Miller AUTOMATIC 1 User manual

Miller AUTOMATIC 1 User manual
November 1983 FORM: OM-1518E
Effective With Serial No. JD699321
MODEL
AUTOMATIC 1
GAS CONTROL
HUB & SPINDLE
WIRE REEL
MILLER ELECTRIC MFG. CO.
718 S. BOUNDS 57, P.O. Box 1079
APPLETON, WI 54912 USA
ADDITIONAL COPY PRICE 70 CENTS
NWSA CODE NO. 4579
PRINTED IN U.5.A.
pre
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
hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants
to its Distributor/ Dealer that all new and unused Equipment
furnished by Miller is free from defect in workmanship and
material as of the time and place of delivery by Miller. No war-
ranty is made by Miller with respect to engines, trade ac-
cessories or other items manufactured by others. Such
engines, trade accessories and other items are sold subject to
the warranties of their respective manufacturers, If any , All
engines are warranted by their manufacturer for one year from
date of original purchase,
Except as specified below, Miller's warranty does not apply
to components having normal useful life of less than one (1)
year, such as spot welder tips, relay and contactor points,
MILLERMATIC parts that come in contact with the welding
wire including nozzles and nozzle insulators where failure does
not result from defect in workmanship or material,
Miller shall be required to honor warranty claims on war-
ranted Equipment in the event of failure resulting from a defect
within the following periods from the date of delivery of Equip-
ment to the original user:
1. Arc welders, power sources and components .. 1 year
2. Original main power rectifiers ................ 3 years
{iabor - 1 year only)
3. Allwelding guns and feeder/guns ............ 90 days
4. All other Millermatic Feeders. . ................ 1 year
5, Replacement or repair parts, exclusive of labor . 60 days
56. Batteries......... ..—. .eecerrecreeere e, 6 months
provided that Miller is notified in writing within thirty (30) days
of the date of such failure.
Че AEE IT 2 IZA
As a matter of general policy only, Miller may honor claims
submitted by the original user within the foregoing periods.
In the case of Miller's breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedies
therefore shall be, at Miller's option (1) repair or {2} replacement
or, where authorized in writing by Miller in appropriate cases, (3)
the reasonable cost of repair or replacement at an authorized
Miller service station or {4) payment of or credit for the purchase
price {less reasonable depreciation based upon actual use) upon
return of the goods at Customer's risk and expense. Upon receipt
of notice of apparent defect or failure, Miller shall instruct the clai-
mant on the warranty claim procedures to be followed.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA-
TION AS TO PERFORMANCE, AND ANY REMEDY FOR
BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX-
CLUDED AND DISCLAIMED BY MILLER.
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN
WRITING, MILLER PRODUCTS ARE INTENDED FOR
ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED AND
EXPERIENCED IN THE USE AND MAINTENANCE OF
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR
CONSUMER USE. MILLER" WARRANTIES DO NOT EXTEND
TO, AND NO RESELLER IS AUTHORIZED TO EXTEND
MILLERS WARRANTIES TO, ANY CONSUMER.
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Section No. Page No.
SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1. Introduction.............222020000 0440040 a 0 ea ee ae ee a ee a ee 006 1
1-2. General Precautions .........._e.ee_rrecoorvecnerorrenrereee 1
1-3. Arc Welding...............esesrerecrenererterererervere
1-4. Standards Booklet Index ............._eomeecrererereerara ene. 11
SECTION 2 - INTRODUCTION
2-1, General Information And Safety .......... cin 14
2-2. Receiving-Handling ...........0000000 0000 aa eee ae na ee ea eee ns 14
2-3. Description ............_._eeoredrecererrererverererenr eee 00 14
SECTION 3 - INSTALLATION
3-1. Location........11220020 000404 4 4 a eee a a ea ee a ee as ea eee 0e 14
3-2. Shielding Gas Connections ...............-eeereeseorrreaeren 14
3-3. Water Connections..........22000 0000 ea a a eee ee era ee ses 00 14
3-4. Remote Start And Stop Connections..........e—e—.—-reeexvacoee 15
3 - 5. Normally-Open And Normally-Closed Contacts Available For Control
OfWeld Fixtures ..........Ññ.eeocesververoecieoreareane ree. 15
2-6. Electrical Connections For Automatic Flux Valve ................. 16
3-7. Weld Control Interconnections ....... cco a se 00 16
3-8. Hub And Spindle Assembly Installation.................. cot. 17
3-9. Installation Qf Spool-TypeWire ............ iii iii, 17
3-10. installation Of Reel-TypeWire............. oii an. 17
3-11. Installation Of Wire Reel.............e--esexerrerrrnvereeeae2A. 18
3-12. Adjusting Hub Tension............_.-.e.>rresecirorerarr ree. 18
3-13. Weld/Crater Voltage Control Connections ...................... 18
SECTION 4 - OPERATOR CONTROLS
4 - 1. POWer SWItCh .. oot ees i 18
4-2, PilotLight...... coco ei aa eee 05 18
4 - 3. Retract-Advance Switch And JOG Push-Button Switch. .......... 18
4-4. Purge Push-Button Switch ..........eo.esrerceceonererarer A 19
4-5. Start Push-Button Switch . ..... iii ities 19
4 - 6. StopPush-ButtonSwitch ........... co iii, 19
4-7. RunlnSpeed Control..............omorreeererrerrererrereco 19
4-8. WireFeed Speed Control. ......... iii 19
4-9. Crater & JOG Speed Contrül. .......0.0...00.000000000 Herr RM 19
4-10. Pre-Flow Time Control... KK KM 19
4-11. Spot-ContinuousSwitch ............. co iin 19
4-12. Spot Time Control KEANE 19
4-13. Crater Time Control ..........o mx rex cia iia 19
4-14. Burnback Control ...........o.eeeeervrrvocereoe en rrecene 19
4-15. Post-Flow Time Control..........._.eeeereonmevoeooreceraan inet. 20
4-16. Meters ........_..eoeeecucreroeeneverereserrrcendaereereonET. 20
4-17. Overload Protection .............e eee .erer ria 00ure AAA 20
4-18. Weld/Crater Voltage Controls. .........e..e.eerenevoererecare. 20
4-19. RunlinVoltage& RuninTimeControls ......................... 20
Section No. Page No.
SECTION 5 - SEQUENCE OF OPERATION
5-1. Gas Metal-Arc Welding & Flux Cored Arc Welding -
Continuous ...........—.—._eceororereccrrecerrredrrecararvecoo, 20
5-2. Gas Metal-Arc Welding & Flux Cored Arc Welding -
SPO Le 20
5-3. ShuttingDown .......... i ee, 21
SECTION 6 - MAINTENANCE & TROUBLESHOOTING
6-1. Inspection AndUpkeep .......... ccna. 21
6-2. General. RR RR a à 21
6 - 3. TroubleshootingChart .................. iii... 21
SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
SECTION 1 - RÈGLES DE SÉCURITÉ POUR LE FONCTIONNEMENT DU POSTE DE SOUDAGE À L'ARC
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 foliow the
rules.
Read and understand these safe practices before at-
tempting to install, operate, or service the equipment.
Comply with these procedures as applicable to the par-
ticular equipment used and their instruction manuals,
for personal safety and for the safety of others.
Failure to observe these safe practices may cause
serious injury or death. When safety becomes a habit,
the equipment can be used with confidence.
These safe practices are divided into two Sections:
1 - General Precautions, common to arc welding and
cutting; and 2 - Arc Welding {and Cutting} (only).
Reference standards: Published Standards on safety are
also available for additional and more complete pro-
cedures than those given in this manual. They are listed
in the Standards Index in this manual. ANSI 249.1 is the
“most complete.
The National Electrical Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements also provide a basis for equip-
ment installation, use, and service.
1-2. GENERAL PRECAUTIONS
Different arc welding processes, electrode alloys,
and fluxes can produce different fumes, gases,
and radiation levels. In addition to the information
in this manual, be sure to consult flux and elec-
trode manufacturers for specific technical data
and precautionary measures concerning their
material.
A. Burn Prevention
Wear protective clothing - gauntlet gloves designed for
use in welding, hat, and high safety-toe shoes. Button
shirt collar and pocket fiaps, 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
1-1. INTRODUCTION - Contrairement а l'appren-
tissage de la vie, l'apprentissage de ia sécurité par ex-
périence personnelle, comme l’enfant qui touche un
poêle chaud, est dangereux, imprudent et inutile.
Instruisez-vous donc de l'expérience d'autrui.
Des méthodes de sécurité issues de l'expérience du
soudage et du coupage sont décrites dans le manuel. La
recherche, le progrès et l'expérience dans ce domaine
ont développé un matériel fiable et des méthodes de
sécurité pour l'installation, le fonctionnement et l'entre-
tien. Des accidents se produisent lorsque le matériel est
inadéquatement utilisé ou entretenu. La raison de ces
méthodes de sécurité peut ne pas être toujours donnée.
Certaines sont fondées sur le sens commun, d'autres
demanderont à être expliquées par des livres techni-
ques. |! est plus sage de suivre les règles.
Lisez et comprenez ces méthodes de sécurité avant
d'essayer d'installer, de faire fonctionner ou de réparer
l'appareil. Pour votre sécurité personnelle et celle
d'autrui, conformez-vous à ces règles et aux manuels
d'instructions.
Manquer d'observer ces méthodes de sécurité pourrait
entrainer des blessures graves ou mème la mort. Quand
la sécurité devient une habitude, le matériel peut alors
être utilisé en toute confiance.
Ces méthodes de sécurité sont divisées en deux sec-
tions: 1 - Précautions générales, communes au
soudage et au coupage à l'arc, et 2 - Soudage à l'arc
(et coupage) (uniquement).
Normes de référence: Des publications des normes
américaines de sécurité sont aussi à votre disposition
pour d'autres modes opératoires plus complets que
ceux du présent manuel. Elles sont données dans l'In-
dex des Normes de ces règles de sécurité. ANSI Z49-1
est la plus complète.
Les codes de I'ACNOR, ies codes provinciaux et
municipaux donnent aussi les exigences pour une in-
stallation, une utilisation et un entretien sûrs.
1-2. PRÉCAUTIONS GÉNÉRALES
Plusieurs procédés du soudage à l’arc, des élec-
trodes alliés, et les flux peuvent produire des
vapeurs, gaz, et niveaux de rayonnement
différents. Pour tout renseignement supplémen-
taire à ce manuel, consultez aussi les fabricants
des électrodes et des flux afin d'obtenir les
renseignements techniques spécifiques et les
mesures de précaution concernant leurs
matériaux.
A. Prévention des brûlures
Portez des vêtements de protection - des gants à crispin
spécialement désignés pour le soudage, un casque et
des chaussures de sécurité. Boutonnez le col de votre
chemise et les pattes de vos poches, et portez des pan-
talons sans revers pour éviter que des étincelles et du
laitier ne s’y introduisent.
Portez? un masque avec lunettes de sécurité ou avec
écrans laté-raux de protection, des lunettes filtrantes ou
des couvre-lentilles (protégés par un verre clair). Pour le
soudage ou le coupage (et le burinage), il est
OM-1518 Page 1
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 uniess medical facilities are close by for im-
mediate treatment of flash burns of the eyes and skin
burns.
Ear plugs should be worn when working on overhead or
in a confined space. A hard hat should be worn when
others work overhead.
Flammable hair preparations should not be used by per-
sons intending to weld or cut.
B. Toxic Fume Prevention
Severe discomfort, illness or death can result from
fumes, vapors, heat, or oxygen enrichment or depletion
that welding (or cutting) may produce. Prevent them
with adequate ventilation as described in ANSI Stan-
dard Z49.1 listed 1 in Standards index. NEVER ventilate
with oxygen.
Lead -, cadmium -, zinc -, mercury -, and beryllium -
bearing and similar materials, when welded (or cut) may
produce harmful concentrations of toxic fumes. Ade-
quate local exhaust ventilation must be used, or each
person in the area as well as the operator must wear an
atr-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
OM-1518 Page 2
OBLIGATOIRE de protéger ses yeux contre l'énergie de
rayonnement et les éclats de métal. Remplacez le verre
protecteur lorsqu'il est brisé, piquëê ou qu'il a reçu des
projections. Voir 1.3A.2.
Évitez de porter des habits imprégnés d'huile ou de
graisse. Une étincelle pourrait les enflammer.
Ne manipulez jamais sans gants un métal chaud tel que
des chutes d'électrode et des pièces à souder.
Premiers soins et traitement des yeux: Tout atelier
devrait avoir à sa disposition un poste de premiers soins
ainsi qu’une personne compétente, à moins qu’ur, ser-
vice médical ne soit à proximité pour soigner immédiate-
ment les brûlures des yeux et de la peau.
Portez des bouche-oreilles lorsque vous travaillez au
plafond ou dans un espace restreint. Portez un casque
lorsque d’autres personnes travaillent au plafond.
Les personnes devant souder ou couper ne doivent pas
employer des préparations inflammables pour leurs
cheveux.
B. Prévention des gax toxiques
Les gaz, !es vapeurs, la chaleur, un enrichissement ou
un manque d'oxygène peuvent entraîner un malaise,
une maladie ou même la mort. Remédiez-y par la ven-
tilation décrite dans la Norme ANS! Z49.1 paragraphe 1
de l'Index des Normes. NE ventilez JAMAIS à l’ox-
ygène.
En soudant ou en coupant, les plomb, cadmium, zinc,
mercure et bérylliium ou autres matériaux semblables
peuvent créer des concentrations nocives de gaz toxi-
ques. On doit avoir recours à une ventilation aspirante
adéquate du iocal, ou alors toute personne sur les lieux,
de même que le soudeur, doit porter un masque à ad-
duction d'air. On doit employer les deux pour le
béryllium.
Les métaux enrobés ou composés de matériaux émet-
tant des gaz toxiques ne doivent pas être chauffés à
Moins que l’enrobage ne soit 6té de la surface à
travailler, que le local ne soit bien ventilé, ou que le
soudeur ne porte un masque à adduction d'air.
Ne travaillez dans un espace restreint que s’il est bien
ventilé et, si nécessaire, portez un masque à adduction
d'air.
On doit éviter les fuites de gaz dans un espace restreint.
Les fuites de gaz en grande quantité peuvent
transformer dangereusement la concentration @’ох-
ygène. N'amenez pas de bouteilles de gaz dans un
espace restreint.
En quittant un espace restreint, FERMEZ le robinet
d'alimentation de gaz de la bouteille. Ainsi on pourra
rentrer en toute sécurité dans la pièce, même si les
robinets “aval” ont été ouverts par accident, ou si on les
a laissés ouverts.
Les vapeurs de dissolvants chlorés peuvent étre décom-
posées par la chaleur de l’arc (ou de la flamme) et
former du PHOSGENE, gaz très toxique, et d’autres
produits irritant les poumons et les yeux. L'énergie
ultra-violette de l'arc peut aussi décomposer les vapeurs
de trichloroéthyléne et de perchloroéthylène pour
former du phosgène. NE SOUDEZ PAS ou ne coupez
pas dans des endroits où les vapeurs de dissolvants peu-
vent être attirées dans l'atmosphère de soudage ou de
energy can penetrate to atmospheres containing even
minute amounts of trichloroethylene or per-
chloroethylene.
C. Fire and Explosion Prevention
Causes of fire and explosion are: combustibles reached
by the arc, flame, flying sparks, hot slag or heated
material: misuse of compressed gases and cylinders;
and short circuits.
BE AWARE THAT flying sparks or falling slag can pass
through cracks, along pipes, through windows or
doors, and through wall or floor openings, out of sight
of the goggled operator. Sparks and slag can fly 35 feet.
To prevent fires and explosion:
Keep equipment clean and operable, free of oil, grease,
and (in electrical parts) of metallic particles that can
cause short circuits.
If combustibles are in area, do NOT weld or cut. Move
the work if practicable, to an area free of combustibles.
Avoid paint spray rooms, dip tanks, storage areas, ven-
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 A6.0,
listed 3 in Standards index.
This includes: a thorough steam or caustic cleaning (or
a solvent or water washing, depending on the com-
coupage et où l'énergie de rayonnement peut pénétrer
dans des atmosphères contenant des quantités même
minuscules de trichloroéthyléne ou de per-
chloroéthylène.
C. Prévention des incendies et des explosions
Les causes d'incendie et d'explosion sont les com-
bustibles atteints par l'arc, la flamme, les étincelles, le
laitier chaud ou les matériaux chauffés, le mauvais
emploi des gaz comprimés et des bouteilles ainsi que les
courts-circuits.
Sachez que les éclats d'étinceiles ou la chute du laitier
peuvent s'infiltrer dans les fissures, le long des
tuyauteries, par les fenétres et les portes et par les
couvertures des murs ou du sol, sans que le soudeur
portant des lunettes ne les voie. Les étincelles et les
scories peuvent voler jusqu’a 35 pieds.
Pour prévenir les incendies et les explosions: Velilez à ce
que votre appareil soit propre et en état de marche,
dénué d'huile et de graisse, et de particules de métal sur
les pièces électriques qui pourraient entraîner des
courts-circuits.
Si des combustibles se trouvent à proximité, ne soudez
pas, ne coupez pas. Si possible, déplacez votre travail
loin des combustibles. Evitez les ateliers de peinture au
pistolet, les cuves d'immersion, les entrepôts, les ven-
tilateurs. Si cela n'est pas possible, placez les com-
bustibles à au moins 35 pieds des étincelles et de la
chaleur et protégez-les des étincelles avec des couver-
tures ou des écrans protecteurs adéquats, bien ajustés
et ignifugés.
On ne doit pas souder (ou couper) le côté opposé des
murs touchant les combustibles. Les murs, plafonds et
planchers proches du travail doivent être protégés par
des couvertures ou écrans protecteurs ignifugés.
Un surveillant doit se tenir à proximité avec un matériel
de lutte contre l'incendie adéquat, pendant et quelque
temps après le soudage ou le coupage s!:
a. Des quantités appréciables de combustibles
(y compris une construction en chantier) se
trouvent à moins de 35 pieds.
b. Des quantités appréciables de combustibles
sont à plus de 35 pieds mais peuvent être
enflammées par des étincelles.
c. Des ouvertures (cachées ou visibles) sur les
planchers ou les murs á moins de 35 pieds
peuvent exposer des combustibles aux
étincelles.
d. Les combustibles adjacents aux murs,
“plafonds, toits ou cloisons métalliques peu-
vent être enflammés par une chaleur rayon-
nante ou transmise.
Avant de commencer, avisez le contremaitre pour qu'il
s'assure que les précautions adéquates soient prises.
Une fois le travail terminé, vérifiez qu’il n'y ait pas
d'étincelles, de cendres ardentes ou de flammes dans le
local.
On ne doit Jamais souder ni couper sur un récipient
ayant contenu des combustibles, ou pouvant produire
des vapeurs inflammables ou toxiques à la chauffe, à
moins que le récipient n'ait été lavé au préalable, com-
me décrit dans la Norme AWS A6.0, figurant au
paragraphe 3 de l’Index des Normes.
Cela comprend: un nettoyage à fond à la vapeur ou au
caustique (ou un lavage avec dissolvant ou eau selon la
solubilité du combustible) suivi d'une purge et d'une in-
OM-1518 Page 3
bustible’s solubility) followed by purging and inerting
with nitrogen or carbon dioxide, and using protective
equipment as recommended in A6.0. Waterfilling just
below working ievel may substitute for inerting.
A container with unknown contents shouid be cleaned
(see paragraph above). Do NOT depend on sense of
smell or sight to determine if it is safe to weid 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-1,
PRECAUTIONS FOR SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS, listed 6 in Stan-
dards index.
1. Pressure Regulators
Regulator relief valve is designed to protect only the
regulator from overpressure; it is not intended to pro-
tect any downstream equipment. Provide such protec-
tion 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 symp-
toms 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 including
third rails, electrical wires, or welding circuits. They can
produce short circuit arcs that may lead to a serious ac-
cident. (See 1-3C.)
ICC or DOT marking must be on each cylinder. It is an
assurance of safety when the cylinder is properly
handled.
OM-1518 Page 4
jection d'azote ou de gaz carbonique, en utilisant un
équipement de protection comme recommandé dans
l’'A6-0. L'atmosphère inerte peut être remplacée par un
niveau d’eau arrivant au-dessous du travail à effectuer.
Vous devez laver un récipient dont la nature de contenu
est inconnue (voir paragraphe ci-dessus). NE vous fiez
PAS à l’odorat ou à la vue pour dire si I'on peut le
souder ou le couper en toute sécurité.
Vous devez pratiquer un évent sur les pièces ou réci-
pients creux avant de les souder ou couper: ils peuvent
exploser.
Atrriosphères explosives: Ne soudez ni ne coupez
jamais dans des lieux où l'air peut contenir des
poussières, gaz ou vapeurs liquides inflammables {tels
que l'essence).
D. Gaz comprimé
Précautions générales: Suivez les précautions de ce
manuel, et celles décrites à la Norme CGA P-1 (Précau-
tions de sécurité pour la manipulation de gaz comprimés
en bouteilles), paragraphe 6 de l’Index des Normes.
1. Détendeurs de pression
La soupape de sûreté d’un détendeur est destinée à pro-
téger seulement le détendeur de la surpression. Elle n'a
pas pour but de protéger les boyaux et le chalumeau: on
protège ceux-ci par des soupapes de retenue conçues
spécialement pour cette fonction.
Ne montez jamais un détendeur sur une bouteille conte-
nant un gaz différent de celui pour lequel le détendeur a
été conçu.
Enlevez immédiaternent un détendeur défectueux pour
le faire réparer (d'abord, fermez le robinet de la
bouteille). Les symptômes suivants dénotent la défec-
tuosité du détendeur:
Fuites - si le gaz fuit extérieurement.
Ascension excessive - si la pression de débit continue à
monter, le robinet du chalumeau étant fermé.
Manomètre défectueux - si l'aiguille du manomètre ne
s'écarte pas de la goupille de butée lors de la mise en
pression, ou ne revient pas sur la goupille après l'échap-
pement de la pression.
Réparation. N'ESSAYEZ PÂS de réparer vous-mêmes.
Envoyez les détendeurs défectueux à réparer aux
ateliers de réparation agréés du fabricant, où des techni-
ques et des outils spéciaux sont utilisés par un person-
nel formé.
2. Bouteilles
Les bouteilles doivent être manipulées avec soin pour
prévenir les fuites ou dégâts à leurs parois, robinets ou
systèmes de sûreté. Evitez qu'un circuit électrique soit
en contact avec les bouteilles, y compris les rails de con-
tact, les fils électriques ou les circuits de soudage. Cela
pourrait créer des arcs courts-circuits pouvant entraîner
des accidents graves {Voir 1.3C.).
Chaque bouteille doit porter les inscriptions ICC ou
DOT, C'est un gage de sécurité pourvu que la bouteille
soit bien manipulée.
Identifying gas content. Use only cylinders with name
of gas marked on them; do not rely on color to identify
gas content. Notify supplier if unmarked. NEVER
DEFACE or alter name, number, or other markings on a
cylinder. It is illegal and hazardous.
Empties: Keep valves closed, replace caps securely;
mark MT; keep them separate from FULLS and return
promptly.
Prohibited use. Never use a cylinder or its contents for
other than its intended use, NEVER as a support or
roller.
Locate or secure cylinders so they cannot be knocked
over.
Passageways and work areas. Keep cylinders clear of
areas where they may be struck.
Transporting cylinders. With a crane, use a secure sup-
port such as a platform or cradle. Do NOT lift cylinders
off the ground by their valves or caps, or by chains,
slings, or magnets.
Do NOT expose cylinders to excessive heat, sparks,
slag, and flame, etc. that may cause rupture. Do not
aliow contents to exceed 130°F. Cool with water spray
where such exposure exists.
Protect cylinders particularly valves from bumps, falls,
faliing objects, and weather. Replace caps securely
when moving cylinders.
Stuck valve. Do NOT use a hammer or wrench to open
a cylinder valve that can not be opened by hand. Notify
your supplier.
Mixing gases. Never try to mix any gases in a cylinder.
Never refill any cylinder.
Cylinder fittings should never be modified or exchang-
ed.
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 or-
dinary wire or other substitute) as a binding to connect
hoses to fittings.
No copper tubing splices. Use only standard brass fit-
tings to splice hose. `
Avoid long runs to prevent kinks and abuse. Suspend
hose off ground to keep it from being run over, stepped
on, or otherwise damaged.
Coil excess hose to prevent kinks and tangles.
Protect hose from damage by sharp edges, and by
sparks, slag, and open flame.
Examine hose regularly for leaks, wear, and loose con-
nections. Immerse pressured hose in water: bubbles in-
dicate leaks.
Identification du gaz: N'utilisez que les bouteilles indi-
quant la nature du gaz; ne vous fiez pas à !3 couleur
pour reconnaître la nature du gaz. Adressez-vous a
votre fournisseur si cela n’est pas indiqué.
NEFFACEZ ou ne modifiez JAMAIS les noms,
numéros ou autres indications sur une bouteille. Cela
est ilégal et dangereux.
Vides: Maintenez les robinets fermés, replacez bien les
chapeaux; inscrivez ‘“Vides’’; séparez-les des ‘’Pieines”
et retournez-les rapidement.
Emploi interdit: N'utilisez une bouteille ou son contenu
que pour ce à quoi elle est destinée, mais JAMAIS com-
me support ou rouleau.
Placez ies bouteilles pour qu'elles ne tombent pas. Lors-
qu'un détendeur (et un boyau) est monté sur elles,
placez les ou attachez-les debout.
Passages et lieux de travail. Enievez les bouteilles d’un
endroit où l’on pourrait les frapper.
Transport des bouteilles. Âvec une grue, utihsez un sup-
port fiable tel qu'une plate-forme ou un cadre. NE
SOULEVEZ PAS des bouteilles du sol par leur robinet
ou chapeau, ou avec des chaînes, élingues ou aimants.
N'EXPOSEZ PAS les bouteilles à une chaleur excessive,
aux étincelles, au laitier et aux flammes, etc., pouvant
causer leur rupture. Le contenant ne doit jamais
dépasser 55°C. Refroidissez en pulvérisant de l'eau si
nécessaire.
Protégez les bouteiiles et particulièrement les soupapes
contre les chocs, les chutes, les chutes d'objets et la
température. Remettez bien les chapeaux lorsque vous
déplacez ies bouteilles.
Robinet coincé. N'UTILISEZ PAS un marteau ou une
clé métallique pour ouvrir un robinet de bouteille que
l'on ne peut pas ouvrir à la main. Avisez votre four-
nisseur.
Mélange de gaz. N'essayez jamais de mélanger des gaz
dans une bouteille.
Ne rechargez jamais une bouteille. Les éléments de la
bouteille ne doivent jamais être modifiés ou remplacés.
3. Boyau
Utilisation interdite. N'utilisez jamais un boyau autre
que celui approprié au gaz indiqué. La règle générale
d'identification est: rouge pour les gaz combustibles,
vert pour l'oxygène, et noir pour les gaz inertes.
Utilisez des bagues ou colliers appropriés au boyau (et
non du fil ordinaire ou autre substitution) pour brancher
les boyaux à l'appareillage.
N'utilisez pas des raccords en cuivre. N‘utilisez que des
accessoires standard en laiton pour raccorder un boyau.
Utilisez une petite longueur de boyau. Cela évitera les
noeuds et l'usure prématurée. Suspendez le boyau au-
dessus du sol pour éviter qu’il ne soit écrasé, piétiné ou
endommagé.
Enroulez le surplus de boyau pour éviter les noeuds et
emmélements. Evitez que le boyau ne soit endommagé
par des tranchants, étincelles, laitier et flamme nue.
OM-1518 Page 5
Repair leaky or worn hose by cutting area out and spiic-
ing (1-2D3). Do NOT use tape.
4. Proper Connections
Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing
outlet away from people and sources of ignition. Wipe
with a clean lintless cloth.
Match regulator to cylinder. Before connecting, check
that the regulator label and cylinder marking agree, and
that the regulator inlet and cylinder outlet match.
NEVER CONNECT a regulator designed for a particular
gas or gases to a cylinder containing any other gas.
Tighten connections. When assembling threaded con-
nections, clean and smooth seats where necessary.
Tighten. lf connection leaks, disassemble, clean, and
retighten using properly fitting wrench.
Adapters. Use a CGA adapter (available from your sup-
plier} between cylinder and regulator, if one is required.
Use two wrenches to tighten adapter marked RIGHT
and LEFT HAND threads.
Regulator outlet {or hose) connections may be iden-
tified by right hand threads for oxygen and left hand
threads (with grooved hex on nut or shank) for fuel gas.
5. Pressurizing Steps:
Drain regulator of residual gas through suitable vent
before opening cylinder (or manifold valve) by turning
adjusting screw in (clockwise), Draining prevents ex-
cessive compression heat at high pressure seat by
allowing seat to open on pressurization. Leave adjusting
screw engaged slightly on single-stage regulators.
Stand to side of regulator while opening cylinder valve.
Open cylinder valve slowly so that regulator pressure in-
creases slowly. When gauge is pressurized (gauge
reaches regulator maximum) leave cylinder valve in
following position: For oxygen, and inert gases, open
fully to seal stem against possible leak. For fuel gas,
open to less than one turn to permit quick emergency
shutoff.
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on
regulators.
Check for leaks on first pressurization and regularly
there-after. Brush with soap solution (capful of Ivory
Liquid* or equivalent per gallon of water). Bubbles in-
dicate leak. Clean off soapy water after test; dried soap
Is combustible.
E. User Responsibilities
Remove leaky or defective equipment from service im-
mediately for repair. See User Responsibility statement
in equipment manual.
*Trademark of Proctor & Gamble
OM-1518 Page 6
Vérifiez régulièrement les fuites, l'usure et les rac-
cordements lâches. Piongez le boyau sous pression
dans de l’eau: les bulles indiqueront les fuites.
Réparation. Coupez la partie percée ou usée, et rac-
cordez (1-2D3). N'UTILISEZ JAMAIS de ruban adhésif.
4. Branchements corrects
Avant de brancher le détendeur, nettoyez la sortie du
robinet de la bouteille des impuretés qui peuvent
obstruer les orifices et endommager les sièges. Sauf
pour l'hydrogène, ouvrez momentanément le robinet,
en éloignant la sortie des personnes et des sources in-
flammables. Essuyez avec un tissu propre et non
graisseux.
Appareillez le détendeur à la bouteille. Avant de bran-
cher, vérifiez que la marque du détendeur et la descrip-
tion de la bouteille concordent, et que l'orifice d'entrée
du détendeur et l’orifice de sortie de la bouteilie aillent
ensemble. NE BRANCHEZ JAMAIS un détendeur
conçu pour un gaz spécial (ou des gaz spéciaux) à une
bouteille contenant d'autres gaz.
Serrez iles branchements. Lorsque vous assemblez des
branchements filetés, nettoyez et polissez !es sièges où
c'est nécessaire. Serrez. Si les branchements perdent,
démontez-les, nettoyez et resserez avec une clef adé-
quate.
Adaptateurs. Placez, si besoin est, un adaptateur CGÂ
(en vente chez votre fournisseur) entre la bouteille et le
détendeur. Avec deux clefs, serrez l'adaptateur fileté A
DROITE et À GAUCHE.
On peut reconnaître les branchements de sortie du
détendeur (ou boyau) à l’aide du filetage à droite pour
l'oxygène et à gauche (identifié par un écrou cannelé)
pour les gaz combustibles.
5. Démarches de mise en pression
Purgez le détendeur de résidu de gaz avant d'ouvrir la
bouteille (ou le robinet de canalisation) en serrant la vis
de réglage (dans le sens des aiguilles d'une montre).
Cette opération permet au siège de haute pression de
s'ouvrir à la mise en pression, supprimant ainsi toute
surchauffe de compression. Maintenez la vis de réglage
des détendeurs à simple détente légèrement engagée.
Avant d'ouvrir le robinet de la bouteille, assurez-vous
que les boyaux sont branchés et que les soupapes aval
sont fermées.
Tenez-vous latéralement au détendeur en ouvrant le
robinet de la bouteille. Ouvrez-le lentement pour que la
pression du détendeur monte progressivement. Lorsque
le manomètre est mis sous pression (indique le max-
Imum) le robinet de la bouteille de gaz inerte ou d’ox-
ygène devra être ouvert à fond pour assurer l'étanchéité
et celui de la bouteille de gaz combustible ouvert de
moins d'un tour pour pouvoir le refermer rapidement en
cas d'urgence.
Référez-vous aux tableaux de pression (distribués par
votre fournisseur} pour un réglage recommandé de
pression sûr et efficace sur les détendeurs. Vérifiez les
fuites à la première mise en pression puis régulièrement,
brossez avec une solution savonneuse (un bouchon
d'ivory Liquid* ou semblable par gallon d'eau}. Les
bulles indiquent une fuite. Enlevez l'eau savonneuse
après examen; le savon sec est inflammable.
*Marque de Commerce de Proctor & Gamble
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. lts 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
teather 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.
E. Responsabilités de l'usager
Ötez immédiatement les parties percées ou défec-
tueuses. Voir \es Responsabilités de l‘Usager du manuel
de l'appareil.
F. Appareil laissé sans surveillance
Fermez l'alimentation de gaz à la source et purgez.
G. Liens et supports temporaires
Pour vos travaux de soudage ou de coupage, n'utilisez
pas de la corde comme soutien, elle est inflammable.
1-3. SOUDAGE À L'ARC - Conformez-vous aux
précautions des paragraphes 1.1 et 1.2 de cette section.
Le soudage à l’arc bien exécuté est sûr, mais un
soudeur négligent est un danger. Le poste de soudage
transporte des courants élevés sous de fortes tensions.
‘arc est très vif et chaud. Les étincelles volent, les
vapeurs montent, l'énergie ultra-violette et infrarouge
rayonnent, les soudures sont chaudes, et des gaz com-
primés peuvent être utilisés. Le soudeur prudent évite
les risques inutiles, se protège et protège autrui contre
les accidents. Les précautions sont décrites ici et dans
les normes données dans l‘Index.
A. Protection contre les brûlures
Conformez-vous aux précautions du paragraphe 1.2.
L'arc de soudage est intense et visiblement vif. Son
rayonnement peut blesser les yeux, traverser les habits
légers, se réfléchir sur les surfaces claires, et brûler la
peau et les yeux. Les brûlures de la peau ressemblent à
un gros coup de soleil. Celles d'arcs sous gaz protecteur
sont plus graves et plus douloureuses. NE VOUS
BRULEZ PAS - SUIVEZ LES PRECAUTIONS.
1. Vétements de protection
Portez des vétements á manches longues (surtout pour
I'arc en atmosphère inerte) avec gants, masque et
chaussures (1.2A.}.
Si nécessaire portez en plus une veste ou des manches
en cuir, un tablier et des guétres ignifugés. De
préférence ne portez pas de vétements en coton non
traité.
Protection de la peau. Portez des vétements épais
foncés. Boutonnez le col pour protéger la poitrine et le
cou, et boutonnez les poches pour prévenir infiltration
d'étincelles.
2. Protection des yeux et de la téte
Évitez que vos yeux soient exposés a l'arc. NE regardez
JAMAIS un arc électrique sans protection.
Lorsque vous soudez, portez un écran ou masque avec
verre filtrant teinté N° 12 ou plus foncé. Mettez-le sur le
visage avant d'amorcer l'arc.
Protégez le verre filtrant d’un couvre-verre clair. NE
PORTEZ PAS un masque fendu ou brisé; le rayonne-
ment peut s'infiltrer et causer des brûlures.
Les verres filtrants fendus, brisés ou lâches doivent être
remplacés IMMÉDIATEMENT. Remplacez un couvre-
verre brisé, piqué ou taché par des projections.
OM-1518 Page 7
Flash goggles with side shields MUST be worn under
the helmet to give some protection to the eyes should
the helmet not be lowered over the face before an arc is
struck. Looking at an arc momentarily with unprotected
eyes {particularly a high intensity gas-shielded arc} can
cause a retinal burn that may leave a permanent dark
area in the field of vision.
3. Protection of Nearby Personnel
Enclosed welding area. For production welding, a
separate room or enclosed bay is best. In open areas,
surround the operation with low-reflective, non-
combustible screens or panels. Allow for free air circula-
tion, particularly at floor level.
Viewing the weld. Provide face shields for all persons
who will be looking directly at the weld.
Others working in area. See that all persons are wearing
flash goggles.
Before starting to weld, make sure that screen flaps or
bay doors are closed.
B. Toxic Fume Prevention
Comply with precautions in 1-2B.
Generator engine exhaust must be vented to the outside
air. Carbon monoxide can kill.
C. Fire and Explosion Prevention
Comply with precautions in 1-2C.
Equipment's rated capacity. Do not overload arc
welding equipment. it may overheat cables and cause a
fire.
Loose cable connections may overheat or flash and
cause a fire.
Never strike an arc on a cylinder or other pressure
vessel. It creates a brittle area that can cause a violent
rupture or lead to such a rupture later under rough
handling.
D. Compressed Gas Equipment
Comply with precautions т 1-20.
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.
OM-1518 Page 8
Vous devez portez des lunettes à écrans latéraux sous le
masque pour protéger les yeux dans.le cas où le masque
ne serait pas abaissé sur le visage avant l'amorçage de
l‘arc. Regarder momentanément un arc sans protection
(principalement un arc en atmosphère inerte à haute in-
tensité) peut brûler la rétine et laisser un point sombre
permanent dans le champ de vision.
3. Protection du personnel à proximité
Local de soudage fermé. Pour le soudage de produc-
tion, il vaut mieux utiliser une salle séparée ou une baie
fermée. Dans les locaux ouverts, entourez les travaux
d’écrans ou panneaux peu réfléchissants et ininflam-
mables. Laissez l’air circuler librement, particulièrement
au niveau du sol.
Donnez des masques aux personnes qui regarderont
directement la soudure.
Autres personnes travaillant sur les lieux. Veillez à ce
que toutes les personnes portent les lunettes de protec-
tion.
Avant d'attaquer la soudure, assurez-vous que les
rebords d'écran ou les portes soient fermés.
B. Prévention des gaz toxiques
Suivez les précautions du paragraphe 1.2B. L'échappe-
ment du moteur de la génératrice doit être ventilé a l'air
extérieur. L'oxyde de carbone peut tuer.
C. Prévention des incendies et des explosions
Suivez les précautions 1.2C. Puissance nominale de
l'appareil. Ne surchargez pas le poste de soudage à
l'arc. Cela peut surchauffer les câbles et causer un in-
cendie.
Les branchements lâches de câble peuvent surchauffer
ou faire des étincelles et causer un incendie.
N’amorcez jamais un arc sur une bouteille ou autre réci-
pient sous pression. Cela créerait un point de rupture
entraînant à plus ou moins longue échéance l'explosion
du réservoir.
D. Gaz comprimé
Suivez les précautions 1.2D.
E. Prévention des décharges électriques
Des conducteurs chargés ou métal nu incorporés au cir-
cuit de soudage ou à un appareil chargé sans mise à la
terre peuvent donner une décharge fatale à la personne
dont le corps devient conducteur. NE SOUDEZ PAS
DEBOUT, ASSIS, COUCHE, PENCHE sur une surface
humide ni en contact avec une telle surface sans protec-
tion appropriée.
To protect against shock:
Keep body and clothing dry. Never work in damp area
without adequate insulation against electrical ‘shock.
Stay on a dry duckboard, or rubber mat when damp-
ness or sweat can not be avoided. Sweat, sea water, or
moisture between body and an electrically HOT
part - or grounded metal - reduces the body surface
electrical resistance, enabling dangerous and possibly
lethal currents to flow through the body.
1. Grounding the Equipment
When arc welding equipment is grounded according to
the National Electrical Code, and the work is grounded
according to ANSI Z49.1 “Safety In Welding And Cut-
ting,” a voltage may exist between the electrode and
any conducting object. Examples of conducting objects
include, but are not limited to, buildings, electrical
tools, work benches, welding power source cases,
workpieces, etc. Never touch the electrode and any
metal object unless the welding power source is
off.
When installing, connect the frames of each unit such
as welding power source, control, work table, and
water circulator to the building ground. Conductors
must be adequate to carry ground currents safely.
Equipment made electrically HOT by stray current may
shock, possibly fatally. Do NOT GROUND to electrical
conduit, or to a pipe carrying ANY gas or a flammable li-
quid such as oil or fuel.
Three-phase connection. Check phase requirements of
equipment before installing. If only 3-phase power is
available, connect single-phase equipment to only two
wires of the 3-phase line. Do NOT connect the equip-
ment ground lead to the third (live) wire, or the equip-
ment will become electrically HOT - a dangerous condi-
tion that can shock, possibly fatally.
Before welding, check ground for continuity. Be sure
conductors are touching bare metal of equipment
frames at connections.
If a line cord with a ground lead is provided with the
equipment for connection to a switchbox, connect the
ground lead to the grounded switchbox. If a three-
prong plug is added for connection to a grounded
mating receptacle, the ground lead must be connected
to the ground prong only. If the line cord comes with a
three-prong plug, connect to a grounded mating recep-
tacle. Never remove the ground prong from a plug, or
use a plug with a broken off ground prong.
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.
Pour vous protéger contre les décharges électriques,
maintenez votre corps et vétements secs. Ne travaillez
jamais dans un endroit humide sans isolation adéquate
contre les décharges électriques. Lorsque vous ne
pouvez éviter ! humidité ou la sueur, placez-vous sur un
caillebotis sec ou un tapis en caoutchouc. La sueur,
l’eau de mer, ou l'humidité entre le corps et une pièce
CHARGÉE, ou une pièce de métal à la masse, réduisent
la résistance électrique de la surface du corps, permet-
tant l'entrée de courants dangereux, voire mortels.
1. Mise à la terre de l'appareil
Lorsque l'appareil de soudage à l'arc est mise à la terre
suivant la norme National Electrical Code, et la masse
est mise a la terre suivant la norme ANSI 749.1 “Safety
in Welding and Cutting,” une tension peut exister entre
l’électrode et un objet conducteur. Certaines de ces ob-
jets sont par exemple (mais pas seulement), des
bâtiments, des outils électriques, des établis, des
châssis de postes de soudure, des pièces d’ouvrage,
etc. Ne jamais touchez l'électrode ou des objets en
métal avant d'avoir mis le poste de soudure à l'arrêt.
À l'installation, branchez les châssis de chaque élément
(source de courant, commande, établi et circuit d’eau) à
la terre. Les conducteurs doivent pouvoir conduire les
courants telluriques en toute sécurité. L'appareil chargé
par les courants vagabonds peut donner une décharge
risquant d'être mortelle. NE BRANCHEZ PAS VOTRE
PRISE DE TERRE à une conduite électrique, ou à un
tuyau de gaz ou de liquide inflammable tel que l'huile ou
un combustible.
Connexion triphasée. Avant l'installation vérifiez la
phase nécessaire à l'appareil. Si seul le triphasé est
disponible, ne branchez l'appareil monophasé qu'à deux
des fils de la ligne triphasée. NE BRANCHEZ PAS le
conducteur de terre de l'appareil au troisième fil (sous
tension), autrement l'appareil serait chargé: condition
dangereuse pouvant donner une décharge fatale.
Avant le soudage, vérifiez si la prise de terre est
uniforme. En branchant, assurez-vous que les con-
ducteurs touchent le métal! nu du châssis de l'appareil.
Lorsqu'un appareil doit être alimenté à partir d’un cof-
fret d'alimentation, le conducteur de terre doit être relié
à celui-ci.
Si vous avez en plus une fiche à trois broches pour la
terre, ne branchez le conducteur de terre qu'à la broche
de terre. Si le cordon d'alimentation a une fiche à trois
broches, reliez-le à une prise femelle tripolaire reliée a la
terre. N'enlevez jamais la broche de terre d'une fiche ou
n'utilisez jamais une fiche dont la broche de terre serait
brisée.
2. Pince-électrodes
Utilisez des pince-électrodes bien isolées. N'UTILISEZ
PAS des pince-électrodes avec vis saillantes.
3. Connecteurs
Utilisez des connecteurs à verrouillage bien isolés pour
assembler de longs câbles.
OM-1518 Page 9
4. Cables
Frequently inspect cables for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn
or damaged insulation to avoid possibly - lethal shock
from bared cable. Cables with damaged areas may be
taped to give resistance equivalent to original cable.
Keep cable dry, free of oil and grease, and protected
from hot metal and sparks.
5. Terminals And Other Exposed Parts.
Terminals and other exposed parts of electrical units
should have insulating covers secured before operation,
6. Electrode
a. Equipment with output on/off control {con-
tactor)
Welding power sources for use with the gas
metal arc welding (GMAW), gas tungsten
arc welding (GTAW) and similar processes
normally are equipped with devices that per-
mit on-off control of the welding power out-
put. When so equipped the electrode wire
becomes electrically HOT when the power
source switch is ON and the welding gun
switch is closed. Never touch the electrode
wire or any conducting object in contact
with the electrode circuit unless the welding
power source is off.
b. Equipment without output on/off control
(no contactor)
Welding power sources used with shielded
metal arc welding (SMAW) and similar pro-
cesses may not be equipped with welding
power output on-off control devices. With
such equipment the electrode is electrically
HOT when the power switch is turned ON.
Never touch the electrode unless the
welding power source is off.
7. Safety Devices
Safety devices such as interlocks and circuit breakers
should not be disconnected or shunted out.
Before instaliation, 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. `
OM-1518 Page 10
4. Câbles
Vérifiez fréquemment l'usure, les fissures et l'altération
des câbles. REMPLACEZ IMMEDIATEMENT ceux dont
I'isolation serait trop usée ou altérée pour prévenir les
décharges mortelles provoquées par un câble dénudé.
Vous pouvez enrouler les parties endommagées de
ruban adhésif en épaisseur suffisante pour donner une
résistance de câble neuf. Maintenez les câbles secs,
dépourvus d'huile et de graisse et mettez-les à l'abri du
métal chaud et des étincelles.
5. Têtes de câbles et autres parties dénudées
Avant la mise en marche, les têtes de câbles et autres
parties dénudées d’un appareil électrique doivent être
munies de leurs couvrefils isolants.
6. Electrode
a. Appareil équipé d'une commande mar-
che/arrét {contacteur)
En général, les postes de soudure utilisés
pour le soudage à l'arc sous protection
gazeuse avec électrode fusible (GMAW), ou
avec électrode tungstène (GTAW) et des
procès semblables sont équipés d'une com-
mande marche/arrêt de la puissance de sor-
tie. Lorsque l'interrupteur est en position
“MARCHE” et l'interrupteur du pistolet est
fermé, le fil d'électrode devient chargé. Ne
touchez jamais le fil électrode ou tout autre
objet conducteur faisant contact avec le cir-
cuit d'électrode sans couper le courant au
poste de soudure.
b . Appareil non-équipé d'une commande mar-
che/arrêt (sans contacteur)
Les postes de soudure utilisés pour le
soudage & l’arc avec électrode enrobée
(SMAW) et des procès semblabes peuvent
être non-équipés d'une commande mar-
che/arrêt de la puissance de sortie. Lorsque
l'interrupteur est en position “MARCHE”
l'électrode devient chargé. Ne touchez
jamais l’électrode sans couper le courant au
poste de soudure.
7. Dispositif de sécurité
Le dispositif de sécurité-verrouillage et coupe-circuit ne
doit pas être débranché ou déshunté.
Avant l'installation, l'inspection ou la réparation de l'ap-
pareil, mettez l'alimentation sur ARRET et enlevez les
fusibles généraux (ou verrouillez les interrupteurs) pour
éviter une remise en MARCHE accidentelle. Débran-
chez tous les câbles de la source de courant ainsi que les
prises des cordons d'alimentation en 115 volts.
Lors du soudage, n'ouvrez pas le circuit d'alimentation
et ne changez pas la polarité. S'il est débranché au
cours d'une urgence, faites attention aux brûlures de
décharge ou aux jaillissements d’étincelles.
Appareil laissé sans surveillance. Mettez toujours sur
ARRET et débranchez l'appareil.
1-4. STANDARDS BOOKLET INDEX - For more in-
formation, refer to the following standards or their latest
revisions and comply as applicable:
1.
10.
11.
ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING obtainabie from the American
Welding Society, 550 Le Jeune Rd, P.O. Box
351040, Miami, FL 33135.
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.
OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the U.S. Govern-
ment Printing Office, Washington, D.C. 20402.
ANSI Standard 287.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
ANSI Standard Z41.1, STANDARD FOR MEN'S
SAFETY -TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018
ANSI Standard 249.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO-
CESSES obtainable from the American National
Standards Institute, 1430 Broadway, New York,
NY 10018.
AWS Standard A6.0, WELDING AND CUT-
TING CONTAINERS WHICH HAVE HELD COM-
BUSTIBLES obtainable from the American
Welding Society, 550 Le Jeune Rd., P.O. Box
351040, FL 33135.
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.
NFPA Standard 70-1978, NATIONAL ELEC-
TRICAL CODE obtainable from the National Fire
Protection Association, 470 Atiantic Avenue,
Boston, MA 02210,
NFPA Standard 518, CUTTING AND WELDING
PROCESSES obtainable from the Nationa! Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS obtainable
from the Compressed Gas Association, 500 Fifth
Avenue, New York, NY 10036.
L'interrupteur d'arrêt doit toujours se trouver a prox-
imité de la source de courant.
1-4. INDEX DES NORMES - Pour plus de
renseignements, référez-vous aux normes de l'ACNOR
ou aux normes américaines suivantes:
1. ANSI Standard 249.1, SAFETY IN WELDING
AND CUTTING distribué par l'American Welding
Society, 550 Le Jeune Rd., P.O. Box 351040
Miami, FL. 33135
2. NIOSH, SAFETY AND HEALTH IN ARC
WELDING AND GAS WELDING AND CUTTING
distribué par le Superintendent of Documents,
U.S. Government Printing Office, Washington
D.C. 20402
3. OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, distribué par U.S. Government
Printing Office, Washington, D.C. 20402,
4. ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION distribué par l'American
National Standards Institute, 1430 Broadway,
New York, NY 10018.
5. ANS! Standard Z41.1, STANDARD FOR MENS
SAFETY - TOE FOOTWEAR distribué par Гаа-
dresse donnee en 4,
6. ANS! Standard 249.2, FIRE PREVENTION IN
THE USE Of CUTTING AND WELDING PRO-
CESSES distribué par l'addresse donnee en 4.
7. AWS Standard A6.0, WELDING AND CUT-
TING CONTAINERS WHICH HAVE COM-
BUSTIBLES distribué par l’addresse donnee en
1.
8. NFPA Standard 51, OXYGEN - FUEL GAS
SYSTEMS FOR WELDING AND CUTTING
distribué par la National Fire Protection Associa-
tion, 470 Atlantic Avenue, Boston, MÁ 02210
9. NFPA Standard 70-1978, NATIONAL ELEC-
TRICAL CODE distribué par l'addresse donnée
en 8
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES distribué par l'addresse donnée en
8
11. CGA Pamphiet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS distribué par
la Compressed Gas Association, 500 Fifth
Avenue, New York, NY 10036.
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING distribue par la Cana-
dian Standards Association, Standards Sales,
178 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W 1R3.
OM-1518 Page 11
12.
13.
14.
15.
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.
NWSA booklet, WELDING SAFETY
BIBLIOGRAPHY obtainable from the National
Welding Supply Association, 1900 Arch Street,
Philadelphia, PA 19103.
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 Welding Society,
550 Le Jeune Rd., P.O. Box 351040, Miami, FL
33135.
ANSI Standard Z88.2 ‘Practice for Respiratory
Protection’ obtainable from the American Na-
tional Standards Institute, 1430 Broadway, New
York, NY 10018.
OM-1518 Page 12
13. NWSA booklet,
14.
15.
WELDING SAFETY
BIBLIOGRAPHY distribué par la National
Welding Supply Association, 1900 Arch Street
Philadelphia, PA 19103.
American Welding Societe Standard AWSF4.1
“Recommended Safe Practices for the Prepara-
tion for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances”,
distribué par l'American Welding Societe, 550 Le
Jeune Rd., P.O. Box 351040, Miami, FL 33135
ANSI Standard Z88.2 ‘Practice For Respiratory
Protection” distribué par American National
Standards Institute, 1430 Broadway, New York,
NY 10018.
—Od SECTION 2 - INTRODUCTION —— nt
Weight
Net Ship
29-1/2 lbs.
Weld Control
{13.38 kg) 45 lbs.
_ (20.4 kg)
Gas Control 1 46 ol
Spool Support 6 Ibs.
Assembly (2.7 kg)
Wire Feed . . .
Speed Range 70 in. (1.8 m) - 760 in. {19 m) per minute
Rated Welding 750 @ 100 volts
Current In Amperes 100% Duty Cycle
Figure 2 - 1. Specification
5/16 in. (7.9 mm) TS .
. Sa TS Le 5-1/8 in.
Diameter 4 Holes Bn 7-3/4 in. - (130 mm)
{203.2 mm) >. 13 mm) ~~ y
Y 12-7/8 in. (352 mm] A Ce
> << 3-1/2 in.
| (89 mm}
и oh
io
en TA-080 485
= 14-3/4 in.
5. (374.7 mm)
15-1/2 in. Î
(394 mm) 4-1/8 i 5/16 in. {7.9 mm)
in. Diameter 2 Holes
(105 mm} |
E AI 2 1 ;
; i 9-7/8 in. |
J F (251 mm) 10179;
; “ 10-1/2 in.
6-1 /8 in. (267 mm) TA-090 479
> (156 mm)
TC-080 430-A
Г Overall Dimensions And
Mounting Hole Layout
re Inches | Millimeters|
: | A | 19-1/2 495
B B | 21-7/8 556
с 13-3/4 349
2-7/8 in,
— 173.0 mm) | E | 2-1/2 63.5
| Ч F | 31/2 88.9
> y | G | 41/2 114
TA-092 440 | H | 10-11/16 275
CL TB-080 486-A
Figure 2 - 2. Overall Dimensions And Mounting Hole Layout
OM-1518 Page 13
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 ali 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 ZEIG and KALT which identify
different ievels of hazard.
КОАО statements include installation, operating,
and maintenance procedures or practices which if not
carefully followed 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.
Cs SECTIÓN 3 -
3 - 1. LOCATION (Figure 2-2) - The service life and
efficiency of this unit and associated components are
reduced when they are subjected to high levels of dust,
dirt, moisture, corrosive vapors, and extreme heat.
The location should allow room to open the front panel
and to remove wrapperís) for installation, inspection,
maintenance, and repair functions.
Provisions have been made for mounting the gas con-
trol on the bottom of the weld control. The gas control
may also be mounted in line with the welding gun
thereby avoiding routing the weld cables and gas hoses
back to the weld control. The instaliation site should
also permit easy access to all components for opera-
tional and maintenance functions. Lead lengths must be
considered when locating all components of the weld
control,
Mounting holes are provided in the weld control, Figure
2-2 gives overall dimensions and mounting hole layout.
3 - 2. SHIELDING GAS CONNECTIONS (Figure
3-3) - Connect a hose of suitable length and construc-
tion from the shielding gas supply to the connector on
OM-1518 Page 14
A third signal word, [ELUSIVE highlights instruc-
tions which need special emphasis to obtain the most
efficient operation 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. À 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) Number of the equipment be supplied.
2-3. DESCRIPTION - This weld control is designed
to automatically cycle preprogrammed welding events
and provide a constant wire feed speed regardless of
varying motor load conditions. This unit is to be used
with a constant potential welding power source.
The standard weld control has provisions to program
the PRE-FLOW TIME, RUN IN SPEED, WIRE FEED
SPEED, SPOT TIME, CRATER & INCH SPEED,
CRATER TIME, BURNBACK time, and POST-FLOW
TIME. Normally-open and normally-closed contacts are
provided on each time control to interface with other
equipment (i.e., starting and stopping a welding
fixture).
For information on the wire drive assembly, see
OM-1538.
INSTALLATION uuu E TTD
the IN panel of the gas control. The gas fittings are
5/8-18 connectors with right-hand threads. The gas
flow must be accurately controlled by a regulator and
flowmeter at the source.
Connect the supplied hose from the gas control to the
barbed fitting on the wire drive housing.
3-3. WATER CONNECTIONS (Optional)
OVERHEATING Gas
Welding gun can damage gun.
e /f using a water-cooled gun and recirculating
coolant system, make connections from the
coolant system directly to the gun hoses. Do not
use water connections on the gas control.
Metal-Arc
When a recirculating coolant system is not employed,
and use of the provided solenoid valve is desired, make
connections at gas control. The water fittings are
5/8-18 connectors with left-hand threads. Connect
water hose from supply to fitting on IN panel of gas
control. Connect another hose between remaining fit-
ting and gun IN fitting. Connect and route a hose from
gun QUT fitting to a proper drain.
Coolant will flow as soon as the POWER switch on the
weld control is placed in the ON position. If coolant flow
is desired only in conjunction with shielding gas flow,
the black lead on terminal B of terminal strip 2T, in the
weld control, must be moved to terminal E on terminal
strip 1T.
3-4. REMOTE START AND STOP CONNEC-
TIONS - For remote control of starting and stopping,
connections must be made to terminal strips 1T and 27
in the weld control. Loosen screw from door on upper
panel of the weld control and open door. Terminal strips
1T and 2T are located on the right side of the control.
КЛАССЕ 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.
A. Momentary Contact Push-Button Switch
1. Route cable from switch through the cable
clamp on the right side of the weld control,
2. Remove jumper between 1TJ and 1TH.
3. Attach two leads from the normaily-open start
switch to 1TH and 1TK.
4. Attach two leads from the normally-closed stop
switch to 1TJ and 1TH.
B. Maintained-Contact (Relay) Switch
1. Route cable from relay through the cable clamp
on the right side of the weld control.
2. Remove jumper between 1TH and 1TG.
3. Connect the normally-open maintained-contact
of the relay to 1TH and 1TK.
4. Closing relay contact will start unit and opening
relay contact will stop unit.
C. Skip Welding (Figure 3-1)
1. Remove jumper link between 1TH and 1TG.
2. Route a 3-conductor cable through the cable
clamp on the right side of the weld control.
3. The switch commons of a double-pole single-
throw switch should be tied together to one lead
of the 3-conductor cable. Connect this lead of
the 3-conductor cable to 1TH.
4. Connect one of two remaining leads to 1TG.
5. Connect remaining lead to 2TA.
6. Closing this switch will start weld cycle and unit
will weld for the time set on the SPOT TIME con-
trol. The setting of the pre-flow and post-flow
timers determines how long weld current is not
present and thereby determines the skip time.
The unit will automatically recycle through the
weld cycle until the switch is opened.
Double Pole - Single Throw Switch
2TA OO
1TG Oo
1TH TA-044 484-B
To Weld
Control
Figure 3 - 1. Skip Welding Switch Connections.
3-5. NORMALLY-OPEN AND NORMALLY-
CLOSED CONTACTS AVAILABLE FOR CONTROL
OF WELD FIXTURES (Figure 3-2) - A set of
normally-open and normally-closed contacts are provid-
ed to work in conjunction with each weld cycle timing
circuit. These contacts may be used to determine fix-
ture movement in conjunction with the weld cycle. For
example: If the operator wants the fixture to start mov-
ing at arc initiation and stop when the STOP push but-
ton is depressed, the normaily-open contacts of CR51
{at receptacle RC4, terminals F and H} would be used to
control fixture movement,
ELLE ELECTRIC SHOCK can kill.
e Do not touch live electrical parts.
® Shut down the weld control and disconnect input
power (115 vac) before making any terminal strip
connections.
Connections can be made to the 3/16 in. male friction
connectors on receptacles RC4 and RC10 located
behind the timing circuit card assembly in the weld con-
trol. To gain access to these receptacles, the timing cir-
cuit card assembly may be removed as follows:
1. Loosen screw from door on upper panel of the
weld control and open door.
2. Remove three screws securing timer panel.
3. Gently pull timer panel part way out.
4. Remove plugs PLG1 and PLG2 from the printed
circuit card assembly.
5, Remove timer panel.
Route leads from the receptacles through the cable
clamp provided on the side of the weld control.
After connections are made to the receptacles, reverse
the steps above to install the timer panel.
OM-1518 Page 15
r- ALLA LL
ra A '4 4 Cr № АА
НИ al HH E
Ns CH51 CH52 Css CH46
CR56* —— T——
| |! |
| ef —— _
CR55* DOTE — — —— —~ |= —-
| |
CR54* -——— — En, onu — | — -
| | | | |
cm nn наи, линии O
| || |
CR51* 7 A — || _———
CR52* eee re | — _
| | ||
5 Weld Time Or Spot Time
© Run In Speed 0-Infinity 0-2.5 Sec.
& >
oD
D .
+ Ne 7 Crater Time
$ ° 0-2.5 Sec.
= | © |
‚Е | a Burnback Time
= a 0-.25 Sec.
= | $
Pre-Flow Time | = Post-Flow Time
“4— 05 Sec. —*! Y | Ç < ай 0-5 Sec. >
pe > Т
Y Arc Time
START Initiation
*The dotted line condition indicates the time during the weld
cycle that the control relay is deenergized. The solid line condi-
tion indicates the time during the weld cycle that the control
relay is energized. TB-080 432
Figure 3 - 2. Weld Control Cycle
3-6. ELECTRICAL CONNECTIONS FOR ® Shut down welding power source and be sure it
AUTOMATIC FLUX VALVE (If Applicable) cannot be accidentally energized before making
interconnections.
LILLIE ELECTRIC SHOCK can kill, ® Be sure weld control is disconnected from its 115
Do not touch live electrical parts. vac supply before making internal connections.
. Disconnect line power from all welding equipment
and associated components before attempting A. Drive Motor Connections
these connections.
Connect three-pole plug RC6 from weld control to plug
Route leads from automatic valve through strain relief PLG11 at drive motor.
clamp on side of weld control. Connect one valve lead
to terminal E on terminal strip 1T, and the remaining B. Gas Control Connections
valve lead to terminal D on terminal strip 2T inside the
weld control (polarity is not important). Connect ten-pole plug PLG7 from weld contro! to
receptacle RC7 on gas control {see Figure 3-3).
The automatic valve will energize and flux will flow
whenever the START button is depressed. Flux flow C. Voltmeter Connections
stops at end of Postflow Time.
For reverse polarity, connect the lead with ring terminal
from the weld control voltmeter to the negative output
3-7. WELD CONTROL INTERCONNECTIONS terminal on welding power source.
КОТО ЕБЕСТВИС SHOCK can kill. For straight polarity, connect the lead with the ring ter-
e Do not touch live electrical parts. minal from the weld control voltmeter to the positive
OM-1518 Page 16
output terminal on welding power source. Reverse the
leads on the weld control voltmeter and ammeter.
D. Weld Output Connections (Figure 3-3 & 4-1)
1. Remove the gas control cover.
2. For reverse polarity, insert proper size weld cable
from positive output terminal of welding power
source through grommet on IN panel of gas con-
trol. Route cable through reed switch bracket
and connect cable to shunt.
3. For straight polarity, insert proper size weld cable
from negative output terminal of welding power
source through grommet on iN panel of gas con-
trol. Route cable through reed switch bracket
and connect cable to shunt.
4. Insert proper size weld cable from weld cable ter-
minal on wire drive housing through grommet on
the other end of gas control. Connect cable to
shunt.
5. Connect proper size weld cable from remaining
output terminal on welding power source to the
work.
6. Replace gas contro! cover.
To Weld Cable Terminal
On Wire Drive Housing
To Welding Power
Source Qutput
Terminal
Shunt
Receptacle
RC7
IN Panel
Figure 3 - 3. Gas Control
E, Electrical Input Connections
Connect the 4-pin plug from the 115 volts ac and con-
tactor control cord to weld control receptacie, located
on weld control side panel. Connect remaining ends to
welding power source as follows: Connect 2-prong plug
to CONTACTOR CONTROL receptacle, and connect
3-prong plug to 115 VOLTS AC twistlock receptacle.
Place CONTACTOR CONTROL switch on welding
power source in the REMOTE position.
3-8. HUB AND SPINDLE ASSEMBLY IN-
STALLATION (Figure 3-4)
The hub, spindle, and support are designed so that the
hub may be mounted on either side of the support and
in any of the provided holes. Install this assembly as
follows:
Retaining Ri
ing Ting Wire Reel*
Brake
Spring-Loaded Washer
Stops Va |
Hub 06
Support
Shaft
Hex Nut
Wing Nuts* x
Hub 7
*Optional waar :
Spindle" TB-070 886
Support
Figure 3 - 4. Hub And Reel Installation
1. Remove hex nut from hub support shaft and in-
sert shaft through one of the sets of holes in the
spindle support (hole selection depends on size
of wire spool). Ensure that the brake washers are
properly seated in the hub.
2. Replace hex nut and tighten until a slight drag is
felt while turning hub.
3. Install welding wire according to the applicable
Section: 3-9 for spool-type wire; and 3-10, 3-11
for reel-type wire.
3-9. INSTALLATION OF SPOOL-TYPE WIRE
(Figure 3-4)
1. Depress the two spring-loaded stops (see Figure
3-4} on retaining ring, and slide retaining ring off
hub,
2. Slide the spool of wire onto the hub so that the
wire feeds off the bottom with the minimum
bend and sharp radius.
3. Rotate the spool until the hole in the spool aligns
with the pin in the hub. Slide the spool onto the
hub until it seats against the back flange of the
hub.
4. Depress the two spring-loaded stops on the re-
taining ring, and slide the retaining ring into pro-
per position on the hub. Release the two stops.
3-10. INSTALLATION OF REEL-TYPE WIRE (Op-
tional) (Figure 3-4)
1. Lay the wire reel (see Figure 3-4) flat on a table
or floor.
2. Loosen the four wing nuts on the fingers of the
wire reel.
3. Pull the four fingers out until they can be rotated
toward the center of the reel.
OM-1518 Page 17
4. Install the wire onto the reel over the four
fingers. Ensure that the wire feeds off the bot-
tom of the reel. The reel turns in a
counterclockwise direction. :
5. Rotate the four fingers back to their proper posi-
tion. Tighten the four wing nuts.
3-11. INSTALLATION OF WIRE REEL (Optional)
(Figure 3-4)
1. Depress the two spring-loaded stops (see Figure
3-4) on retaining ring, and slide retaining ring off
hub.
2. Slide the wire reel onto the hub. Rotate wire reel
until hub guide pin is seated in reel.
3. Depress the two spring-loaded stops on the re-
taining ring, and slide retaining ring into proper
position on hub. Release the two stops.
3-12. ADJUSTING HUB TENSION (Figure
3-4) - Check hub tension by slowly pulling 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 feeder is shut off. If ad-
justment is required, loosen or tighten the hex nut (see
Figure 3-4) on the end of the hub support shaft accor-
dingly.
3-13. WELD/CRATER VOLTAGE CONTROL CON-
NECTIONS
A Weld/Crater Voltage control cord is provided on the
right side of the weld control for making connection to
the welding power source voltage control circuitry.
Align keyway on 4-pin Weld/Crater Voltage control
plug with key on 4-socket plug on the Voltage Control
cord; insert plug and rotate locking ring.
Align keyway on 5-pin plug on Voltage Control cord
with key on welding power source REMOTE VOLTAGE
CONTROL receptace; insert plug and rotate locking
ring.
—_—_—_—_———"" SECTION 4 - OPERATOR CONTROLS mrs ms
Voltmeter
Pilot Light
DS
Fuse mo
Circuit Breaker
Crater & Jog Speed |
Wire Feed Speed ————_|
Run In Speed —.. |
Pre-Flow Time
Spot-Continuous Switch
Spot Time
Crater Time
Burnback
Post Flow Time
Ammeter
Retract-Advance Switch
Power Switch
“J
Jog Push Button
7
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TC-080 430-A
Figure 4 - 1. Front Panel Controls
4 - 1. POWER SWITCH (Figure 4-1) - Placing the
POWER switch on the weld control in the ON position
will apply 115 volts ac to the unit and thereby place it in
an operational condition, permitting the preprogramm-
ed welding cycle to start when the START button is
depressed, or gas to flow when the PURGE button is
depressed, or welding wire to feed if the JOG switch is
depressed. Placing the POWER switch in the OFF posi-
tion will shut the weld control down.
OM-1518 Page 18
4 - 2. PILOT LIGHT (Figure 4-1) - The pilot light
PL1, when illuminated, indicates that the weld control
POWER switch is ON and the unit is energized.
4 - 3. RETRACT-ADVANCE SWITCH AND JOG
PUSH-BUTTON SWITCH (Figure 4-1} - With the
RETRACT-ADVANCE switch in the RETRACT position,
the welding wire will retract into the gun at the speed
set by the CRATER & JOG SPEED control only while
the JOG push-button switch is depressed.
With the RETRACT-ADVANCE switch in the AD-
VANCE position, the welding wire will advance from the
gun at the speed set by the CRATER & JOG SPEED
control only while the JOG push-button switch is
depressed.
The JOG push-button switch is a normally-open,
momentary-contact switch. Depressing the switch will
energize the drive motor without energizing the welding
power source contactor or gas control circuitry.
4 - 4. PURGE PUSH-BUTTON SWITCH (Figure
4-1) - The PURGE push-button switch is a normally-
open, momentary-contact switch. Depressing the push
button will energize the gas solenoid and thereby purge
the shielding gas line to the gun.
4 -5. START PUSH-BUTTON SWITCH (Figures
4-1 & 3-2) - Depressing the START push-button
switch will start the preprogrammed weld cycle. See
Figure 3-2 for weld cycle events. The weld cycle will
continue untit the STOP push-button switch is depress-
ed or the SPOT TIME times out.
4 - 6. STOP PUSH-BUTTON SWITCH (Figures 4-1
& 3-2) - Depressing the STOP push-button switch will
initiate the preprogrammed crater fill, burnback, and
post-flow time. See Figure 3-2 for weld cycle events.
4 - 7. RUN IN SPEED CONTROL (Figure 4-1) - The
RUN IN SPEED control provides a means of selecting
the rate at which welding wire will feed prior to arc in-
itiation. After arc initiation, the wire feed speed is
governed by the WIRE FEED SPEED control.
The RUN IN SPEED control is marked 0-100 for
reference. When the control is set at 0, wire will feed at
the slowest rate; when set at 100, wire will feed at the
fastest rate.
4-8. WIRE FEED SPEED CONTROL (Figure
4-1) - The WIRE FEED SPEED control provides a
means of selecting the rate at which welding wire will
feed into the weld during the welding cycle.
The WIRE FEED SPEED control is marked 0-100 for
reference. When the control is set at 0, wire will feed at
the slowest rate; when set at 100, wire will feed at the
fastest rate.
4-9. CRATER 6 JOG SPEED CONTROL (Figure
4-1) - The CRATER & JOG SPEED control provides a
means of selecting the rate at which wire will feed into
the weld during the crater fill time and the rate at which
wire will advance or retract when the JOG switch is
depressed.
The CRATER & JOG SPEED control is marked 0-100
for reference. When the control is set at O, wire will feed
at the slowest rate; when set at 100, wire will feed at
the fastest rate.
4-10. PRE-FLOW TIME CONTROL (Figure
4-1) - An adjustable 0 to 5 PRE-FLOW TIME control is
provided for selecting the period of time the shielding
gas flows before arc initiation. The PRE-FLOW TIME
control starts to time when the START switch is
depressed.
Rotating the control in a clockwise direction increases
the pre-flow time. The scale surrounding the PRE-
FLOW TIME control is calibrated in seconds to aid in the
selection of a pre-flow time period suited to the in-
dividual welding operation.
4-11. SPOT-CONTINUOUS SWITCH (Figure
4-1) - The SPOT-CONTINUQUS switch provides selec-
tion of either normal weld cycle or a timed weld cycle.
Placing the SPOT-CONTINUQUS switch in the SPOT
position will provide a timed weld as determined by the
SPOT TIME control. Placing the SPOT-CONTINUOUS
switch in the CONTINUOUS position will cause the
weld control to operate normally.
4-12. SPOT TIME CONTROL (Figure 4-1) - An ad-
justable SPOT TIME control is provided for selecting the
time welding wire will feed into the weld at the speed
selected by the WIRE FEED SPEED control. The SPOT
TIME control starts to time out at arc initiation.
Rotating the control in a clockwise direction increases
the spot time. The scale surrounding the SPOT TIME
control is calibrated from 0 to 2.5 seconds to aid in the
selection of a spot time suited to the individual welding
operation.
4-13. CRATER TIME CONTROL (Figure 4-1) - An
adjustable CRATER TIME control is provided for selec-
ting the time welding wire will feed into the weld at the
rate set by the CRATER & JOG SPEED control. The
CRATER TIME control starts to time out when the
STOP switch is depressed or when the SPOT TIME
times out. Rotating the control in a clockwise direction
increases the crater fill time. The scale surrounding the
CRATER TIME control is calibrated from 0 to 2.5
seconds to aid in the selection of a crater fill time period
suited to the individual welding operation.
4-14. BURNBACK CONTROL (Figure 4-1) - An ad-
justable BURNBACK contro! is provided for selecting
the time the welding wire will remain electrically
energized after the drive motor stops. The BURNBACK
control starts to time out after the CRATER TIME con-
trol has timed out.
Rotating the control in a clockwise direction increases
the burnback time. The scale surrounding the BURN-
BACK control is calibrated from 0 to .25 second. By ad-
justing this control properly, the welding wire will
neither freeze in the weld puddle nor in the contact tube
of the gun. If the welding wire freezes to the work, in-
crease the burnback time. If the welding wire burns
back into the contact tube, decrease the burnback time.
OM-1518 Page 19
4-15. POST-FLOW TIME CONTROL (Figure
4-1) - An adjustable POST-FLOW TIME control is pro-
vided for selecting the time shielding gas will flow after
the BURNBACK control has timed out.
Rotating the control in a clockwise direction increases
the post-flow time. The scale surrounding the POST-
FLOW TIME control is calibrated in seconds to aid in the
selection of a post-flow time period suited to the in-
dividual welding operation.
4-16. METERS (Figure 4-1) - The meters are provid-
ed to monitor the welding operation. They are not in-
tended for exact current or voltage measurements. The .
voltmeter will indicate the voltage at the output ter-
minals, but not necessarily the actual voltage at the
welding arc {due to cable resistance, poor connections,
etc.). The ammeter will indicate the current output of
the welding power source.
4-17. OVERLOAD PROTECTION (Figure
4-1) - The weld control is protected from damage due
to an internal short or excessive overload by fuse F1. If
fuse F1 should open, the weld control would completely
shut down.
The drive motor is protected from damage due to
overload by circuit breaker CB1. If circuit breaker CB1
should open, the weld control would completely shut
down. The reset button would have to be manually
depressed to reset the circuit breaker.
4 - 18. WELD/CRATER VOLTAGE CONTROLS
(Optional)
The Weld/Crater Voltage Controls provide a means of
setting the welding power source output voltage during
weld and crater time of the weld cycle from the weld
control. Rotating the Weld Voltage and Crater Voltage
potentiometers clockwise increases output voltage.
The scales surrounding the voltage
potentiometers indicate a percentage of the welding
power source load voltage range and not an actual
voltage setting.
4 -19. RUN IN VOLTAGE & RUN IN TIME CON-
TROLS (Optional)
The RUN IN VOLTAGE control provides a means of set-
ting the voltage available when the wire contacts the
workpiece. The run in voitage is available until the RUN
IN TIME control times out initiating wire feed at the rate
and voltage set on the WIRE FEED SPEED and WIRE -
FEED VOLTAGE controls respectively.
The RUN IN TIME control provides from 0 to 2.5
seconds of wire feed at the rate set on the RUN IN
SPEED control.
o SECTION 5 - SEQUENCE OF OPERATION 1uv=ee== UD
RUE ELECTRIC SHOCK can kill; MOVING
PARTS can cause serious injury.
e Donot touch live electrical parts.
e Keep clear of moving parts,
ARC RAYS, SPARKS, AND HOT SURFACES can
burn eyes and skin; NOISE can damage hearing.
e Wear correct eye, ear, and body protection.
FUMES AND GASES can seriously harm your
health.
e Use enough ventilation to keep fumes and gases
from the breathing zone.
See Section 1 - Safety Rules For Operation Of Arc
Welding Power Source for basic welding safety infor-
mation.
5 - 1. GAS METAL-ARC WELDING & FLUX COR-
ED ARC WELDING - CONTINUOUS
1. Mount and position all components.
2. Make all connections as instructed in Section 3.
3. Set wire feed speed controls and weld cycle
timers to desired positions to program the weld
cycle as instructed in Section 4.
4. Hf applicable, set the RUN IN VOLTAGE, WELD
VOLTAGE, CRATER VOLTAGE, and RUN IN
TIME controls to the desired position.
b. Place the SPOT-CONTINUOUS switch in the
CONTINUOUS position (see Section 4-11).
OM-1518 Page 20
6. Turn on shielding gas at the source.
7. Energize the welding power source.
8. Place the weld control POWER switch in the ON
position {see Section 4-1).
9. Purge the gas line by depressing the PURGE but-
ton for one minute (see Section 4-4).
10. Depress the weld control START button (see
Section 4-5).
11. To terminate the weld cycle, depress the weld
control STOP button (see Section 4-6).
> - 2. GAS METAL-ARC WELDING & FLUX COR-
ED ARC WELDING - SPOT
1. Mount and position all components.
2. Make all connections as instructed in Section 3.
3. Set wire feed speed controls and weld cycle
timers to desired positions to program the weld
cycle as instructed in Section 4.
4. If applicable, set the RUN IN VOLTAGE, WELD
VOLTAGE CRATER VOLTAGE, and RUN IN
TIME controls to the desired position.
5. Place the SPOT-CONTINUOUS switch in the
SPOT position (see Section 4-11).
6. Rotate the SPOT TIME control to the desired
position (see Section 4-12).
7. Turn on shielding gas at the source.
8. Energize the welding power source.
9. Place the weld control POWER switch in the ON
position (see Section 4-1).
10. Purge the gas line by depressing the PURGE but-
ton for one minute (see Section 4-4),
11. Depress the weld control START button (see
Section 4-5).
12. The weld cycle will automatically terminate when
the SPOT TIME control times out.
. SHUTTING DOWN
1. Place the weld control POWER switch in the OFF
position.
2. Turn off all associated equipment.
3. Turn off the shielding gas at the source.
ERDE HIGH CONCENTRATION OF
SHIELDING GAS can harm health or kill.
e Shut off gas supply when not in use.
mess SECTION 6 - MAINTENANCE & TROUBLESHOOTING meu
ELLI ELECTRIC SHOCK can kill.
e Do not touch live electrical parts.
® Disconnect unit from input power and shut down
welding power source before internally inspecting
or servicing.
Troubleshooting of internal parts to be performed only
by qualified persons.
6 - 1. INSPECTION AND UPKEEP
Periodically inspect the labels on this
unit for legibility. All precautionary labels must be main-
tained in a clearly readable state and replaced when
necessary. See the Parts List for part number of precau-
tionary labels.
Usage and shop conditions will determine the frequency
and type of maintenance. inspect equipment as follows:
1. Repair or replace, as required, all hose and cable;
give particular attention to frayed and cracked in-
sulation and areas where it enters equipment.
2. Remove grease and grime from components;
moisture from electrical parts and cable.
6 - 2. GENERAL - It is assumed that proper installa-
tion has been made, according to Section 3 of this
manual, and that the unit has been functioning properly
until this trouble developed.
6 - 3. TROUBLESHOOTING CHART - The follow-
ing chart is designed to diagnose and provide remedies
for some of the troubles that may develop in this unit,
Use the chart in conjunction with the circuit diagram
while performing troubleshooting procedures. If the
trouble is not remedied after performing these pro-
cedures, the nearest Factory Authorized Service Sta-
tion should be contacted. In all cases of equipment
malfunction, the manufacturer's recommendations
should be strictly followed.
TROUBLE
PROBABLE CAUSE
REMEDY
Depressing START button
will not start weld cycle.
Electrode wire is not
energized and shielding gas
does not flow.
ON-OFF POWER switch 51
in wrong position or defec-
tive.
Place switch to ON position.
Replace defective POWER switch.
Circuit breaker CB1 tripped.
Manually reset circuit breaker by depressing the
button on the front panel of the weld control label-
ed RESET.
115 volts ac input plug
PLG9 is not secure in recep-
tacle.
Insert plug fully into 115 vac receptacle and rotate
plug clockwise.
115 volts input fuse F1
open.
Replace fuse F1.*
Wire feeds, shielding gas
flows, but electrode wire is
not energized.
Contactor Control cable
leads not secure on contac-
tor plug terminals.
Secure leads to plug terminals.
Defect in welding power
source.
See troubleshooting section in welding power
source instruction manual.
*If it becomes necessary to replace any fuse in this unit, ensure that a fuse of the proper size, type, and rating is
used.
OM-1518 Page 21
PLizg
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OPTIONAL:
PLG1YHH
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OM-1518 Page 22
VOLTAGE CONT RGL
(OPTIONAL)
Figure 6-2. Circuit Diagram For Motor Control Circuit Board PC1
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OM-1518 Page 23
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OM-1518 Page 24
Circuit Diagram No. B-091 918
Figure 6 - 4. Circuit Diagram For Models With Hot Start Option
November 1983 FORM: OM-1518E
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OM-1518 Page 1
Item Dia. Part
No. Mkgs. No. Description Quantity
Fi A 080 169 Control Box (Std)
'gure 092 928 Control Box (Used With Travel Master)
1 \ 025 638 METER, volts dc 0-100 .......111111 01114 2 4 Le 4 a a a a a ee ee ee ee ea 0 1
2 A 025 103 METER, amp dc 5SOMV 0-600 1.120002 0 0000 ea ea a ae ee ea a eee 00 1
3 079 579 DOOR, cabinet... eee 1
603 116 WEATHERSTRIPPING, adhesive 5/32 x 3/8 20er 4 ft
4 010 855 RETAINER, SCrew ..... it tte teeta eee tie eae 1
5 S2 011 043 SWITCH, toggle DPDT6amp125volts ............. cca... 1
6 51 011 233 SWITCH, toggle SPDT 10 amp 250voltsac .......................... 1
72 PB1,2 011 232 SWITCH, pushbutton SPDT ican 2
8 CB1 011 991 CIRCUIT BREAKER, 1P 1.5 amp 250 volts ...............ere0e0reee. 1
9 +08b 3566 CABINET, control {consistingof) .............. GH 1
10 073 487 NUT, speed NO. 2 . i ieee eee cee teen anes 1
11 Figure A2 PANEL, w/components (Pg 6) ...............e—ee0eereerer care ar em 1
047 497 LABEL, general precautionary ...............ceeoeeeeereeeonrerenee.. 1.
12 604 311 GROMMET, rubber 1/4 1D x 3/8 mounting hole 1/16 groove. ........... 1
13 010 193 TUBING, steel 3/80D x18 gawallx 1/4... ...... iii... 6
14 079 683 HEAT SINK, resistor .............ePéecoexceeeoeaoraer asno rerarerane— 1
15 030 949 HEAT SINK, rectifier..........1112100 0004 44 4 4 4 a 4 4 a 4 4 ea ea a eee ea aa 0 1
16 R2 030 941 RESISTOR, WW fixed 100 watt 5 ochm ........222220 04104 4 a a anse 0 1
17 056 170 SHIELD ... oe ee ee eee eee ee 1
18 010 199 TUBING, steel 0.275IDx0.048wallx1 ................ iia. 2
19 010 916 CONNECTOR, clamp -cable3/4inch ............ec0s0s0rrere.ae.am e 2
20 010 610 CONNECTOR, clamp - cable 1/2 inch ..............—.rreerresoccoooe. 1
21 RC9 048 283 RECEPTACLE, w/pins {consistingof) ........................ ....... 1
079 535 . TERMINAL, male ......20202 002244 ee a ae a a ae a a 0 0 4
048 027 PLUG, connector - keying ........2122400 21401444 ea a a a a aa a a ae aan 0 1
22 010311 CLAMP, 3/4 dia.................. ee eee eee a ee 1
23 R5,19,21 030 943 POTENTIOMETER, carbon 1 turn 2 watt16Kohm..................... 3
24 D6,7 026 202 DIODE, 1 amp 400 volts SP .................0,00s0 00. a0rrrareaaea 2
25 R16,18 030 854 RESISTOR, carbon 0.5 watt 18K ohm .............—..oee0mereesverev.. 2
26 R15,17 030 863 RESISTOR, carbon0.5watt2200ohm .............................. 2
27 057 066 BRACKET, mounting -terminalblock. .............. cc. iL. 2
28 038 785 STRIP, terminal3 pole ........... iii ee esc eau 2
29 PB4 079 724 SWITCH, push button SPDT 125 volts ac red button ................_.. 1
30 PB3 079 723 SWITCH, push button ........2222200 04 4 44 aa 4 4 a 0 ae a 4 ee a a a a ea ae ee» 1
31 085 268 CIRCUIT CARD, timer(FigAT Pg4)...... ci ieee. 1
32 NAMEPLATE (order by model and serialnumbers)................... .. 1
33 079 725 GUARD, switch ... ee ee 2
34 024 366 KNOB, pointer ie ee cette RER aan 3
35 PL1 027 645 LIGHT, indicator-redlens12bvoltsac ............ cc. iii... 1
36 012 617 HOLDER, fuse-miniature 1/4 x 1/4... i iii 1
37 F1 012 655 FUSE, miniature - glass 10 amp...............eeecerevccoceaaaaa ena 1
38 010 853 FASTENER, screw -slottedhd No.2 ..................... .... ....... 1
066 462 HOSE ASSEMBLY, gas 10 ft(consistingof) .......................... 1
010 603 . FITTING, hose -barbed nipple 1/4 TBG. ............................ 1
010 606 . FITTING, hose-nutb/8-18 RH ......... iii iii 1
056 298 . HOSE, 988 2 aa AL a aa AA ee a A a a ea ea aa a a ee ee» 1
079 717 CORD, interconnecting 10 ft or {consistingof) ........................ 1
092 599 CORD, gas/shunt 2-1/2 ft (used w/ Travel Master) (consisting of) ........ 1
073 140 .CORD, No. 18 10/c (order by ft) ................e 0.0000 aa 0 As Reg'd
0793 739 .CLAMP, cable ....................s000000arerieaarenarveraneen a 1
PLG7 048 598 . HOUSING PLUG E SOCKETS (consistingof). ....................... 1
079 534 .. TERMINAL, female ................e0eceeecedireea00ear0aenoan 16
081 964 CORD, control - interconnecting {consistingof) ....................... 1
PLG8 039 635 . CONNECTOR BODY, twistlock 2P2W 20 amp 250 volts. .............. 1
PLGY 048 284 . HOUSING PLUG & SOCKETS (consistingof)........................ 1
079 534 .. TERMINAL, female. ........ ci eee eee a 4
OM-1518 Page 2
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure A
080 169
092 928
Control Box (Std)
Control Box (Used With Travel Master)
PLG12
RC6
CR2
R24
R25
PLG1
R22,23
PLG13
WS1
039 687
079 531
049 455
604 571
079 716
092 598
048 380
079 534
600 737
079 706
079 714
027 810
027 811
048 029
049 970
079 844
009 156
028 770
024 366
079 796
009 156
024 366
088 912
088 913
039 828
007 826
047 001
039 273
039 685
600 341
047 544
039 828
092 131
010 603
010 606
604 550
080 594
003 538
010 605
602 934
079 573
080 596
—
‚ САР, twistlock - graunded 2P3W 15 amp 277 volts ...................
CLAMP, cable .. eaeraedeaearaCenóoaceneronoana
‚ СОВО, Мо. 18 2/с (order by ft) .......... on...
. CORD, No. 18 4/clorderby ft) ......... ei,
CORD, motor 10 ft or (consisting of) ......................00. 20...
CORD, motor 6ft (used w/ Travel Master) (consisting of) ................
. HOUSING PLUG 6 SOCKETS (consisting of). .......................
.. TERMINAL, female .................... iin,
. CORD, No. 16 3/c (order by ft)... erraeederenem As
. CLAMP, cable ......... LL AV LL LL ana
—
Ne
—
—
+
2.5
in
—
eq'd
— — 0
Optional Parts
RELAY, enclosed 24 volts dc 4 PDT... ote i iis
CONNECTOR, 14 pin... oe
CLIP, retaining-socket relay ................. 1.0.0... a a ea a aa aan
BRACKET, mounting-relay. ............. i.
SPRING, holddown-relay. ............... ein.
POTENTIOMETER, carbon 1 turn 2 watt 2.5K ohm .....................
POTENTIOMETER, carbon 1 turn 2 watt 1 meg ohm ............_eeereoé.
KNOB, pointer ................ aa aa da ad ea Aa ea La aa da aa
HOUSING, terminal 3 position locking arm ............................
POTENTIOMETER, carbon 1 turn 2 watt2.6Kohm .....................
KNOB, pointer ......... 0111 La aa a LL ALL LA AR LL
CORD, interconnecting (consistingof} ................................
. RECEPTACLE, 4 pin MS-3101A-14S-2PX ...... aa aan ..
CLAMP, cable «oe
. CORD, No. 183/clorderby ft} ......... ei,
CORD, interconnecting-control/ machine {consistingof) . ................
. PLUG, 5 pin MS-3106A-168-28X ....... aaa enana
. CLAMP, cable ............ LL LL a a aan
. CORD, No. 16 3/c (order by ft) ............ iin. 1
. PLUG, 4 socket MS-3106A-14S-28X ii,
. CLAMP, cable .......... ee a ana
HOSE, gas-special {consisting of) ................. cui...
. FITTING, hose-brass barbed nipple 1/4 TBG. . ........... cue...
. FITTING, hose-brass nut 5/8-18 RH......... e enano,
. HOSE, neoprene No, 1 x3/16 (order by ft) ................._._.........
WATER CONTROL KIT {consistingof) . ...............................
. VALVE, 115 volts ac 2 way 1/4 IPS port 1/8 orifice (Controls)... .........
FITTING, позе-БизЫтпа 1/4 №РТ х 5/8 - 18 ВН... ...................,.
. FITTING, pipe-coupling 1/4 NPT... ie ie
. FITTING, pipe-nipple L1/4 NPT X6 ............ i.
COVER, locking . . ...... AL LL LA LA AAA LL
— > = + RR MI — — nd = ==» 5
со
+
—
—
MN
— BN) eh md mE ed ed od ed a O ed od nn
—h
—
+ When ordering a component originally a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1518 Page 3
Item Part
No. No. Description Quantity
Figure A1 085 268 Timer Assembly (Fig A Pg 2 item 30)
1 024 366 KNOB, pointer ............eeee.eeenconevrerrerrerrrrereererecarerrT 5
2 080 242 PLATE, indicator .............eooceceeecoeecerecoorerrrernereróre ran 1
3 079 684 BRACKET, mounting - timer ..........._.eee_eeeeerrerrrseoreeereroera. 1
4 Figure ATA CIRCUIT CARD (Pg5}......1..202 000244 a tea a ae a a ee see ee a a ee eee ee 0 1
TB-080 368
Figure A1 - Timer Assembly
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1518 Page 4
Dia. Part
Mkgs. No. Description Quantity
Figure A1A Circuit Card (Fig A1 Pg 4 Item 4)
A50-52 009 159 IC, linear 358 ................ 002000. eee 3
C50 039 482 CAPACITOR, electrolytic 100 uf 35 volts de ...............— em... .. 1
C51,52,54 005 023 CAPACITOR, tantalum 2.2 uf 20 volts...............___eonrrecevroc. 3
C53,55 031 677 CAPACITOR, tantalumb.6uf3bvoltsdc ............... co... 2
C56 073 714 CAPACITOR, tantalum0.22uf3bvolts ........................... 1
CR50-56 027 810 RELAY, enclosed 24 volts de 4PDT ..............erreveccarererro. 7
079 843 SOCKET, relay ......2202112 211 La ea a a a aa a a a a a a aa a ae a ua a a a aan a 7
D50-57,59-71 026 202 DIODE, rectifier 1 amp 400 volts straightpolarity . ................... 21
D568 037 449 DIODE, zener 15 volts 1 watt straightpolarity. .. .................... 1
Q50-55 073 535 TRANSISTOR, 100MA 30 volts NPN .................. iin... 6
R50,64,68,76 039 332 RESISTOR, carbon fim 0.25 watt 15Kohm ........................ 4
R51,81-84 082 708 POTENTIOMETER, WW 1 watt 1 meg Ohm ........................ 5
R52 030 018 RESISTOR, carbon Twatt8200hm........... citi. 1
R53,59,60,61,62,
65,71,72,73,77,
80 035 827 RESISTOR, carbon fim 0.25 watt 10Kohm ........................ 11
R54,63,69,70,
78,79 035 886 RESISTOR, carbon fiim0.25watt22Kohm ........................ 6
R55,56 035 823 RESISTOR, carbon film 0.25 watt 100 ohm ........................ 2
R57,58,66,67,
74,75 605 912 RESISTOR, carbon 0.25 watt4700ohm........................... 6
RCT 079 795 TERMINAL, header 13 pin........2020042 0440 a a ea a a ee a a na aa a 1
RC2 079 793 TERMINAL, headerd pin. ...... cc. iii. 1
RC3 079 794 TERMINAL, header 3 pin.........._w._.eeeeeencrceooneooraeerra a 1
S50 079 722 SWITCH, toggle SPDT 4amp2-4voltsde ......................... 1
079 844 SPRING, hold down relay ...........ce_erracocodeeovrecerarane omo. 7
COMPONENTS TO BE
REPLACED BY QUALIFIED
PERSONNEL ONLY
To |
©
°
o o
CR50 o CR51 CRA? 6 CR53 © CR54 CR55 CRS6
o 1 vs o o
o os1 o 052 € 054 055
pas
0000 aso |le | 50 S& Q 8 О
Nod lo | R77
DWN LES
0088 o
+ [a]
Ocs & CE] SRE BEL EE Hon
à =
2 ~ RE |g : Je “E 7 5
a o R67 oO | C55 |
Des D62 067 R75
TB-080 37%
Figure A1A - Circuit Card
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1518 Page 5
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure A2 Panel, W/Components (Fig A Pg 2 Item 11)
1 RC4 079 783 CONNECTOR, circuit card 14 position ..........c.c iiiiiiiinn.. 1
2 057 544 SPRING, compression 0.240 OD x 1... iii iii, 4
3 038 784 STRIP, terminal 1 pole.............__.eeeéexerecnrnecrrrraraenor rece. 1
4 R14 030 940 RESISTOR, carbon 0.5 watt 2000 ohm..............o_—e.-.eesee0eecenmeva 1
5 031 251 BRACKET, mounting - connector ..........e..e.—eeemearraran oder uen 2
6 RC5 039756 CONNECTOR, edge .............oeeeeeeeeoonameveraorenrer Denon em 1
7 057 314 CIRCUIT CARD (Fig AZA Pg 7) .............7000s00rara rre a. 1
8 010 301 BUSHING, 9/64IDx1/40DxXx5/16....... cc iii at. 3
9 R1 030651 RESISTOR, WWfixed25watt10ohm............ coin, 1
10 SR1 035914 RECTIFIER, integrated30 amp400 volts ........ ......... cc iit. 1
11 C1 031692 CAPACITOR, electrolytic 750 uf 200 volts de .................-........ 1
12 006 426 BRACKET, mounting - capacitor ............—.——e_eee_eerererevrocereene. 1
13 CR1 034 841 RELAY, 24 voltsac DPDT.............emmrrrrec ecarireceaa rea ena» 1
14 1,21 038 782 BLOCK, terminal 20 amp 10 pOle .....0000000 Lena nee» 2
601 219 LINK, JUmMpeTr RR temas eae aan a 4
15 R13 079497 RESISTOR, WW fixed 25 watt 2000 ohm. .............eoee.rrx.eseeaa_. 1
16 080 204 PANEL, mounting - components ..............._ece.rreaeererereerea,. 1
17 T1 036135 TRANSFORMER, 115/24 voltsac........... ...__—-e.-eoxmenvrroorreean 1
18 080 191 STRIP, insulator - block terminal ccc, 1
19 RC10 079 784 CONNECTOR, circuitcard 12 position ......... iii... 1
20 PLG2 079 797 HOUSING, terminal 4 position locking ram .........eeeeee.rerenmevenrea. 1
21 PLG1 079 798 HOUSING, terminal 13 position locking ram. ................. ieee 1
11
Fig AZA
TC-080 367
Figure A2 - Panel, W/Components
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1518 Page 6
Dia. Part
Mkgs. No. Description Quantity
Figure A2A 057 314 Circuit Card (Fig A2 Pg 6 Item 7)
C2,3 044 602 CAPACITOR, poly film 0.47 uf 400 volts de ................... aa aan 2
C4,8,9 031 643 CAPACITOR, ceramic0.01 ufb00wvoltsdc ................ civ... 3
C7 031 693 CAPACITOR, mylar 0.33 uf 75 volts de .................0.002 22000 eres... 1
C10 031 633 CAPACITOR, electrolytic 80 uf 25 volts de. .....0.0000000 aa ea a ane eee 1
C12 031 721 CAPACITOR, mylar 0.22 uf 200 volts de 102.11 a a La eee aa ane 1
D1-4 026 202 DIODE, 1 amp 400 volts SP .............. 2... 0: a a a a aa ae a a eee 00 0 4
D5 037 250 DIODE, zener 24 volts 1 watt SP .....11111100 404004 aa a a a a a a ae ee ea eue» 1
Q1 037 824 THYRISTOR, 7.4 amp 200 volts .......1111121 11244 a ae a a a a aa a aa aa aan» 1
037 261 HEAT SINK 111112104444 RR RR RR KR 4 14 8e ee a a 0 a a aan 0 1
Q2 037 239 TRANSISTOR, unijunction 50MA 35 volts ............—.—_—.—__eeeeeeeeeeeoo 1
R3 030 937 RESISTOR, carbon 0.5 watt 10 ohm..............e0 00000 x0re ee. 1
R4 030 854 RESISTOR, carbon 0.5 watt 18K ohm ......... iinet 1
R6 030 945 RESISTOR, carbon 2 watt 4700 ohm ..............—_—...... a. resaca 1.
R7,10 028 276 RESISTOR, carbon0.5watt22000hm............. cco. 2
R8 030 944 POTENTIOMETER, WW Tt turn2 watt5000 ohm ........................ 1
R9 030 936 RESISTOR, carbon 0.5 watt 33K ohm ......._.......e -rersvadoeaeeeneca i
R11 030 938 RESISTOR, carbon 0.5 watt 1200 ohm. 1.111121 00 Lea aa a a a aa a ee 1
R12 030 934 RESISTOR, carbon 0.5 watt 6800 ohm............2.122020200 14 1 aa a aa a 0 1
R20 030 090 RESISTOR, carbon 0.5 watt47 ohm...........2210 0040 1e aa aa a a ea aa eee 1
T2 085 399 TRANSFORMER, pulse.........1242210 000044 a aa a a a a aa ae ee ea a a a aa a ne 1
< о ©
m +1 Vo
p-
To! :
O a Ta) |
o
= R3
9 re LF
O = <
Q ay
n e O
u O
«С N N
О xo
©
: = Ta
o RS — — |
TA-057 314
Figure A2A - Circuit Card
COMPONENTS TO BE
REPLACED BY QUALIFIED
PERSONNEL ONLY
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1518 Page 7
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure B 080 167 Control, Gas/Shunt
1 RC7 090 246 RECEPTACLE W/PINS (consistingof} ......................... Cee 1
079 535 . TERMINAL, male............0222004 00400 sa a ea a ee 4 ee ae se ea se ea eee 0
2 079 687 RELAY, current{consistingof}. .......... iii iii re 1
3 604 525 . CORD, portable No. 18 2/c (order by ft) ..........22102 2000 sa ane ae eee es 1 ft
4 057 091 SWITCH, reed SPST... iii i ie ee tte ae 1
5 030 084 SHUNT, meter 50MV 600 amp ..........2200 000000 ee ae ee ae a a ana eee 0 1
6 +079 682 WRAPPER eK KEG 1
047 497 LABEL, general precautionary ............024000 00 es eee ae ae aa eee ee ee es 1
7 010 494 BUSHING, snap 1-3/8 1D x 1-3/4 mtg. hole .............e-.ereeservesco 2
8 057 358 BUSHING, snap1iD1-3/8mtg.hole............ cco. 2
9 601 158 BLANK, snap-in7/8inch ........ cc ieee 2
10 010 604 FITTING, hose - bushing 1/4 NPT x5/8-18RH............... ont, 2
11 602 934 FITTING, pipe-coupling 1/4 NPT... Lies 1
12 079 573 FITTING, pipe - nipple L 1/4 NPT x6 ...............rrexvecmerverereeco 1
13 079 686 CASE SECTION, bottom/front/sides ..........._.—ee—eeeerererereeerecee 1
14 079 574 BRACKET, mounting - component ..........._.eeeeerecrererteneaerT 2
15 GS1 003 538 VALVE, 115 volts ac 2 way 1/4 IPS port 1/8 orifice (Controls) .............. 1
TC-080 365
Figure B - Control, Gas/Shunt
+ When ordering a component originally displaying a precautionary label, the label should aiso be ordered,
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1518 Page 8
Item Part
No. No. Description Quantity
Figure C Hub & Spindie Assembly
072 094 HUB E SPINDLE (consisting off ..................... 0 ree a arder
058 428 . HUB, spool................ ee a LL Aa LA a ane
058 628 . WASHER, steel - brake . eee ee tetera
010 191 . WASHER, fiber 5/8 1D x 1-1/20D x 1/8... ee ei
085 980 .NUT, hex5/8-11 ............... 0 erecraraereren as enenec0adancaereceoeao
057 971 WASHER, flat-keyed 1-1/2 dia ............... 2... ee,
010 233 . SPRING, COMPIeSSION «o.oo iit ttt ee ee ee ee ee eee,
072 292 . SHAFT, Spo0l- SUPPOM oie eee ee ee ee ee ee aa da da
058 427 . RING, retaining - spool . .... oii r.ececocreCerdacaeaacecieaeoacoara
092 989 SUPPORT, spindie (consisting of).................—.—.—... eee
070 634 . LABEL, warning electric shock cankill, etc ............ e rerecec a
©) L0O0N00AH6A0N-
—
—o — — ==А = — №) К) = wk
> a
5
Includes
Items 6 thru 9
a SR
o
TB-070 844
Figure C - Hub & Spindle Assembly
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1518 Page 9
Item Part
No. No.
Figure D 056 416
Description
Reel, Wire
Quantity
604 051
056 312
056 313
010 224
601 880
056 314
СО сл + WN
TR
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
NUT, wing 1/2-13 oo i iii einen
FINGER, Feel RR
STUD, 1/2-13 x 7 inches ................—.0es0s0x0carveraro.
PIN, spring 3/16 x 1 CAR
NUT, hex jam 1/2-13............e.0.200xvreocare 0 rrecreroo
REEL RER
``
Figure D - Reel, Wire
ARAS
TC-056 416-A
OM-1518 Page 10
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