Miller SWINGARC DIGITAL-2 12 AND 16 Owner's manual

December

1979

FORM:

OM-1523

Effective

With

Serial

No.

HK328924

MODEL

SWINGARC

DIGITAL

-2

12

SWINGARC

DIGITAL

-2

16

OWN

ERS

MANUAL

!I!111EI

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

PAINTED

IN

U.S.A.

~P

LIMITED

WARRANTY

EFFECTIVE:

JANUARY

I,

1979

This

warranty

supersedes

all

warranties

and

is

cx-

S

clusive

with

no

other

guarantees

or

warranties

expressed

or

implied.

LIMITED

WARRANTYSubject

to

the

terms

and

conditions

As

a

matter

of

general

policy

only,

Miller

may

honor

claims

hereof,

Miller

Electric

Mfg.

Co.,

Appleton,

Wisconsin

warrants

to

su~t~itted

by

the

original

user

within

the

foregoing

periods.

its

Distributor/Dealer

that

all

new

and

unused

Equipment

furnished

S

by

Miller

is

free

from

defect

in

workmanship

and

material

as

of

the

In

the

case

of

Millers

breach

of

warranty

or

any

other

duty

time

and

place

of

delivery

by

Miller.

No

warranty

is

made

by

Miller

with

respect

to

the

quality

of

any

goods,

the

exclusive

remedies

with

respect

to

engines,

trade

accessories

or

other

items

manu-

therefor

shall

be,

at

Millers

option,

(1)

repair

or

(2)

replacement

or,

factured

by

others.

Such

engines,

trade

accessories

and

other

where

authorized

to

writing

by

Miller

in

appropnate

cases,

(3)

the

items

are

sold

subject

to

the

warranties

of

their

respective

manu-

reasonable

cost

of

repair

or

replacement

at

an

authorized

Miller

ser

facturers,

if

any.

At

the

present

time,

the

manufacturers

warranty

on

vice

station

or

(4)

payment

of

or

credit

for

the

purchase

price

(less

the

Mag-Diesel

engine

on

DEL-200

is

limited

to

six

months

and

on

reasonable

depreciation

based

upon

actual

use)

upon

return

of

the

all

other

engines

to

one

year.

goods

at

Customers

risk

and

expense.

Upon

receipt

of

notice

of

apparent

defect

or

failure,

Miller

shall

instruct

the

claimant

on

the

~

Except

as

specified

below,

Millers

warranty

does

not

apply

to

warranty

claim

procedures

to

be

followed.

components

having

normal

useful

life

of

less

than

one

(1)

year,

such

ANY

EXJRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

as

spot

welder

tips,

relay

and

contactor

points,

MILLERMATIC

parts

ANY

IMPLIED

WARRANTY

GUARANTY

OR

REPRESENTA

that

come

in

contact

with

the

welding

wire

including

nozzles

aM

TION

AS

TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

nozzle

insulators

where

failure

does

not

result

from

defect

in

BREACH

OF

CONTRACT

WHICH,

BUT

FOR

THIS

PROVISION,

workmanship

or

material.

MIGHT

ARISE

BY

IMPLICATION,

OPERATION

OF

LAW,

CUS

TOM

OF

TRADE

OR

COURSE

OF

DEALING

INCLUDING

ANY

Miller

shall

be

required

to

honor

warranty

claims

on

warranted

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

OF

FITNESS

Equipment

in

the

event

of

failure

resulting

from

a

defect

within

the

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

TO

ANY

AND

following

periods

from

the

date

of

delivery

of

Equipment

to

the

ALL

EQUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

J

original

user:

AND

DISCLAIMED

BY

MILLER.

I.

Arc

welders,

power

sources

aM

components

. .

.

1

year

EXCEPT

AS

EXPRESSLY

PROVIDED

BY

MILLER

IN

WRIT-

2.

Original

main

power

rectifiers

3

years

ING,

MILLER

PRODUCTS

ARE

INTENDED

FOR

ULTIMATE

(labor

-

I

year

only)

PURCHASE

BY

COMMERCIAL/INDUSTRIAL

USERS

AND

FOR

3.

All

welding

guns

and

feeder/g~s

90

da~

OPERATION

BY

PERSONS

TRAINED

AND

EXPERIENCED

IN

4.

All

other

Millermatic

Feeders

1

year

THE

USE

AND

MAINTENANCE

OF

WELDING

EQUIPMENT

AND

5.

Replacement

or

repair

parts,

exclusive

of

labor

. -

60

days

NOT

FOR

CONSUMERS

OR

CONSUMER

USE.

MILLER

WAR-

6.

Batteries

6

months

RANTIES

DO

NOT

EXTEND

TO,

AND

NO

RESELLER

IS

provided

that

Miller

is

notified

in

writing

within

thirty

(30)

days

of

AUTHORIZED

TO

EXTEND

MILLERS

WARRANTIES

TO,

the

date

of

such

failure.

ANY

CONSUMER.

~

,5

~t.

_..,I,

~

~%

~

...~b

...-~%

--~~b

ERRATA

SHEET

After

this

manual

was

printed,

refinements

in

equipment

design

occurred.

This

sheet

lists

exceptions

to

data

appearing

later

in

this

manual.

AMENDMENT

TO

SECTION

3

-

iNSTALLATION

Amend

Section

3-11.

MOTOR

CONTROL

CONNECTION

(Figure

3-8)

A

receptacle

is

provided

for

connecting

the

motor

control

plug

to

the

control.

Align

keyways

and

insert

the

plug

from

the

control

end

of

the

boom

into

the

receptacle

and

rotate

the

plug

threaded

collar

clockwise

as

far

as

possible..

AMENDMENT

TO

SECTION

7

-

TROUBLESHOOTING

T~

Quantity

Item

Or

Dia.

Part

Replaced

Model

Page

No.

Mkgs.

No.

With

Description

12

I

16

37

047

901

046

757

CONTROL

BOX

(EffW/JA364525)

1

140

047

227

045

896

CIRCUIT

CARD,

motor

speed

(Eff

W/JA386589)

1

148

047

104

046 754

BRACKET,

mtg

-

gas/water

(EffW/JA364525)

1

158

047107

046751

CASE

SECTION,

front/bottom/back

(Eff

W/JA364525)

1

Page

8

C57

035

835

031

677

CAPACITOR,

tantalum

5.6

uf

35

volts

dc 2

2

Page

8

D50-54,

56-60

026202

DIODE(qtychange)

10

Page

8

R51,53-57,

63,64,68,

74,75,81,

82,84,89

035

827

035 827

RESISTOR

(qty

change)

15

Page

8

R67

039

331

039

331

RESISTOR

(qty

change)

1

Page

8

R80

035

886

035

886

RESISTOR

(qty

change)

1 1

179

047170

045391

TUBING,neoprene3/8IDx3/32waIlx8

2 2

181

047171

045390

LINER,monocoil3/32-1/8wirex9

2

189

073

664

024

605

BEARING,

baIl

1

197

073

695

047 224

KNOB,

t-bar

1

051

297

ADAPTER

(added

to

item

15)

1

010

193

TUBING

2

048

336

COVER

STOP

2

045233

GUIDE,

antiwear

2

079

029

NUT,

hex-full

3/4-16

1

t045

503

LOCKING

COVER

1

tOptional

Parts.

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBERS

WHEN

ORDERING

REPLACEMENT

PARTS.

-

-.

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Serial

No.

JA386589

TABLE

OF

CONTENTS

Section

No.

Page

No.

SECTION

1

-

SAFETY

RULES

FOR

OPERATION

OF

ARC

WELDING

POWER

SOURCE

1

-

1.

Introduction

1

-

2.

General

Precautions

1

-3.

Arc

Welding

3

1

-

4.

Standards

Booklet

tndex

4

SECTION

2

-

INTRODUCTION

2-1;

General

5

2

-

2.

Receiving-Handling

5

2

-

3.

Description

5

2-4.

Safety

5

SECTION

3

-

INSTALLATION

3

-

1.

Location

And

Assembly

5

3

-

2.

Drive

Motor

7

3

-

3.

Installation

Of

Wire

Support

7

3

-

4.

Reinstallation

Of

Hub

Assembly

7

3

-

5.

Installation

Of

Wire

Reel

7

3

-

6.

Drive

Roll

And

Wire

Installation

7

3

-

7.

Water

Control

Kit

(Optional)

Connections

8

3

-

8.

Welding

Gun

Connections

9

3

-

9.

Shielding

Gas

Connections

9

3-10.

Boom

Adjustments

9

3-11.

Motor

Control

Connection

10

3-12.

Gun

Trigger

Connections

10

3-13.

Weld

Cable

Connection

10

3-14. 115

Volts/Contactor

Control

Connections

10

3-15.

Installation

Of

Spool-Type

Wire

11

3-16.

Installation

Of

Reel-Type

Wire

11

3-17.

AdjustmentOfHublension

11

3-18.

WeldingWireThreading

11

SECTION

4

-

FUNCTION

OF

CONTROLS

4

-

1.

Power

Switch

12

4

-

2.

Wire

Speed

Controls

12

4

-

3.

Remote

Control

Receptacles

And

Switches

12

4

-

4.

Purge

Buttons

12

4

-

5.

Inch

Switches

12

4

-

6.

Inches

Per

Minute

Meter

12

4

-

7.

Reset

Circuit

Breaker

13

4

-

8.

Burnback

Controls

13

SECTION

5

-

SEQUENCE

OF

OPERATION

5

-

1.

Gas

Metal-Arc

Welding

(GMAW)

13

5

-

2.

Shutting

Down

13

SECTION

6

-

MAINTENANCE

6

-

1.

Inspection

And

Upkeep

13

6

-

2.

Cleaning

Of

Drive

Rolls

14

6-3.

Fuse

14

6

-

4.

Brush

Inspection

&

Replacement

14

SECTION

7

-

TROUBLESHOOTING

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

to

follow

the

rules.

IRead

and

understand

these

safe

practices

before

attempting

to

install,

operate,

or

service

the

equipment.

Comply

with

these

procedures

as

applicable

to

the

particular

equipment

used

and

their

instruction

manuals,

for

personal

safety

and

for

the

safely

of

others.

Failure

to

observe

these

safe

practices

may

cause

serious

in

jury

or

death.

When

safety

becomes

a

habit,

the

equipment

can

be

used

with

confidence.

These

safe

practices

are

divided

into

two

Sections:

1

-

General

Precautons,

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

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

in

spection

requirements

also

provide

a

basis

for

equipment

in

stallation,

use~

and

service.

GENERAL

PRECAUTIONS

Burn

Prevention

Wear

protective

clothing

-

leather

(or

asbestos)

gauntlet

gloves,

hat,

and

high

safety-toe

shc~s.

Button

shirt

collar

and

pocket

flaps,

and

wear

cuffless

trousers

to

avoid

entry

of

sparks

and

slag.

Wear

helmet

with

safely

goggles

or

glasses

with

side

shields

underneath,

appropriate

filter

lenses

or

plates

(protected

by

clear

cc~ier

glass).

This

is

a

MUST

for

welding

or

cutting,

(and

chipping)

to

protect

the

eyes

from

radiant

energy

and

flying

metal.

Replace

cover

glass

when

broken,

pitted,

or

spattered.

See

1-3A,2,

Avoid

Oily

or

greasy

clothing.

A

spark

may

ignite

them.

Hot

metal

such

as

electrode

stubs

and

workpieces

should

never

be

handled

without

gloves.

Medical

first

aid

and

eye

treatment.

First

aid

facilities

and

a

qualified

first

aid

person

should

be

available

for

each

shift

unless

medical

facilities

are

close

by

for

immediate

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

ove

the

ad.

Flammable

hair

preparations

should

not

be

used

by

persons

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

Stan

dard

Z49.1

listed

1

in

Standards

index.

NEVER

ventilate

with

oxygen.

Lead

-,

cadmium

.,

zinc

.,

mercury

-,

and

beryllium

-

bearing

and

similar

materials,

when

welded

(or

cut)

may

produce

harmful

concentrations

of

toxic

fumes.

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

the

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

at

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

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

products.

The

ultra

violet

(radiant)

energy

of

the

arc

can

also

decompose

tn

chioroethylene

and

perchloroethylene

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

trichloroethylene

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

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

cuti.

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

tion)

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

wi

thin

35

feet

may

expose

combustibles

to

sparks

d.

combustibles

adjacent

to

walls,

ceilings,

roofs,

or

metal

partitions

can

be

ignited

by

radiant

or

conducted

heat.

Hot

work

permit

should

be

obtained

before

operation

to

ensure

supervisors

approval

that

adequate

precautions

have

been

taken.

After

work

is

done,

check

that

area

is

free

of

sparks,

glowing

embers,

and

flames.

An

empty

container

that

held

combustibles,

or

that

can

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-1523

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

as

recom

mended

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

gaso

line).

0.

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.

i.

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

when

pressurized,

nor

returns

to

stop

after

pressure

release.

Repair.

Do

NOT

attempt

repair.

Send

faulty

regulators

for

repair

to

manufacturers

designated

repair

center,

where

special

techniques

and

tools

are

used

by

trained

personnel.

2.

Cylinders

must

be

handled

carefully

to

prevent

teaks

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

1-3C.)

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

130F.

Cool

with

water

spray

where

such

exposure

exists.

Protect

cylinders

particularly

valves

from

bumps,

falls,

falling

oblects.

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

to

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

sharp

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

to

seal

stem

against

possible

leak.

For

fuel

gas,

open

to

less

than

one

turn

to

permit

quick

emergency

shutoff.

age2

Use

pressure

charts

(available

from

your

supplier)

for

safe

and

efficient,

recommended

pressure

settings

on

regulators.

Check

for

leaks

on

first

pressurization

and

regularly

there

after.

Brush

with

soap

solution

(capful

of

Ivory

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

g~

supply

at

source

and

drain

g~.

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

g~-shielded

arcs

are

more

severe

and

painful.

DONT

GET

BURNED;

COMPLY

WITH

PRECAUTIONS.

1.

Protective

Clothing

Wear

long-sleeve

clothing

(particularly

for

ga-shielded

arc)

in

addition

to

gloves,

hat,

and

shoes

(1-2A).

As

necessary,

use

additional

protective

clothing

such

~

leather

jacket

or

sleeves,

flame-proof

apron,

and

fire-resistant

leggin~.

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

filterplate

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

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

are~,

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

directly

at

the

weld.

Others

working

in

area.

See

that

all

persons

are

wearing

flash

goggles.

Before

starting

to

weld,

make

sure

that

screen

flaps

or

bay

doors

are

closed.

B.

Toxic

Fume

Prevention

Comply

with

precautions

in

1-2B.

Generator

engine

exhaust

must

be

vented

to

the

outside

air.

Carbon

monoxide

can

kill.

C.

Fire

and

Explosion

Prevention

Comply

with

precautions

in

1-2C,

Equupment~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

1-20.

E.

Shock

Prevention

Exposed

hot

conductors

or

other

bare

metal

in

the

welding

circuit,

or

in

ungrounded,

electncatly.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

mat

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

water

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-phsse

connection.

Check

phsse

requirement

of

equip

ment

before

installing.

If

only

3-phase

power

is

available,

connect

single-phase

equipment

to

only

two

wires

of

the

3-ph~e

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-1523

Page

3

2.

ElectrodeHolders

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

plu~.

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,

FIa.

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

Stwidard

518,

CUTTING

AND

WELDING

PRO.

CESSES,

obtainable

same

as

item

4.

6.

CGA

Pamphlet

P-i.

SAFE

HANDLING

OF

COM

PRESSED

GASES

IN

CYLINDERS,

obtainable

from

the

Compressed

Gas

Association,

500

Fifth

Avenue,

New

York,N.

V.

10036.

7.

OSHA

Standard

29

CFR.

Part

1910,

Subpart

0.

WELD.

ING.

CUTTING

AND

BRAZING.

~age4

SECTION

2

-

INTRODUCTION

Model

Dual

12

I

Dual

16

Speed

Range

50-785

l.P.M.

Boom

Length

12

ft.

I

16

ft.

Swing

360

Vertical

Lift

Horizontal

To

60

Above

Maximum

Height

(With

4

Ft

Post)

At

Full

Lift

Of

Boom

17

ft.

21

ft.

Counterbalance

(Patented)

Compression

Spring

Is

Designed

To

Balance

Boom

At

Any

Angle.

Pressure

Adjustment

Is

Provided

To

Hold

The

Boom

At

Any

Desired

Angle

Or

To

Limit

The

Vertical

Lift

At

40,

50,

or

60.

Weight

(Pounds)

Net

Ship

Net

Ship

210

330

275

415

2

-

1.

GENERAL

-

This

manual

has

been

prepared

especially

for

use

in

familiarizing

personnel

with

the

design,

installation,

operation,

maintenance,

and

troubleshooting

of

this

equipment.

All

information

presented

herein

should

be

given

careful

consideration

to

assure

optimum

performance

of

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

on

request

if

occasion

to

file

claim

arises.

When

requesting

information

concerning

this

equip

ment,

it

is

essential

that

Model

Description

and/or

Stock

Number

and

Serial

(or

Style)

Numbers

of

the

equipment

be

supplied.

2

-

3.

DESCRIPTION

-

This

unit

is

a

boom

mounted

digital

wire

control/feeder.

The

control/feeder

is

of

the

constant

wire

feed

speed

type

which

feeds

wire

alter

nately

from

two

welding

guns.

It

is

designed

to

be

used

in

conjunction

with

1

or

2

constant

potential

welding

power

source.

The

boom

is

a

patented

design

allowing

both

vertical

lift

and

swing.

Cables

are

routed

through

the

boom

from

the

feeder

control

to

the

wire

drive

assembly.

The

control/feeder

is

a

heavy

duty

wire

feeding

unit

which

maintains

constant

wire feed

speed

regardless

of

line

or

load

variations.

It

contains

all

the

controls

and

equipment

needed

to

supply

welding

wire

and

shielding

gas

to

the

welding

guns.

2

-

4.

SAFETY

-

Before

the

equipment

is

put

into

operation,

the

safety

section

at

the

front

of

this

manual

should

be

read

completely.

This

will

help

avoid

possible

injury

due

to

misuse

or

improper

welding

applications.

The

following

definitions

apply

to

CAUTION,

IMPOR

TANT,

and

NOTE

blocks

found

throughout

this

manual:

CAUTION:

_____

Under

this

heading,

installation,

operating,

and

maintenance

procedures

or

practices

will

be

found

that

if

not

carefully

followed

may

create

a

hazard

to

personnel.

IMPORTANT

______________

Under

this

heading,

operating,

and

maintenance

procedures

or

practices

will

be

found

that

if

not

carefully

followed

may

result/n

damage

to

equip

ment.

I~I~I~

Under

this

heading,

explanatory

statements

will

be

found

that

need

spec/al

emphasis

to

obtain

the

most

efficient

operation

of

the

equipment.

SECTION

3

-

INSTALLATION

3

-

1.

LOCATION

AND

ASSEMBLY

(Figure

3-1)

A.

Location

A

suitable

location

for

this

unit

will

allow

room

for

the

boom

to

swing

horizontally

in

the

desired

arc,

and

to

pivot

upward

to

the

desired

angle.

Proper

placement

will

also

proide

sufficient

clearance

from

obstruction

at

the

wire

support

end

of

the

unit

when

the

boom

swings.

The

structure

to

which

the

unit

is

being

installed

should

be

of

sufficient

construction

to

support

the

weight

of

the

unit

when

the

boom

is

in

the

horiziontal

position.

B.

Assembly

1.

Existing

Support

(Customer

Supplied)

OM-1523Page5

IMPORTANT

_____________

In

selecting

the

pipe

used

to

support

the

unit

the

model

utilizing

a

12

foot

boom

requires

a

2-1/2

inch

diameter,

Schedule

40

pipe

(wall

thickness

of

.203

inches).

The

model

with

a

16

foot

boom

requires

a

5

inch

diameter,

Schedule

40

pipe

(wall

thickness

of

.258

inches).

ture.

k.

2.

Post

Support

(Optional)

CAUTION

___________

The

structure

to

which

the

post

support

is

mounted

must

be

of

sufficient

construction

to

sup

port

the

weight

of

the

unit

when

the

boom

is

in

the

horizontal

position.

c.

Remove

yoke

(1),

nut

(10),

washers

(9

&

17)

and

bolt

(18)

from

the

yoke

(3)

and

swivel

plates

(16).

CAUTION:

Do

not

remove

safety

collar

(11)

until

in

structed

to

do

so.

The

swivel

base

(8)

contains

high

pressure

springs

to

counter

balance

the

weight

at

the

weld

head.

d.

Place

bearing

(13)

on

top

of

post

(14)

and

in

sert

swivel

(8)

into

post

(14).

e.

Place

the

boom

base

plate

(19)

in

between

the

two

swivel

plates.

f.

Slide

washer,

(17)

onto

bolt

(18)

and

insert

bolt

(18)

through

hole

(15).

Slide

washer

(9)

onto

bolt

(18)

and

install

nut

(10)

onto

bolt

(18).

Tighten

nut

(10);

then

back

off

nut

(10)

1/2

turn.

g.

Insert

(1)

through

yoke

(3),

hole

(2),

and

install

cotter

(4)

through

(1).

h.

Connect

the

welding

guns

to

the

drive

assembly

as

instructed

in

the

Owners

Manual

for

the

desired

welding

guns.

i.

Grasp

bar

(20)

and

pull

boom

down

slightly.

The

boom

should

be

pulled

down

only

far

enough

to

remove

the

pressure

which

is

ap

plied

to

the

safety

collar

(11).

j.

Remove

the

safety

collar

(11)

and

retain

for

future

adjustments.

k.

The

boom

should

now

balance

in

any

posi

tion

from

horizontal

to

60

degrees

above

horizontal.

If

the

boom

does

not

balance

properly,

proceed

to

Section

3-10.

3.

Base

Support

(Optional)

I

~

If

an

optional

base

support

was

purchased

with

the

unit,

mounting

ho/es

are

provided

for

fastening

the

base

support

to

the

floor.

IMPORTANT

When

an

optional

base

support

is

us

ed,

the

base

must

be

securely

mounted

to

the

floor.

As

a

minimum,

1/2

dia.,

S.A.

E.

grade

5

bolts,

with

ade

quate

corrosion

protection

should

be

used

to

secure

the

base.

If

the

unit

is

to

be

mounted/n

an

extremely

damp

environment,

mounting

bolts

made

of

a

non-corrosive

material

with

a

strength

equivalent

to

S.A.

E.

grade

5

steel

should

be

used.

a.

Uncrate

and

remove

all

packing

material

from

the

unit.

a.

Uncrate

and

remove

all

packing

material

from

the

unit.

b.

Mount

pipe

post

(14)

to

the

desired

struc

I

~T)

5

6

8

.9

15

12

13

14

Figure

3-1.

Base

And

Boom

Assembly

CAUTION

___________

The

structure

to

which

the

pipe

post

is

mounted

must

be

of

sufficient

construction

to

support

the

weight

of

the

unit

when

the

boom

is

in

the

horizon-

ta/position.

IiIsIl

~

The

post

support

(14)

is

provided

with

a

fitting

TB-081

~

for

lubricating

the

swivel

periodically,

to

prevent

premature

wear

and

to

ease

turning

during

operation.

Excessive

greasing

~of

support

fitting

is

not

required

or

recommended.

c.

Proceed

to

Subsection

B2,

Steps

c

through

a.

Uncrate

and

remove

all

packing

material

from

the

unit.

b.

Mount

post

support

(14)

to

the

desired

structure.

b.

Fasten

base

support

to

the

floor.

c.

Complete

Steps

c

through

k,

Subsection

B2.

I~.)1~

The

base

support/s

provided

with

a

fitting

for

lubricating

the

swivel

periodically,

to

prevent

premature

wear

and

to

ease

turning

during

operation.

Excessive

greasing

of

support

fitting

is

not

required

or

recom

mended.

4.

Swingpak

Base

(Optional)

a.

Uncrate

and

remove

all

packing

material

from

the

Swingpak

base.

The

installation

of

the

we/ding

power

source

onto

the

Swingpak

base

should

precede

moun

ting

of

the

Swingarc

unit

in

order

to

prevent

tipping

of

the

frame

under

the

weight

of

the

boom.

b.

Uncrate

and

remove

all

packing

material

from

the

Swingarc

unit.

c.

Complete

Steps

c

through

k,

Subsection

B2.

I~I.I

I

~

The

Swingpak

base

is

provided

with

a

fitting

for

lubricating

the

swivel

periodically,

to

prevent

premature

wear

and

to

ease

turning

during

operation.

Excessive

greasing

of

support

fitting

is

not

required

or

recommended.

3

-

2.

DRIVE

MOTOR

-

The

drive

motor

is

provided

with

a

vent

screw

which

must

be

removed

prior

to

the

operation

of

the

control/feeder.

The

vent

screw

can

be

removed

through

the

hole

provided

in

the

motor

shroud

(see

Figure

3-6).

3

-

3.

INSTALLATION

OF

WIRE

SUPPORT

(Figure

3-1)

1.

Remove

the

securing

screws

(5)

and

lock

washers

(6)

from

the

swivel

base

(8)

2.

Lift

the

wire

support

(7)

in

place

over

the

holes

in

the

swivel

base

(8).

3.

Insert

securing

screws

(5)

with

lock

washers

(6)

and

tighten.

3

-

4.

REINSTALLATION

OF

HUB

ASSEMBLY

(Figure

3-2)

-

If

it

should

become

necessary

to

replace

part

or

all

of

the

hub

assembly(s),

reinstall

the

new

hub

assembly(s)

as

follows:

IMPORTANT

3.

Depress

the

two

spring

loaded

stops

(11)

on

the

retaining

ring

(12)

and

slide

the

retaining

ring

(12)

into

proper

position

on

the

hub

(4).

Release

the

two

stops

(11).

3

-

5.

INSTALLATION

OF

WIRE

REEL

(Optional)

(Figure

3-3)

-

The

following

procedures

for

the

installa

tion

of

the

wire

reels

are

applicable

to

the

left

and/or

right

sides.

1.

Slide

the

following

items

onto

the

spindle

sup

port

shaft

(1)

in

order

given:

a.

Fiber

Washer

(2)

b.

Flat

Washer

(3)

c.

Hub

(4)

d.

Flat

Washer

(5)

e.

Fiber

Washer

(6)

f.

Keyed

Washer

(7)

g.

Spring

(8)

h.

Flat

Washer

(9)

2.

Rotate

hex

nut

(10)

onto

support

shaft

(1).

Hex

nut

should

be

rotated

only

until

a

slight

drag

is

felt

while

turning

hub

(4).

2.

Slide

the

wire

reel

(1)

onto

the

hub

(5).

Rotate

the

wire

reel

(1)

until

the

hub

guide

(6)

is

seated

in

the

reel

(1).

3.

Replace

the

retaining

ring

(4).

3

-

6.

DRIVE

ROLL

AND

WIRE

GUIDE

INSTALLA

TION

(Figures

3-4

&

3-5)

-

Upon

intitial

installation,

or

as

a

result

of

changes

in

wire

size

and

type,

it

is

necessary

to

install

the

required

drive

rolls

and

wire

guides.

I~IsI

I

~

Base

selection

of

drive

rolls

upon

the

follow

ing

recommended

usages:

1.

V-Groove

rolls

for

hard

wire.

4

10

11

12

Figure

3-2.

Wire

Support

And

Hub

Assembly

TBO81

754

2

3

5.

4

Figure

3-3.

Reel

Installation

1.

Remove

the

retaining

ring

(4).

TB-O81

766

OM-1523

Page

7

2.

U-Groove

rolls

for

soft

and

soft

shelled

cored

wires.

3.

U-Cog

rolls

for

extremely

soft

shelled

wires

(usually

hard

surfacing

types).

4.

Spilt

V-Knurled

rolls

for

hard

shelled

cored

wires

(seff-shielding

and

CO2

shielded

types).

5.

Drive

roll

types

may

be

mixed

to

suit

particular

re

quirements

(example:

V-knurled

roll

in

combination

with

U-groove).

Having

selected

the

appropriate

drive

rolls

and

wire

guides

proceed

to

the

installation

instructions

for

the

type

of

drive

roll

to

be

used.

A.

Drive

Roll

Installation

(Figures

3-4

&

3-5)

1.

Loosen

pressure

adjustment

wing

nut

(item

2,

Figure

3-4)

and

pivot

it

free

of

cover.

2.

Pivot

gear

cover

(4)

away

to

expose

pressure

gear.

3.

Loosen

and

remove

the

three

securing

screws

(7

&

12)

on

each

gear

(5

&

9).

4.

For

one

piece

drive

rolls

(8

&

13):

Slide

a

drive

roll

onto

the

drive

gear

(9)

and

pressure

gear

(5)

with

holes

aligned

and

secure

with

screws

(7

&

12).

For

split

drive

rolls

(6

&

10):

Align

holes

on

each

side

of

split

drive

rolls,

insert

a

securing

screw

(7

&

12)

and

slide

a

drive

roll

onto

the

drive

gear

(9)

and

pressure

gear

(5)

with

screw

in

line

with

one

of

the

threaded

holes.

Insert

remaining

screws

(7

&

12)

and

tighten.

I~SIl~

One-piece

drive

rolls

(8

&

13)

are

of

the

double

usage

type.

When

the

grooves

become

worn,

reverse

each

drive

roll,

locating

the

unused

groove

in

position

to

feed

the

wire.

Spilt

drive

rolls

(6

&

10)

are

of

the

double

usage

type.

When

the

knurled

groove

of

the

drive

roll

becomes

worn,

the

split

halves

may

be

reversed

so

that

the

unus

ed

edges

will

now

provide

a

new

knurled

groove.

I~i~l~

To

ensure

proper

gripping

action

of

U-Cog

drive

rolls,

both

rolls

should

be

installed

showing

slots

on

the

side

or

both

should

show

the

side

without

slots.

Also,

it

is

necessary

to

line

up

the

blunted

teeth

on

the

pressure

gear

roll

directly

over

the

spaces

between

the

teeth

on

the

drive

gear

roll

as

illustrated

in

Figure

3-5.

B.

Inlet

Wire

Guide

(Figure

3-4)

1.

Loosen

the

inlet

wire

guide

securing

screws

(3).

I~sI

I

~

Wire

guides

should

be

installed

so

that

the

tip

of

the

guide

is

as

close

to

the

drive

roll

as

possible

without

touching.

2.

Insert

the

inlet

wire

guides

(1)

into

drive

assembly

as

illustrated

in

Figure

3-4.

Secure

by

tightening

screws

(3).

~

I

~

Behind

the

drive

gear

is

a

spring

washer(s).

To

obtain

proper

alignment

of

the

drive

roll

on

the

drive

gear

with

the

wire

guides

rotate

the

drive

gear

securing

bolt

(11)

thereby

moving

the

drive

roll

in

or

out

to

the

desired

position.

The

drive

roll

on

the

pressure

gear

will

locate

itself

on

the

wire

when

the

gear

cover

is

replaced

and

the

gears

mesh

together.

3

-7.

WATER

CONTROL

KIT

(Optional)

CONNEC

TIONS

Water

coolant

is

supplied

to

either

one

gun

or

both

guns

utilizing

one

water

solenoid

and

the

same

input,

output,

and

return

hoses.

The

solenoid

is

energized

when

the

POWER

switch

is

placed

in

the

ON

position.

Connect

a

hose

from

the

water

supply

to

the

Water

in

put

fitting

at

the

rear

of

the

control.

This

fitting

has

a

left-hand

thread.

The

water

supply

hose

routed

through

the

boom,

connects

to

the

Water

fitting

at

the

front

of

the

control.

Drive

Gear

U-Cog

RollS

U-Cog

Roil

Slotted

Side

of

U-Cog

Roil

TA-OSi

756

Figure

3-5.

U-Cog

Drive

Rolls

Installation

Figure

3-4.

Drive

Rolls

Installation

age8

When

water

is

required

for

one

gun

only,

connect

the

adapter

to

the

appropriate

weld

terminal

on

the

drive

assembly

and

connect

the

water

return

hose

to

this

adapter.

If

water

is

required

for

both

guns,

connect

the

return

hose

V

assembly

to

an

adapter

at

each

weld

terminal.

The

water

return

hose

is

routed

through

the

boom

to

an

appropriate

disposal.

3-8.

WELDING

GUN

CONNECTIONS

A.

Outlet

Wire

Guides

(Figure

3-4)

I~Is~I~

The

outlet

guide

is

provided

as

part

of

each

gun

assembly.

1.

Loosen

the

outlet

guide

adjustable

knob(s)

(16).

I~II1t~

Wire

guides

should

be

installed

so

that

the

tip

of

the

guide

is

as

close

to

the

drive

roll

as

possible

without

touching.

2.

Insert

the

gun/feeder

adapter(s)

(14)

from

the

gun(s)

which

includes

the

installed

outlet

guide(s),

into

the

drive

assembly

opposite

the

respective

inlet

wire

guide(s)

(1)

as

illustrated

in

Figure

3-4.

3.

Tighten

the

outlet

guide

adjustable

knobs

(16).

B.

Weld

Cables

(Figure

3-6)

Two

holes

are

provided

in

the

drive

assembly

for

con

necting

the

boom

weld

cables

and

the

corresponding

gun

weld

cables

(see

Figure

3-6).

Connect

the

Left

Gun

weld

cable

(if

so

equipped)

to

the

boom

weld

cable

on

the

left

side

of

the

drive

assembly

and

the

Right

Gun

weld

cable

(if

so

equipped)

to

the

boom

weld

cable

on

the

right

side

of

the

drive

assembly

using

the

supplied

hardware.

Figure

3-6.

Gun

Weld

Cable

Connections

C.

Shielding

Gas

The

shielding

gas

hose

from

each

gun

is

to

be

con

nected

to

the

appropriate

gas

hose

which

extends

out

of

the

motor

end

of

the

boom.

Connect

the

gas

hose

from

the

Left

Gun

to

the

hose

labeled

LEFT

GAS

and

the

gas

hose

from

the

Right

Gun

to

the

other

gas

hose.

I~.)

I

~

Integral

gas

input

fittings

are

provided

on

the

drive

assembly

for

guns

utilizing

this

type

of

connection

(see

Figure

3-6).

If

the

gas

hoses

which

extend

out

of

the

motor

end

of

the

boom

are

provided

with

fittings,

cut

the

fittings

off

and

push

the

hoses

onto

the

ap

propriate

barbed

fittings

on

the

drive

assembly.

See

the

appropriate

welding

gun

Owners

Manual

for

instruc

tions

on

making

this

connection.

0.

Gun

Trigger

Two

four-contact

receptacles

extend

out

of

the

motor

end

of

the

boom

for

connecting

the

gun

trigger

plugs

to

the

control.

Connect

the

Left

Gun

to

the

gun

trigger

receptacle

labeled

LEFT

TRIGGER,

and

the

Right

Gun

to

the

other

gun

trigger

receptacle

by

inserting

the

plugs

fully

into

the

receptacles

and

rotating

the

locking

rings.

CAUTION

___________

When

one

we/ding

power

source

is

utiliz

ed,

both

electrode

wires

will

be

electrically

energized

when

either

gun

trigger

is

depressed.

E.

Water

(If

Applicable)

If

water

coolant

is

required

for

one

gun

only,

connect

the

gun

water

input

hose

to

the

water

output

hose

at

the

motor

end

of

the

boom.

(If

water

is

required

for

both

guns,

the

water

output

hose

from

the

control

divides

at

the

motor

end

of

the

boom

to

accept

connections

from

both

gun

water

input

hoses).

Connect

the

water

return

hose

from

the

gun

to

the

adapter

at

the

appropriate

weld

terminal

on

the

drive

assembly.

Reducing

bushings

are

provided

to

accept

5/8-18

L.H.

fittings.

If

the

reducing

bushings

are

removed,

7/8-14

L.H.

fittings

can

be

accomodated.

3

-

9.

SHIELDING

GAS

CONNECTIONS

-

A

divided-hose

assembly

is

supplied

with

the

unit

for

mak

ing

connections

to

the

Shielding

Gas

input

fittings

at

the

rear

of

the

control

from

one

shielding

gas

source.

These

fittings

have

a

right-hand

thread.

I~IeI

I

~

If

a

different

shielding

gas

is

required

for

each

welding

gun,

a

separate

hose

can

be

connected

from

each

shielding

gas

source

to

the

appropriate

input

fit

ting

at

the

control.

3-10.

BOOM

ADJUSTMENTS

(Figure

3-7)

A.

Weight

Lift

Adjustment

CAUTION

___________

Ensure

that

during

all

adjustment

pro

cedures,

full

threads

on

the

adjustment

rod

are

main

tained

through

the

yoke.

If

full

threads

are

not

maintain

ed,

the

boom

may

suddenly

drop

down

and

cause

injury

to

personnel

or

damage

to

equipment.

Gun

Weld

integral

Gas

Cable

Fitting

The

gas

hoses,

routed

through

the

boom,

connect

to

Vent

Screw

the

appropriate

Shielding

Gas

output

fittings

at

the

Accesa

Hole

front

of

the

control.

TA-081

811

OM-1523

Page

9

The

amount

of

weight

which

the

boom

can

retract

into

the

upright

position

when

released

can

be

varied

by

ad

justing

the

jam

nut

and

adjustment

rod

located

at

the

base

of

the

boom.

If

heavier

guns

are

installed

on

the

end

of

the

boom

thereby

making

it

necessary

to

in

crease

the

amount

of

weight

that

the

boom

can

lift,

loosen

the

jam

nut

and

rotate

the

adjustment

rod

so

that

adjustment

rod

threads

into

the

yoke.

When

the

proper

adjustment

is

obtained,

tighten

the

jam

nut

against

the

base

of

the

yoke.

If

lighter

guns

are

used

with

the

Swingarc,

rotate

the

adjustment

rod

so

that

the

adjust

ment

rod

threads

out

of

the

yoke.

B.

Locking

Knob

By

rotating

the

Locking

knob,

located

on

the

side

of

the

swivel

plate,

in

a

clockwise

direction,

the

boom

may

be

held

in

any

desired

position.

Rotating

the

Locking

Knob

in

a

counterclockwise

direction

will

permit

the

boom

to

free

travel.

Changing

the

position

of

the

Locking

Knob

to

the

other

threaded

holes

provided

along

the

side

of

the

swivel

plate,

limits

the

lift

of

the

boom

to

50

degrees

or

40

degrees

respectively

during

free

travel.

3-11.

MOTOR

CONTROL

CONNECTION

(Figure

3-8)

-

A

two

pole

receptacle

is

provided

on

the

rear

panel

of

the

control.

Insert

the

two-pin

plug

from

the

control

end

of

the

boom

into

this

receptacle

and

rotate

the

plug

threaded

collar

clockwise

as

far

as

possible.

3-12.

GUN

TRIGGER

CONNECTIONS

(Figure

4-1)

-

Two

receptacles,

labeled

TRIGGER,

are

provided

on

the

front

panel

of

the

control

for

making

gun

trigger

control

connections.

The

gun

trigger

control

cables

ex

tend

out

of

the

control

end

of

the

boom.

Insert

the

gun

trigger

control

plug,

labeled

LEFT

TRIGGER,

into

the

gun

trigger

control

receptacle

on

the

Left

control

and

the

other

gun

trigger

control

plug

into

the

receptacle

on

the

Right

control

and

rotate

the

threaded

collars

clockwise.

3-13.

WELD

CABLE

CONNECTION

-

Two

weld

cables

extend

out

of

the

control

end

of

the

boom

for

making

secondary

connections

to

the

welding

power

source(s).

The

end

of

each

weld

cable

is

equipped

with

a

terminal

for

a

1/2

stud.

Connect

weld

cables

to

the

desired

POSITIVE

or

NEGATIVE

output

terminal

on

the

appliable

welding

power

source.

TA-046

105

Gas

input

Right

Contactor

Fitting

Control

Receptacle

Figure

3-8.

Rear

Panel

Connections

I~IIl~

If

one

we/ding

power

source

is

used,

connect

the

weld

cab/es

from

the

control/feeder

to

the

welding

power

source

POSITIVE

orNEGA

TIVE

output

terminals

as

desired.

3-14.

115

VOLTS/CONTACTOR

CONTROL

CON

NECTIONS

(Figure

3-8)

A.

Using

One

Welding

Power

Source

The

contactor

control

circuitry

in

this

control/feeder

is

connected

to

operate

both

guns

from

one

welding

power

source.

Align

keyways

and

insert

the

115

volts/contactor

con

trol

plug

into

the

Left

115

Volts/Contactor

Control

receptacle

and

rotate

the

threaded

collar

clockwise.

In

sert

the

115

volts

power

plug

into

the

115

volts

ac

receptacle

on

the

welding

power

source

and

rotate

clockwise.

Insert

contactor

control

plug

into

the

welding

power

source

contactor

control

receptacle

and

rotate

clockwise.

Store

the

remaining

contactor

control

cable.

CAUTION

____________

Both

electrode

wires

will

be

electrically

energized

when

either

gun

switch

is

closed.

B.

Using

Two

Welding

Power

Sources

Through

minor

modification,

the

contactor

control

cir

cuitry

of

the

control/feeder

can

be

adapted

to

operate

two

welding

power

sources,

that

is,

the

left

gun

trigger

governing

contactor

control

to

one

welding

power

source

and

the

right

gun

trigger

governing

contactor

control

to

the

other.

Two

cables

are

supplied

for

making

the

appropriate

connections.

CAUTION

__________

Placing

the

POWER

switch

in

the

OFF

position

does

not

remove

power

from

all

of

the

controls

internal

circuitry.

Completely

terminate

all

electrical

power

to

the

control

by

removing

the

115

volts

ac

plug

from

its

power

supply,

and

ensure

that

machinery

lockout

procedures

have

been

employed

on

the

welding

power

sources

input

line

(see

Instruction

Manual

on

welding

power

source)

before

attempting

any

inspection

or

work

inside

the

unit.

DVC

Switching

Relay

Receptacle

Yoke

i

Nut

Left

115

Voit./

Contactor

Control

TAO81

757

Figure

3-7.

Boom

Adjustments

Page

10

1.

Remove

the

wrapper

from

the

control

box

on

the

control/feeder.

2.

Locate

terminal

strip

iT

on

the

bottom

panel

of

the

control.

ceases.

If

adjustment

is

required,

loosen

or

tighten

the

hex

nut

(10)

on

the

end

of

the

spindle

support

shaft

(1)

accordingly.

3-18.

WELDING

WIRE

THREADING

3.

Disconnect

lead

No.

39

from

terminal

K

on

ter

minal

strip

iT

and

reconnect

it

to

terminal

E.

4.

Replace

wrapper.

5.

Align

keyways

and

insert

the

contactor

control

plug

into

the

Right

Contactor

Control

receptacle

and

rotate

the

threaded

collar

clockwise.

Insert

contactor

plug

into

the

right

welding

power

source

contactor

control

receptacle

and

rotate

clockwise.

6.

Align

keywaysand

insertthe

li5volts/contactor

control

plug

into

the

Left

115

Volts/Contactor

Control

receptacle

and

rotate

threaded

collar

clockwise.

Insert

the

115

volts

power

plug

into

the

115

volts

ac

receptacle

on

the

welding

power

source

and

rotate

clockwise.

Insert

contactor

control

plug

into

the

welding

power

source

con

tactor

control

receptacle

and

rotate

clockwise.

3-15.

INSTALLATION

OF

SPOOL-TYPE

WIRE

(Figure

3-2)

1.

Remove

the

retaining

ring

(12).

2.

Slide

the

spool

of

wire

onto

the

hub

(4)

so

that

the

wire

will

feed

off

the

top

of

the

spool.

The

spool

turns

in

a

clockwise

direction.

3.

Rotate

the

spool

until

the

hole

in

the

spool

aligns

with

the

in

the

hub

(4).

Slide

the

spool

onto

the

hub

until

it

seats

against

the

back

flange

of

the

hub.

4.

Replace

the

retaining

ring

(12).

3-16.

INSTALLATION

OF

REEL-TYPE

WIRE

(Figure

3-3)

1.

Loosen

the

four

wing

nuts

(3)

on

the

fingers

(2)

of

the

wire

reel

(1).

2. Pull

the

four

fingers

(2)

out

until

they

can

be

rotated

toward

the

center

of

the

reel

(1).

3.

Install

the

wire

onto

the

reel

(1)

over

the

four

fingers

(2).

Ensure

that

the

wire

feeds

off

the

top

of

the

reel

(1).

The

reel

(1)

turns

in

a

clockwise

direction.

4.

Rotate

the

four

fingers

(2)

back

to

their

proper

position.

Tighten

the

four

wing

nuts

(3).

CAUTION:

_____

Prior

to

threading

the

we/ding

wire

through

the

gun,

ensure

that

weld

power

is

not

available

at

the

weld

head.

1.

Install

the

wire

(reel-type

or

spool-type)

as

in

structed

in

Section

3-15

or

3-16

on

the

desired

side.

2.

Cut

off

any

portion

of

the

free

end

of

the

wire

which

is

not

straight.

Ensure

that

the

cut

end

is

free

from

rough

surfaces

to

permit

proper

feeding.

3.

Route

the

wire

through

the

wire

guide

tube

on

the

side

of

the

boom,

over

the

wire

pulley,

and

to

the

drive

assembly.

4.

Loosen

the

wing

nut

on

the

drive

roll

pressure

adjustment,

pivot

the

pressure

adjustment

free

of

the

cover,

and

pivot

the

pressure

gear

assembly

away

until

it

is

in

an

open

position.

5.

Feed

the

wire

through

the

inlet

wire

guide,

past

the

drive

rolls,

and

on

into

the

outlet

wire

guide.

Feed

approximately

4

inches

of

wire

into

the

outlet

wire

guide.

i~i.u~

If

when

the

gear

cover

is

closed,

the

U-Cog

drive

rolls

are

not

aligned

properly

(see

Section

3-6),

pivot

the

gear

cover

away

from

the

drive

gear

and

rotate

the

pressure

gear

one

tooth.

6.

Pivot

the

gear

cover

closed

making

sure

the

teeth

on

the

pressure

gear

mesh

with

the

teeth

on

the

drive

gear.

The

welding

wire

must

also

be

in

the

grooves

of

the

drive

rolls.

7.

Pivot

the

pressure

adjustment

wing

nut

until

the

washer

on

the

pressure

adjustment

is

seated

on

top

of

the

gear

cover.

8.

Turn

the

pressure

adjustment

wing

nut

in

a

clockwise

direction

until

the

drive

rolls

are

tight

against

the

welding

wire.

Do

not

overtighten.

Further

adjustment

to

attain

diiiiid

clØrnpirig

pressure

can

be

made

after

the

welding

power

source

and

the

control/feeder

are

put

into

opera

tion.

9.

Draw

the

gun

cable

out

straight.

10.

Repeat

Steps

1-9

on

the

opposite

side.

11.

Energize

the

welding

power

source.

3-17.

ADJUSTMENT

OF

HUB

TENSION

(Figure

3-2)

-

Check

the

hub

tension

by

slowly

pulling

the

wire

toward

the

feed

roll.

The

wire

should

unwind

freely,

but

the

hub

tension

should

be

sufficient

to

keep

the

wire

taut

and

prevent

backlash

when

the

wire

feeding

12.

Place

the

control

POWER

switch

in

the

ON

posi

tion.

13.

Depress

the

Left

INCH

switch.

This

will

run

the

welding

wire

through

the

Left

Gun

without

plac

OM-1523

Page

11

ing

weld

current

on

the

wire.

Release

the

Left

INCH

switch

when

welding

wire

extends

approx

imately

one

inch

out

of

the

gun

tip.

14.

Depress

the

Right

INCH

switch

until

welding

wire

extends

approximately

one

inch

out

of

the

Right

Gun

tip.

Weld

current

will

not

be

present

on

the

wire.

SECTION

4

-

FUNCTION

OF

CONTROLS

4

-

1.

POWER

SWITCH

(Figure

4-1)

-

Placing

the

POWER

switch

on

the

control

in

the

ON

position

will

apply

115

volts

ac

to

the

unit

and

thereby

place

it

in

an

operational

condition,

ready

to

feed

wire

and

permit

shielding

gas

to

flow

from

either

gun.

Placing

the

POWER

switch

in

the

OFF

position

will

shut

the

con

trol/feeder

down.

CAUTION

__________

Placing

the

POWER

switch

in

the

OFF

position

does

not

remove

power

from

all

of

the

controls

internal

circuit,y.

Completely

terminate

all

electrical

power

to

the

control

by

removing

the

115

volts

ac

plug

from

its

power

supply,

and

ensure

that

machinery

lockout

procedures

have

been

employed

on

the

we/ding

power

sources

input

line

(see

Instruction

Manual

on

welding

power

source)

before

attempting

any

inspection

or

work

insde

the

unit.

4

-

2.

WIRE

SPEED

CONTROLS

(Figure

4-1)

-

The

ten

turn

WIRE

SPEED

controls

provide

the

means

of

determining

the

rate

at

which

welding

wire

is

fed

into

the

weld.

Rotating

the

Left

WIRE

SPEED

control

in

a

clockwise

direction

will

increase

the

rate

at

which

wire

is

fed

from

the

Left

Gun.

Rotating

the

Right

WIRE

SPEED

control

in

a

clockwise

direction

will

increase

the

rate

at

which

wire

is

fed

from

the

Right

Gun.

4-3.

REMOTE

CONTROL

RECEPTACLES

AND

SWITCHES

(Figure

4-1)

-

The

Remote

Control

recep

tacles

and

switches

are

provided

for

use

in

conjunction

with

certain

optional

controls.

When

an

optional

control

is

connected

across

a

Remote

Control

receptacle,

the

corresponding

switch

must

be

in

the

REMOTE

position.

If

no

optional

controls

are

utilized,

the

Remote

Control

switches

must

be

in

the

STANDARD

position.

4

-

4.

PURGE

BUTTONS

(Figure

4-1)

-

The

PURGE

buttons

are

momentary

contact

switches.

The

Left

PURGE

button

will

energize

the

Left

Gas

Solenoid

and

purge

the

shielding

gas

line

of

the

Left

Gun.

The

Right

PURGE

button

will

energize

the

Right

Gas

Solenoid

and

purge

the

shielding

gas

line

of

the

Right

Gun.

The

PURGE

buttons

also

allow

the

shielding

gas

regulator(s)

to

be

adjusted

without

energizing

the

welding

circuit.

4

-

5.

INCH

SWITCHES

(Figure

4-1)

-

The

INCH

switches

are

spring

loaded

toggle

switches.

When

ac



tivated,

either

switch

completes

the

circuit

to

the

motor



without

having

to

depress

the

corresponding

gun

trig

ger

switch.

The

Left

INCH

switch

permits

inching

of

the

Left

wire

at

the

Left

WIRE

SPEED

control

setting

and

the

Right

INCH

switch

permits

inching

of

the

right

wire

at

the

Right

WIRE

SPEED

control

setting,

without

energizing

the

welding

circuits

or

the

corresponding

shielding

gas

valves.

4

-

6.

INCHES

PER

MINUTE

METER

(Figure

4-1)

This

meter

displays

the

wire

speed

in

inches

per

minute.

When

the

control

is

turned

on,

the

meter

displays

the

wire

speed

set

by

the

Right

WIRE

SPEED

RIght

Inch

Switch

Right

Remote

Control

Receptacle

Figure

4-1.

Control

Components

~ge

12

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