Miller JB559844 Owner's manual

Miller
Brand
Miller
Model
JB559844
Category
Welding System
Type
Owner's manual

This manual is also suitable for

June
1982
FORM:
OM-1537
Effective
With
Seriai
No.
J8559844
MODEL
System
9
RL~T~r~
/
OWN
ERS
MANUAL
HilliER
~
~
~
~
~
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON
~JI
54912
USA
ADDITIONAL
COPY
PRICE
$1.50
NWSA
CODE
NO.
4579
PAINTED
IN
U.S.A.
LIMITED
WARRANTY
EFFECTIVE:
JUNE
1,
1979
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
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
Ill
repair
or
12)
replacement
cessories
or
other
items
manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
13)
engines,
trade
accessories
and
other
items
are
sold
sub~ect
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of
their
respective
manufacturers,
if
any
.
All
Miller
service
station
or
41
payment
of
or
credit
for
the
purchase
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
less
reasonable
depreciation
based
upon
actual
usel
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-
l~
Except
as
specified
below,
Millers
warranty
does
not
apply
mant
on
the
warranty
claim
procedures
to
be
followed,
S
to
components
having
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
MILLERMATIC
parts
that
come
in
contact
with
the
welding
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA-
?
wire
including
nozzles
and
nozzle
insulators
where
failure
does
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
not
result
from
defect
in
workmanship
or
material.
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
~
MIGHT
ARISE
BY
IMPLICATION.
OPERATION
OF
LAW,
Miller
shall
be
required
to
honor
warranty
claims
on
war-
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
within
the
following
periods
from
the
date
of
delivery
of
Equip-
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
1
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
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.
MILLERS
WARRANTIES
TO.
ANY
CONSUMER.
Ji
t,
J~
,~
t, J~
,~
....,~
~
~
-i
4
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
-
SAFETY
RULES
FOR
OPERATION
OF
ARC
WELDING
POWER
SOURCE
1
-
1.
Introduction
1
1
-
2.
General
Precautions
1
1
-
3.
Arc
Welding
4
1
-
4.
Standards
Booklet
Index
5
SECTION
2
-
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
9
3
-
6.
Weld
Control
Interconnections
9
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
16
5-2.
Run/Set
Up
Switch
16
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.
ProgramRunPush
Button
17
5-11.
SequenceAdvance
Push
Button
17
5-12.
Halt/Resume
Push
Button
17
SECTION
6
-
PROGRAMM1NG
6
-
1.
Mini-Cassette
Tape
Operation
18
6
-2.
Programming
Module
Operation
19
6
-
3.
Programming
Examples
20
6
-
4.
Running
A
Program
20
SECTION
7
-
MAINTENANCE
B~
TROUBLESHOOTING
7
-
1.
Running
The
Diagnostic
Program
29
7
-
2.
Inspection
And
Upkeep
29
7
-
3.
Memory
Batteries
29
7
-
4.
Troubleshooting
29
V
LV
:j,,~
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
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
A.
Burn
Prevention
Wear
protective
clothing
-
leather
(or
asbestos)
gauntlet
gloves,
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
w~thout
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
Adequate
ventilation.
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
Standard
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
highly
toxic
gas,
and
other
lung
and
eye
irritating
pro
ducts.
The
ultraviolet
(radiant)
energy
of
the
arc
can
also
decompose
trichloroethylene
and
per
chloroethylene
vapors
to
form
phosgene.
DO
NOT
WELD
or
cut
where
solvent
vapors
can
be
drawn
into
the
welding
or
cutting
atmosphere
or
where
the
radiant
energy
can
penetrate
to
atmospheres
containing
even
minute
amounts
of
trichloroethylene
or
per
chloroethylene.~
rules.
OM-1537
Page
1
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
or
conducted
heat.
Hot
work
permit
should
be
obtained
before
operation
to
ensure
supervisors
approval
that
adequate
precautions
have
been
taken.
After
work
is
done,
check
that
area
is
free
of
sparks,
glowing
embers,
and
flames.
An
empty
container
that
held
combustibles,
or
that
can
produce
flammable
or
toxic
vapors
when
heated,
must
never
be
welded
on
or
cut,
unless
container
has
first
been
cleaned
as
described
in
AWS
Standard
A6.O,
listed
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
prctect
only
the
regulator
from
overpressure;
it
Is
not
intended
to
protect
any
downstream
equipment.
Provide
such
protection
with
one
or
more
relief
devices.
Never
connect
a
regulator
to
a
cylinder
containing
gas
other
than
that
for
which
the
regulator
was
designed.
Remove
faulty
regulator
from
service
immediately
for
repair
(first
close
cylinder
valve).
The
following
symptoms
indicate
a
faulty
regulator:
Leaks
-
if
gas
leaks
externally.
Excessive
Creep
-
if
delivery
pressure
continues
to
rise
with
downstream
valve
closed.
Faulty
Gauge
-
if
gauge
pointer
does
not
move
off
stop
pin
when
pressurized,
nor
returns
to
stop
pin
after
pressure
release.
Repair.
Do
NOT
attempt
repair.
Send
faulty
regulators
for
repair
to
manufacturers
designated
repair
center,
where
special
techniques
and
tools
are
used
by
trained
personnel..
2.
Cylinders
Cylinders
must
be
handled
carefully
to
prevent
leaks
and
damage
to
their
walls,
valves,
or
safety
devices:
Avoid
electrical
circuit
contact
with
cylinders
in
cluding
third
rails,
electrical
wires,
or
welding
cir
cuits.
They
can
produce
short
circuit
arcs
that
may
lead
to
a
secious
accident.
(See
1-3C.)
ICC
or
DOT
marking
must
be
on
each
cylinder.
It
is
an
assurance
of
safety
when
the
cylinderis
properly
handled.
Identifying
gas
content.
Use
only
cylinders
with
name
of
gas
marked
on
them;
do
not
rely
on
color
to
identify
gas
content.
Notify
supplier
if
unmarked.
NEVER
DEFACE
or
alter
name,
number,
or
other
markings
on
a
cylinder.
It
is
illegal
and
hazardous.
Page
2
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.
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
bevented
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
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
surface
when
welding,
without
suitable
protection.
Page
4
To
protect
against
shock:
5.
Terminals
And
Other
Exposed
Parts
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
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.
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
~nd
grease,
and
protected
from
hot
metal
and
sparks.
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
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,
2501
NW
7th
St.,
Miami,
FL
33125.
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
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
5.
ANSI
Standard
Z41.1,
STANDARD
FOR
MENS
SAFETY-TOE
FOOTWEAR
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
OM-1537
Page
5
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,
2501
NW
7th
Street,
Miami,
FL
33125.
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
W117.2,
CODE
FOR
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from
the
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1R3.
13.
NWSA
booklet,
WELDING
SAFETY
BIBLIOGRAPHY
obtainable
from
the
National
Welding
Supply
Association,
1900
Arch
Stree~t,
Philadelphia,
PA
19103.
14.
American
Welding
Society
Standard
AWSF4.1
Recommended
Safe
Practices
for
the
Prepara
tion
for
Welding
and
Cutting
of
Containers
and
Piping
That
Have
Held
Hazardous
Substances,
obtainable
from
the
American
W~ding
Society,
2501
NW
7th
Street,
Miami,
FL
33i25.
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
ipm
(1.3-20.3
mpm)
Depends
On
Welding
Power
Source
Open-Circuit
Voltage
115
Volts
AC
4
Amperes
83
lbs.
(37.6
kg.)
Figure
2-1.
Specifications
2
-
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
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
two
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
I~IIIITi1
which
identify
different
levels
of
hazard.
______
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.
(7.9
mm)
er
2
Holes
(106
mm)
li
~!l
~!J
(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.
28-112
in.
(673.1
mm)
TC-085
225
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
next
sequence.
IMPORTANT
A
limit
switch
must
be
used
when
codes
5
or
5
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.
3
-
4.
LIMIT
SWITCH
CONNECTIONS
(Figure
3-2)
-
When
an
untimed
sequence
is
programmed,
an
external
limit
switch,
connected
to
termin~al
strip
2T,
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.
TA-080
485
CAUTION
WARNING

I
ELECTRIC
SHOCK
can
kill.
_________
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
coo/ant
flow.
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.
~Page8
Figure
3-2.
Terminal
Strip
Connections
TA-086
273
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.
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.
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
Preftow
of
the
next
program
using
a
limit
switch,
make
connections
between
2TA
and
2TF.
9.
Close
and
secure
weld
control
door.
3
-
5.
AUXILIARY
OUTPUT
CONNECTIONS
(Figure
3-2)
I~i~h~IJ~er
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
iT.
3.
Connect
equipment
leads
to
iT
as
desired
accor
ding
to
program
needs
and
data
entered.
3
-
6.
WELD
CONTROL
INTERCONNECTIONS
(Figures
3-3
and
3-5)
~
ELECTRIC
SHOCK
can
kill.

Do
not
touch
live
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
3-3).
Connect
re
maining
ends
as
follows:
Connect
leads
with
ring
tar
minais
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.
x

~N~i
~
~
~
~
~
r~
*
Customer
Supplied
Limit
Switches
Customer
Supplied
Switches
K/L-J-Remote
Halt/Resume
K/L-M-Remote
Program
Run
A/B-C
Weld
1
-
Weld
2
limit
switch
A/B-O
Weld
2
-
Weld
3
limit
switch
A/B-E
Weld
3
-
Pause
limit
switch
A/B-F
Pause.
Preflow
of
next
program
limit
switch
OM-1537
Page
9

Fuse
.Circuit
Breaker
.Strain
Relief
Clamp
115
VAC
Power/
Contactor
Control-E
Gas
Control-D
Motor
Control-C
Voltage
Sensing-A
Voltage
Control-B
IC-085
225
Figure
3-3.
Weld
Control
Interconnections
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.
D.
Gas
Control
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).
Figure
3-4.
Gas
Control
Assembly
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.
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.
E.
Weld
Output
Connections
(Figure
3-4)
Page
10
Weld
Control
(System
9)
3-7.
FIELD
INSTALLATION
OFMHA-2
(Figure
3-6)
~
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.
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.
I
Wi
I
~
~I
f1
~
~
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.
8.
Connect
PLG51
to
MHA-2
circuit
card
assembly.
9.
Connect
PLG9
to
microprocessor
board
PCi
through
slot
in
door
shield.
Be
sure
connection
is
secure.
10.
Locate
one
lead
No.
31
at
pin
A
of
relay
CR1
in
weld
control.
CR1
is
enclosed
relay
to
left
of
other
relays.
Cut
cable
ties
as
necessary
to
gain
access
to
this
lead
No.
31.
IMPORTANT
__________
Install
supplied
adhesive
back
wiring
retainers
onto
case
as
necessary,
and
route
leads
pro
perly
through
retainers
before
making
connections.
11.
Using
supplied
tab
connector,
splice
lead
No.
31
from
PLG51
pin
1
to
lead
No.
31
near
CR1.
12.
Locate
terminal
A
on
terminal
strip
2T
inside
weld
control.
13.
Connect
lead
No.
42
from
PLG51
pin
2
to
ter
minal
A
on
strip
2T.
I
Wi
I
~1
~
V.1
~
~
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
reinstallation
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
MI-IA-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.
14.
Locate
lead
No.
54
that
goes
to
pin
7
of
recep
tacle
RC18.
RC18
is
the
motor
control
receptacle
(third
from
top)
on
side
of
weld
control
as
shown
in
Figure
3-3.
The
pin
numbers
can
be
identified
from
the
outside
of
the
receptacle.
Cut
cable
ties
as
necessary
to
gain
access
to
lead
No.
54.
15.
Using
supplied
tab
connector,
splice
lead
No.
54
from
PLG51
pin
6
to
lead
No.
54
near
rear
of
RC18.
16.
Disconnect
lead
from
terminal
K
on
strip
iT
arid
remove
jumper
link
between
terminals
K
and
L
on
11;
reconnect
removed
lead
back
onto
ter
minal
K
on
iT.
17.
Disconnect
lead
from
terminal
L
on
iT
arid
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
termaining
end
of
lead
from
Step
18
to
pin
12
on
receptacle
RC18
(see
Step
14
fro
loca
tion
method
of
pin
numbers).
115
VAC/ContactOr
Control
Cord
Deltaweld
Welding
Power
Source
Figure
3-5.
Connection
Diagram
OM.1
537
Page
11
20.
Locate
lead
No.
6
connected
from
terminal
G
on
Strip
2T
to
pin
3
of
receptacle
RC1
6.
Receptacle
RC16
is
the
gas
control
receptacle
(second
from
top)
on
side
of
weld
control
as
shown
in
Figure
3-3.
The
pin
numbers
can
be
identified
from
the
outside
of
the
receptacle.
21.
Disconnect
lead
No.
6
from
terminal
G
on
2T,
and
cut
off
ring
terminal.
22.
Using
supplied
tab
connector,
splice
lead
No.
6
(from
Step
21)
to
one
end
of
supplied
1-1/2
in.
(38
mm)
long
lead.
23.
Connect
remaining
end
of
new
lead
No.
6
(from
Step
22)
into
pin
14
of
receptacle
RC18.
24.
Connect
one
end
of
supplied
5
in.
(127
mm)
long
lead
into
pin
11
of
receptacle
RC18.
25.
Connect
remaining
end
of
lead
from
Step
24
to
terminal
G
on
strip
2T.
26.
Using
supplied
cable
ties
and
clips,
secure
new
leads
to
existing
wiring
harnesses
where
possi
ble.
27.
Connect
one
end
of
supplied
cord
with
amp
plugs
on
both
end
to
single
(left
end)
receptacle
on
MHA-2.
28.
Connect
remaining
end
to
motor
control
recep
tacle
on
side
of
weld
control
as
shown
in
Figure.
3-3
and
3-6.
29.
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).
30.
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).
31.
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
21
in
the
MHA-2
unit
can
be
changed.
If
HEAD
NO.
1
is
to
be
activated
for
any
program,
no
jumper
link
should
be
placed
between
program
number
and
a
CR
terminal.
Ex
ample:
If
HEAD
NO.
1
is
to
be
run
by
program
9,
remove
the
jumper
link
between
2T9
and
2TCR.
DO
NOT
remove
wire
jumpers.
If
HEAD
NO.
2
is
to
be
ac
tivated
for
any
program,
a
jumper
link
must
be
placed
between
program
number
and
CR
terminal.
Example:
If
HEAD
NO.
2
is
to
be
run
by
program
2,
a
jumper
link
must
be
placed
between
112
and
1TCR.
Extra
jumper
links
are
located
on
2T.
If
shielding
media
(gas
or
flux)
is
used
with
HEAD
NO.
2,
make
electrical
connections
between
2TJ
and
1
TL.
When
the
relays
in
MHA-2
energize,
115VAC
is
available
between
2TJ
and
1
IL
to
control
the
shielding
media
valve(s).
32.
Reinstall
cover
auto
MHA-2.
33.
Close
and
secure
weld
control
door.
WARNING
__________
ELECTRIC
SHOCK
can
kill.

Do
not
touch
live
electrical
parts.

Both
weld
heads
are
energized
even
though
only
one
is
we/ding.

Do
not
make
contact
with
unused
head.
Figure
3-6.
Connection
Diagram
With
MHA-2
115
VAC/Contactor
Control
Cord.
Weld
Control
(System
9)
Interconnecting
Cord
Welding
Power
Source
Gas
Control
Assembly
Wire
Drive
Assembly
(HEAD
NO.
2)
Page
12
SECTION
4
-
DEFINiTIONS
OF
PROGRAM
TERMS
NOTE:
_____
(Code
display
shows
code
programmed
into
pause
sequence.)
X
(Meters
blanked
when
in
sequence;
no
values
ac
cepted
at
programming.)
Table
4-1.
Weld
Program
Sequences
8
Variables
4
-
1.
PROGRAM
DEFINITIONS
A.
Sequence
-
One
of
a
series
of
controlled
ac
tions
that
produces
a
weld.
One
part
of
a
weld
program.
1.
Standby
-
see
Table
4-1.
The
unit
is
ready
to
operate.
2.
Preflow
-
see
Table
4-1.
When
the
PRO
GRAM
RUN
button
is
pressed,
the
shielding
gas
(and
optional
water)
valve
opens
allowing
shielding
gas
(and
water)
to
flow
before
an
arc
is
struck.
The
output
used
to
energize
the
shielding
gas
valve
could
also
be
used
for
on/off
control
of
other
shielding
media
such
as
flux
used
in
the
Submerged
Arc
Welding
process.
3.
Run-In
see
Table
4-1.
When
the
Preflow
sequence
is
finished,
the
unit
ad
vances
to
the
next
sequence:
Run-In.
At
the
beginning
of
the
Run-In
sequence
the
welding
power
source
contactor
is
energized
and
wire
begins
to
feed.
Run-in
time
does
not
start
until
an
arc
is
struck.
The
Run-In
sequence.
ends
when
the
run-
in
time
elapses.
4.
Weld
1,2,
&
3
-
see
Tables
4-1
&
4-2.
After
the
arc
is
established
and
the
Run-In
time
has
expired,
the
unit
advances
to
the
weld
sequences.
As
shown
in
Tables
4-1
and
4-2,
the
weld
sequences
can
be
pro
grammed
for
a
wide
variety
of
conditions.
When
an
untimed
sequence
is
programm
ed,
an
external
limit
switch,
connected
to
terminal
strip
2T,
can
be
used
to
end
the
sequence
and
allow
the
unit
to
advance
to
the
next
sequence,
or
the
SEQUENCE
AD
VANCE
button
can
be
depressed
if
the
code
allows
sequence
advance
(see
Table
4-2).
See
Section
3-4
for
making
the
ex
ternal
limit
switch
connections.
5.
Crater
-
see
Table
4-1.
The
Crater
fill
se
quence
allows
a
time
before
the
arc
is
ex
tinguished
in
which
Volts
and
Feed
Speed
can
be
programmed
to
provide
crater
fill.
After
the
crater
time
elapses,
the
unit
ad
vances
to
the
next
sequence.
6.
Burnback
see
Table
4-1.
The
Burnback
sequence
allows
the
welding
wire
to
re
main
energized
after
the
wire
drive
motor
has
stopped.
The
burnback
parameters
should
be
set
to
allow
the
welding
wire
to
burn
back
out
of
the
weld
puddle.
After
the
burnback
time
expires,
the
unit
ad
vances
to
the
postilow
sequence.
7.
Postflow
-
see
Table
4-1.
During
the
Postflow
sequence
shielding
gas
(and
water)
flows
for
a
programmed
time
after
the
arc
is
extinguished
before
the
valve(s)
close.
When
the
postflow
time
is
finished,
the
welding
portion
of
the
program
is
finished.
8.
Pause
-
see
Tables
4-1
&
4-2.
The
Pause
is
a
sequence
that
can
be
used
to
allow
time
between
weld
programs
for
things
such
as
reloading
a
fixture,
repositioning
of
work
or
gun,
etc.
Codes
1
through
6
may
be
used
as
outlined
in
Table
4-2.
When
codes
1
through
3
are
used,
the
next
program
will
start
at
the
end
of
the
Pause
sequence.
When
codes
4
through
6
are
used,
the
next
program
will
start
after
a
limit
switch
closure.
When
code
0
is
us
ed,
the
unit
will
advance
to
the
next
pro
gram
but
will
not
start
the
program.
If
a
timed
Pause
is
required,
enter
0-99.8
seconds.
If
an
untimed
Pause
is
required,
enter
99.9
seconds;
the
unit
requires
a
limit
switch
closure
to
advance
to
the
next
program.
Code
0
allows
halt
but
not
se
quence
advance.
B.
Codes
-
Each
sequence
(except
Standby)
uses
a
code.
The
code
defines
whether
the
sequence
is
timed
or
untimed
and
also
allows
or
disallows
the
operator
use
of
certain
controls
during
the
sequence.
See
Table
4-2
for
code
definitions.
Recognized
Sequence
Codes
Feed
Time
Volts
Speed
(Sec.)
Standby
X
X
Preftow
1,2,3
X

X
Run-In
1,
2,
3
0
-
99.9
0
.
Weld
1
Weld2
1
-
6
1-6
0
-
99.9
0-99.9
0
0
Weld
3
1
-
6
0
-
99.9
0
Crater
1,2,
3
0-99.9
0

Burnback
1,2,
3
0-99.9
X
.
PostIlow
1,2,3
X
X
Pause
0-6
X
X
-
800
-
800
-
800
-
800
-
800
x
0
-
99.9
0
-
9.99
0
-
99.9
0
-
99.9
0
-
99.9
0
-
9.99
0
-
.999
0
-
99.9
0
-
99.9
OM-1537
Page
13
Table
4-2.
Code
Definitions
4
-
2.
ALPHA
NUMERIC
DISPI..AY
DEFINITIONS
o
-
Timed:
halt
allowed.
Unit
advances
to
next
pro
gram
but
does
not
start
program.
Untimed:
halt
allowed.
Unit
advances
to
next
pro
gram
after
limit
switch
closure
but
next
program
does
not
start.
1
-
Timed
function
allowing
sequence
advance
and
halt.
2
-
Timed
function
not
allowing
sequence
advance;
allow
halt.
3
-
Timed
function
not
allowing
sequence
advance
or
halt.
4
-
Untimed
function
allowing
sequence
advance
and
halt.
5
-
Untimed
function
not
allowing
sequence
advance;
allow
halt.
6
-
Untimed
function
not
allowing
sequence
advance
or
halt.
C.
Program
-
The
weld
program
consists
of
a
related
group
of
sequences
that
control
a
weld
from
start
to
finish.
To
program
a
weld,
informa
tion
concerning
weld
parameters
for
each
se
quence
must
be
input
into
the
weld
control.
D.
Auxiliary
Outputs
-
The
auxiliary
outputs
A
and
B
can
be
used
for
such
things
as
regulating
fixture
movement
or
energizing
other
pieces
of
equipment.
The
outputs
can
change
(off
to
on)
at
the
beginning
of
each
sequence;
therefore
the
outputs
must
be
programmed
for
each
se
quence.
See
Section
3-5
for
connection
informa
tion.
IMPORTANT
______________
On
the
main
circuit
board
there
is
a
6-pin
jumpering
socket:
J9
1
0
0
J1O
~UT
2
0
0
AUX
V
3
0
0
ARC
Figure
4-1.
Jumpering
Socket
The
unit
is
shipped
with
J
10
jumper
between
1
and
2.
With
J10
in
this
position,
the
A
and
B
auxiliary
outputs,
if
programmed,
change
state
when
the
arc
is
struck
in
the
Run-In
sequence.
If
the
jumper
is
moved
to
2
and
3,
A
and
B
change
state
at
the
beginning
of
the
Run-In
se
quence.
E.
Limit
Switches
-
It
may
be
necessary
for
the
customer
to
supply
limit
switches
for
the
number
of
untirned
sequences
programmed.
The
limit
switches
are
to
be
used
to
advance
the
program
when
in
an
untimed
sequence.
(Weld
1
to
Weld
2,
Weld
2
to
Weld
3,
Weld
3
to
Crater,
and/or
Standby
to
Preflow
of
next
Program).
The
closure
of
a
limit
switch
will
only
be
recognized
when
in
the
sequence
with
which
the
switch
is
associated.

A.
Program
Definitions
/
STANDBY!
The
unit
is
in
Standby.
I
PAUSE!,
/
PREFLOW!,
/
RUN@lN/,
/
WELD
1/,
/
WELD
2/,
/
WELD
3/,
/
CRATER!,
/8URNBACK/,
/POSTFLOW/
When
these
appear
on
the
alpha-numeric
display,
the
unit
is
either
in
the
indicated
sequence
or
the
unit
is
being
pro
grammed
for
the
sequence
indicated.
/
INVALID!
Incorrect
data
has
been
entered
through
the
programming
module
or
tape,
or
incorrect
pro
cedure
was
used
to
enter
data.
/
PROGRAM!
The
unit
is
in
standby,
the
program
ming
module
is
plugged
into
the
weld
control,
and
the
Program
Select
button
on
the
programming
module
has
been
depressed.
B.
Mini-Cassette
Tape
Definitions
/
REWIND!
The
program
tape
is
rewinding.
/POSIT1ON/
The
program
tape
is
advancing
to
where
program
information
begins.
/
WRITE!
Tape
is
ready
to
receive
information
stored
in
memory.
To
gain
access
to
the
memory,
the
weld
control
RUN-SET
UP
switch
must
be
in
the
RUN
position.
To
record
the
information
on
to
the
tape,
the
HALT/RESUME
button
must
be
pressed.
/
READ/
Tape
is
ready
to
input
information
into
the
weld
control
memory.
To
gain
access
to
the
memory,
the
weld
control
RUN-SET
UP
switch
must
be
in
the
SET-UP
position.
To
read
information
off
of
the
tape
and
into
the
memory,
press
the
HALT/RESUME
but
ton.
!
CHECK!
This
appears
on
the
alpha-numeric
when
the
microprocessor
checks
the
data
to
ensure
that
all
data
is
in
usable
decimal
form.
C.
Power
Up
Diagnotic
Definitions
!PROM
BAD!
Each
time
power
is
applied
to
the
weld
control
a
check
of
the
permanent
memory
is
made.
If
the
memory
is
okay,
the
next
check
is
made;
whereas,
if
the
memory
is
defective,
the
alpha
numeric
displays
/PROM
BAD!.
The
memory
must
be
repaired
before
the
unit
will
work.
/
RAM
BAD!
Each
time
power
is
applied
to
the
weld
control
a
check
of
the
temporary
(or
program)
memory
is
made.
If
the
memory
is
okay,
the
next
check
is
made;
whereas,
if
the
memory
is
defective,
the
alpha-numeric
displays
/
RAM
BAD!.
The
memory
must
be
repaired
before
the
unit
will
work.
/
VERIFY!
This
appears
on
the
alpha-numeric
to
TA-o84
633
confirm
that
the
information
written
onto
or
read
from
the
tape
was
received
and
corresponds.
Page
14
/DATA
BAD!
Each
time
power
is
applied
to
the
weld
control
a
check
of
the
stored
information
is
made.
Due
to
technical
problems
(such
asnoise
interference)
a
bit
of
information
may
be
lost
from
memory
which
would
make
the
weld
program
incomplete.
If
this
happens
/DATA
BAD/
appears
on
the
alpha
numeric.
The
reset/diagnostic
switch
on
the
main
printed
circuit
board
must
be
pressed
and
/STANDBY/
must
appear
on
the
alpha-numeric
before
data
can
be
reentered.
The
program
must
be
reentered.
The
preferred
method
of
program
reentry
is
to
first
read
a
tape
that
has
been
pro-

grammed
with
all
zeros
followed
by
reading
a
tape
with
correct
program
parameters.
Instead,
a
tape
with
cor
rect
program
parameters
can
be
read.
If
a
tape
is
not
available,
reenter
data
into
all
nine
programs
using
zeros
for
all
parameters
of
programs
not
used.
/????????/
A
visual
test
of
all
segments
of
the
alpha
numeric
can
be
done
by
pressing
and
holding
for
two
seconds
the
HALT/RESUME
button
when
the
unit
is
in
Standby.
P.
Diagnostic
Test
Definitions
/MICRO@OK/
The
tests
normally
associated
with
power
up
are
performed
in
sequence
and
if
they
all
check
out,
/MICRO@OK/
appears
on
the
alpha
numeric.
If
there
is
a
problem,
one
of
the
power
up
diagnostic
displays
will
appear.
/
MOT@OK/,
I
MOT~DEFfThemotorissignalled
by
the
weld
control
to
provide
a
certain
predetermined
speed.
The
actual
speed
is
monitored
by
the
weld
con~
trol.
If
the
feedback
is
okay,
/
MOT@OK/,
appears
on
the
alpha-numeric.
If
the
feedback
indicates
that
the
motor
is
not
capable
of
maintaining
the
predetermined
speed,
/
MOT@OEF/
appears.
/
VOLT@OK/,
/
VOLT@DEF/
The
welding
power
source
is
signalled
by
the
weld
control
to
provide
a
cer
tain
predetermined
voltage.
The
actual
voltage
is
monitored
by
the
weld
control.
If
the
feedback
is
okay,
/
VOLT@OK/
appears
on
the
alpha-numeric.
If
the
feedback
indicates
that
the
preset
voltage
is
not
main
tained,
/VOLT@DEF/
appears
on
the
alpha-numeric.
SECTION
5
-
OPERATOR
CONTROLS
Voltage
Error
Reset
Button
Purge
Button
Up
Button
Jog
Speed
Control
Figure
5-1.
Weld
Control
Front
Panel
View
Jog
Down
Button
Run/Setup
Switch
1C085
225
Program
Select.
Button
Sequence
Advance
Button
Digital
Displays
Stop
Program
Run
Button
Wire
OM-1537
Page
15
uI~I~,]f~t~Ig
The
push
button
switches
except
for
the
EMERGENCY
STOP
button
on
the
weld
control
wi/I
be
lit
if
the
button
is
functional
or
coded
for
use
during
a
weld
program.
If
a
button
is
not
lit,
pressing
the
button
will
not
change
anything
because
the
button
is
not
functional.
The
HAL
TIRES
UME
button
will
flash
when
in
the
HALT
mode
and
will
continue
to
flash
until
the
program
is
resumed
or
terminated.
5-1.
POWER
EMERGENCY
STOP
BUTTON
(Figure
5-1)
-
Pulling
the
EMERGENCY
STOP
button
out
applies
115
vac
input
power
to
the
weld
control
thereby
making
it
operational.
Pressing
the
POWER
EMERGENCY
STOP
button
deenergizes
the
weld
control.
When
power
is
removed
in
this
manner,
all
pertinent
weld
program
data
is
stored
in
a
battery
powered
memory.
If
a
weld
program
was
being
run
when
power
was
shut
off,
the
program
can
be
continued
when
power
is
returned
(see
Section
5-12).
IMPORTANT
There
are
2
Nicad
size
AA
batteries
on
the
power
supply
circuit
board
in
the
unit.
These
bat
teries
supply
power
to
the
memory
when
the
unit
is
shut
off.
Initially,
the
unit
should
be
left
on
for
12
hours
to
ensure
that
the
batteries
are
fully
charged.
Failure
to
keep
batteries
charged
may
result
in
loss
of
data
stored
in
memory.
5
-
2.
RUN/SET
UP
SWITCH
(Figure
5-1)
-
When
the
RUN/SET
UP
switch
is
in
the
SET
UP
position,
depressing
the
PROGRAM
RUN
button
causes
the
weld
control
to
cycle
through
all
sequences
of
a
program
without
striking
an
arc.
The
welding
power
source
con
tactor
and
the
wire
feed
motor
are
not
energized.
programming,
the
indicators
will
show
what
is
program
med
but
the
actual
output
will
not
be
on.
5
-
5.
ALPHA-NUMERIC
DISPLAY
(Figure
5-1)
-
The
alpha-numeric
display
shows
the
sequence
that
the
weld
program
is
in.
See
Section
4-2
for
display
definitions.
5-6.
WELD
PROGRAM
INDICATORS
(Figure
5-1)
A.
Program
Indicator
The
PROGRAM
indicator
displays
the
number
(1-9)
of
the
weld
program
that
is
being
run
or
that
will
be
run
when
the
PROGRAM
RUN
button
is
pressed.
B.
Next
Program
Indicator
The
NEXT
PROGRAM
indicator
displays
the
number
(1-9)
of
the
weld
program
that
is
to
follow
the
weld
pro
gram
shown
on
PROGRAM
indicator.
C.
Code
Indicator
The
CODE
indicator
displays
the
code
number
(0-6)
of
the
sequence
shown
on
the
alpha-numeric.
When
in
Standby,
the
CODE
indicator
shows
the
code
of
the
Pause
sequence
for
the
program
shown
on
the
PRO
GRAM
indicator.
IMPORTANT
_____________
if
no
data
is
supplied
for
a
sequence,
the
respective
display
will
indicate
this
by
displaying
a
zero,
decimal
point,
zero,
etc.
pattern.
D.
Volts
Indicator
When
in
the
RUN
position,
the
weld
control
cycles
through
the
weld
program
in
the
normal
manner.
5
-
3.
JOGGING
CONTROLS
(Figure
5-1)
A.
Wire
Jogging
Speed
Control
The
WIRE
JOGGING
SPEED
control
varies
the
wire
feed
speed
only
when
the
JOG
UP
and
JOG
DOWN
buttons
are
pressed.
B.
JOG
Up
Push
Button
Switch
When
the
JOG
UP
button
is
pressed,
a
brief
delay
will
occur,
and
then
wire
will
retract
back
toward
the
wire
spool
at
a
rate
set
by
the
WIRE
JOG
SPEED
control.
C.
JOG
Down
Push
Button
Switch
When
the
JOG
DOWN
button
is
pressed,
wire
will
ad
vance
from
the
wire
spool
at
a
rate
set
by
the
WIRE
JOG
SPEED
control.
Normally
this
control
is
used
dur
ing
welding
wire
threading
and
to
obtain
proper
elec
trode
stick
out
for
starting
the
arc.
5
-
4.
AUXILIARY
OUTPUT
INDICATORS
(Figure
5-1)
-
Auxiliary
output
indicators
A
and
B
will
be
on
when
the
corresponding
output
is
active,
and
off
when
output
is
inactive
while
a
program
is
running.
During
The
VOLTS
indicator
displays
the
actual
arc
voltage
(0-99.9)
while
the
program
is
running
and
the
program
med
arc
voltage
when
the
unit
is
idling.
If
the
welding
power
source
cannot
maintain
the
programmed
voltage,
the
VOLTS
indicator
will
flash
on
and
off
while
welding
until
a
voltage
is
set
within
the
range
of
the
welding
power
source.
~
On
the
main
Circuit
board
there
is
a
6-pin
jumpering
socket:
J9
lfQ
0
J1O
CUT
210
V
3L0
0
ARC
Figure
5-1.
Jumpering
Socket
TA-~84
633
The
unit
is
shipped
with
J.9
jumper
between
2
and
3.
With
J9
in
this
position,
the
VOL
TS
indicator
flashes
on
and
off
if
the
welding
power
source
cannot
mŁintain
programmed
voltage.
If
the
jumper
is
moved
to
1
and
2,
the
unit
will
shut
down
as
if
the
HAL
TIRES
UME
button
(see
Section
5-12)
were
pressed
when
the
we/ding
power
source
Cannot
maintain
programmed
voltage.
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16
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Miller JB559844 Owner's manual

Miller
Brand
Miller
Model
JB559844
Category
Welding System
Type
Owner's manual
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