistlock
receptacle
on
welding
power
source
and
rotate
plug
clockwise
(see
Section
3-6E).
115
volts
ac
input
fuse
Fi
open.
Locate
and
replace
fuse
Fl
on
front
panel.*
Wire
feeds,
shielding
gas
flows,
but
electrode
wire
is
not
energized.
Contactor
Control
plug
is
not
secure
in
receptacle
on
welding
power
source.
Insert
plug
fully
into
CONTACTOR
CONTROL
receptacle
on
welding
power
source
and
rotate
plug
clockwise
(see
Section
3-6E).
Defect
in
welding
power
source.
See
troubleshooting
section
in
welding
power
source
instruction
manual.
Erratic
voltmeter
display.
Incorrect
or
loose
voltage
sensing
connections.
Check
connections
and
be
sure
they
are
correct
and
secure
(see
Section
3-6A).
Voltage
control
plug
is
not
secure
in
receptacle
on
welding
power
source.
Connect
voltage
control
plug
securely
to
VOLTAGE
CONTROL
receptacle
on
welding
power
source
(see
Section
3-6B).
*If
it
becomes
necessary
to
replace
any
fuse
in
this
unit,
ensure
that
a
fuse
of
the
proper
size,
type,
and
rating
is
used.
Page
14
Wi
c~~1!t1
~3i
:
;
iti
n~mn
______
-~_____
*3~t2h~.
~9j~52n~
CI-,
4
~43
FF
1111L032
c221rq3~2E
~
~
1l03
:t~i~
~
Circuit
Diagram
No.
D~83
075
~j>72
>~S3lS3
~L
~
________
22
ft
I
112
a
Figure
6-1.
Circuit
Diagram
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Miller JB500222 Owner's manual
- Category
- Welding System
- Type
- Owner's manual
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