Miller AUTOMATIC 1DA-PS User manual

Millerfi
FORM:
October 1989
OM-1548A
Effective With Serial Number JK661802
MODEL: AUTOMATIC 1 DA-PS
Gas/Current
Sensing Control
Hub & Spindle Assembly
Spool Support
OWNERS
IMPORTANT:
MANUAL
Read and understand the entire contents of both this manual
and the power source manual used with this unit, with special emphasis on
the safety material throughout both manuals, before Installing, operating, or
maintaining this equipment. This unit and these instructions are for use only
by persons
trained and
experienced
In the sale
operation
of
welding equip
MILLER ELECTRIC
A MitIe~
Gro~
L%d.
Mfg. Co.
Con~as~y
P.O. Box 1079
WI 54912 USA
Tel. 414-734-9821
Appleton,
ment. Do not aiiow untrained persons to instail, operate, or maintain this unit.
Contact your distributor if you do not fully understand these instructions.
PRINTED IN U.S.A
1~
LIMITED WARRANTY
EFFECTIVE: MARCH 15, 1989
supersedes all previous MILLER
This warranty
LIMITED WARRANTY
Subject to
warranties and is exclusive with
the terms and conditions
hereof, Miller Electric Mfg. Co., Appleton, Wisconsin
warrants
its Distributor/Dealer that all new and unused Equipment fur
nished by Miller is free from defect in workmanship and material
as of the time and place of delivery by Miller. No warranty is
made by Miller with respect to engines, trade accessories or
other items manufactured by others. Such engines, trade ac
cessories and other items are sold subject to the warranties of
their respective manufacturers, if any. All engines are war
ranted by their manufacturer for one year from date of original
purchase, except Tecumseh and Onan engines which have a
to
two year
warranty.
Except as specified below, Millers 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, MILLER
MATC parts that come in contact with the welding wire includ
and nozzle insulators where failure does not result
from defect in workmanship or material,
ing nozzles
Miller shall be required to honor warranty claims on warranted
Equipment in the event of failure resulting from a defect within
the following periods from the date of delivery of Equipment to
the original user:
2.
3.
Arc welders, power sources, robots, and
components
Loadbanks
Original main power rectifiers
4.
All
1.
(labor
5.
6.
7.
1 year
1 year
lyear
the date of such failure.
I
or
warranties
expressed
or
implied.
of Millers breach of warranty or any other duty with
quality of any goods, the exclusive remedies
therefore shall be, at Millers option (1) repairor (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 Customers risk and expense.
MILLERs option of repair or replacementwill be FOB., Factory
at Appleton, Wisconsin, or F.O. B. at a MILLER authorized serv
ice facility, therefore, no compensation for transportation costs
of any kind will be allowed. Upon receipt of notice of apparent
defect or failure, Miller shall instruct the claimant on the war
ranty claim procedures to be followed.
In the
respect
case
to the
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY GUARANTY OR REPRE
SENTATION AS TO PERFORMANCE, AND ANY REMEDY
FOR BREACH OF CONTRACT WHICH, BUT FOR THIS PRO
VISION, MIGHT ARISE BY IMPLICATION, OPERATION OF
LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN
CLUDING ANY IMPUED WARRANTY OF MERCHAN
TABILITY OR OF FITNESS FOR PARTICULAR PURPOSE,
WITH RESPECT TO ANY AND ALL EQUIPMENT FUR
NISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
only)
90 days
guns, feeder/guns and torches
All other Millermatic Feeders
1 year
Replacement or repair parts, exclusive of labor 60 days
Batteries
6 months
provided that Miller is notified in writing within thirty (30) days of
,
other guarantees
3 years
welding
As a matter of
submitted by the
no
general policy only, Miller may honor claims
original user within the foregoing periods.
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN
WRITING, MILLER PRODUCTS ARE INTENDED FOR ULTI
MATE PURCHASE BY COMMERCIAL/INDUSTRIAL USERS
AND FOR OPERATION BY PERSONS TRAINED AND EXPE
RIENCED IN THE USE AND MAINTENANCE OF WELDING
EQUIPMENT AND NOT FOR CONSUMERS OR CON
SUMER USE. MILLERS WARRANTIES DO NOT EXTEND
TO, AND NO RESELLER IS AUTHORIZED TO EXTEND
MILLERS WARRANTIES TO, ANY CONSUMER.
1.
OM.1548A- IW~O
RECEIVING-HANDLING
unpacking equipment, check carton for any damage that may have occurred during shipment. File any
claims for loss or damage with the delivering carrier.
Assistance for filing or settling claims may be obtained
from the distributor and/or the equipment manufacturBefore
Use the
following spaces to record the Model Designa
Style Number of your unit. The infor
on the data card or the nameplate.
tion and Serial or
mation is located
Model
______________________________
ers
Transportation Department.
Senal
requesting information about this equipment, al
ways provide the Model Description and Serial or Style
or
Style
No.
___________________
When
Date of Purchase
____________________
Number.
TABLE OF CONTENTS
Section No.
SECTION 1
-
Page
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1
1-1.
Introduction
1-2.
General Precautions
1-3.
Arc
1-4.
Standards Booklet index
1
4
Welding
2-1.
General Information And
2-2.
Safety
3-1.
5
PRECAUTIONS AND SIGNAL WORDS
SECTION 2SAFETY
SECTION 3
No.
Alert
Symbol
And
Safety
Signal Words
6
6
SPECIFICATIONS
Description
7
SECTION 4-INSTALLATION
4-1.
Site Selection
4-2.
Equipment Installation
4-3.
Internal Connections
10
12
9
9
4-4.
Wire Drive Motor
4-5.
Weld Control Interconnections
13
4-6.
Gas/Current
14
4-7.
Welding Wire
Speed Calibration Selection
Sensing
Control Interconnections
Installation
15
SECTION 5-OPERATOR CONTROLS
5-1.
Power Switch And Pilot
5-2.
Retract
-
Light
Advance Switch And
15
Jog
Switch
15
5-3.
Purge
5-4.
Start Switch
16
5-5.
Stop
Switch
16
5-6.
Press To Set Buttons
16
5-7.
Digital
Meters
16
Switch
16
5-8.
Run In Wire
17
5-9.
Weld Wire
17
5-10.
Weld
17
Speed Control
Speed Control
Background Voltage Control
Page
Section No.
SECTION 5- OPERATOR CONTROLS
(Continued)
Weld Peak Amperage Control
Crater & Jog Wire Speed Control
Crater Background Voltage Control
17
17
5-16.
Crater Peak Amperage Control
PrefiowTimeControl
Spot Continuous Switch
5-17.
SpotlimeControl
17
5-18.
Crater Time Control
17
5-19.
Burnback Control
Postfiow Time Control
17
5-11.
5-12.
5-13.
5-14.
5-15.
5-20.
5-21.
SECTION 6
6-1.
17
17
17
17
-
Optional
17
18
Run In Controls
SEQUENCE OF OPERATION
Gas Metal Arc Welding (GMAW) And
Flux Cored Arc Welding (FCAW) Continuous
19
Gas Metal Arc Welding (GMAW) And
Flux Cored Arc Welding (FCAW) Spot
Shutting Down
19
-
6-2.
-
6-3.
SECTION 7
7-1.
7-2.
19
MAINTENANCE & TROUBLESHOOTING
20
Routine Maintenance
Overload Protection
20
Hub Reinstallation
Circuit Board Handling Precautions
20
7-4.
7-5.
Troubleshooting
21
7-3.
SECTION 8
ELECTRICAL DIAGRAMS
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
SECTION 9
21
23
8-1. Circuit
8-2.
8-3.
8-4.
8-5.
8-6.
8-7.
8-8.
Diagram
Winng Diagram
Circuit Diagram
Circuit Diagram
Circuit Diagram
Circuit Diagram
Circuit Diagram
Circuit Diagram
24
For Models With Run In
Option
26
For Motor Control Board PC2
27
For Timer Board PC3
28
For Tach Board PC4
29
For
29
Board PC5
Relay
Speed Calibration
For Low
Board PC8
30
PARTS LIST
Figure 9-1.
Figure 9-2.
Figure 9-3.
Figure 9-4.
Figure 9-5.
Figure 9-6.
Figure 9-7.
Figure 9-8.
Figure 9-9.
Figure 9-10.
Figure 9-11.
Control Box
32
Meter, Volt-Digital
Panel, W/Components
Circuit Card, Motor Speed PC2
35
37
Circuit Card,
39
Relay
36
40
Circuit Card, Timer PC3
Circuit Card
41
Control, Gas/Shunt
42
Hub &
Spindle Assembly
43
44
Reel, Wire
Circuit Card Low
Speed
Motor Calibration PC8
44
LIST OF CHARTS AND TABLES
Table 3-1.
Specifications
Table 3-2. Weld Parameters
Table 7-1. Troubleshooting
7
7
21
No.
SECTION 1
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
INTRODUCTION
I-i.
We learn
by experience. Learning safety through per
experience, like a child touching a hot stove is
harmful, wasteful, and unwise..Let the experience of oth
sonal
ers
teach you.
Safe practices developed from experience in the use of
welding and cutting are described in this manual. Re
search, 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 rea
son for the safe practices may not always be given.
Some are based on common sense, others may require
technical volumes to
explain. It is wiser
to follow the
rules.
Read and understand these safe practices before at
tempting to install, operate, or service the equipment.
Comply with these procedures as applicable to the par
ticular equipment used and their instruction manuals, for
personal safety and for the safety of others.
Failure to observe these safe practices may cause seri
ous 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 cut
ting;
and 2-Arc
Welding (and Cutting) (only).
Reference standards: Published Standards on safety
also available for additional and more complete pro
cedures than those given in this manual. They are listed
in the Standards Index in this manual. ANSI Z49.1 is the
are
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.
or cutting, (and chipping) to protect the eyes
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
welding
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
Avoid
oily
or
greasy clothing. A
spark may ignite
Hot metal such as electrode stubs and
should never be handled without gloves.
them.
workpieces
Medicai first aid and eye treatment. First aid facilities and
qualified first aid person should be available for each
a
shift unless medical facilities are close by for immediate
treatment of flash burns of the eyes and skin burns.
Ear
plugs should be worn when working
overhead
on
confined space. A hard hat should be
others work overhead.
in
a
worn
Flammable hair preparations should not be used
intending to weld or cut.
or
when
by per
sons
B.
Toxic Fume Prevention
Severe discomfort, illness or death can result from
fumes, vapors, heat, or oxygen enrichment or depletion
(or cutting) may produce. Prevent themwith
adequate ventilation as described in ANSI Standard
that welding
Z49.1 listed in Standards Index. NEVER ventilate with
oxygen.
Lead -, cadmium -, zinc-, mercury-, and beryllium-bear
and similar materials, when welded (orcut) may pro
duce harmful concentrations of toxic fumes. Adequate
local exhaust ventilation must be used,or each person in
the area as well as the operator must wear an air-sup
plied respirator. For beryliium, both must be used.
ing
Metals coated with orcontaining materials that emit toxic
fumes should not be heated unless coating is removed
from the work surface, the area is well ventilated and, if
necessary, while wearing an air-supplied respirator.
Work in a confined space only while it is being ventilated
and, if necessary, while wearing an air-supplied respira
tor.
Gas leaks in
Leaked gas in
a
confined space should be avoided.
large quantities can change oxygen con
centration dangerously. Do not bring gas cylinders into a
confined space.
manual, be sure to consult flux and electrode manu
facturers MaterIal Safety Data Sheets (MSDS5) for
specific technical data and precautIonary measures
concerning their materIal.
Leaving confined space, shut OFF gas Supply at source
prevent possible accumulation of gases in the space if
downstream valves have been accidentally opened or
A.
re-entering
Burn Prevention
Wear protective clothing-gauntlet gloves designed for
use in welding, hat, and high safety-toe shoes. Button
shirt collar and
to avoid
pocket flaps,
and wear cutf less trousers
entry of sparks and slag.
Wear helmet with safety goggles and glasses with side
shields underneath, appropriate filter lenses or plates
(protected by clear cover glass). This is a MUST for
to
left open. Check to be
it.
sure
that the space is safe before
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 prod
ucts. The ultraviolet
(radiant) energy of the
arc can
also
decompose trichioroethyiene and perchloroethyiene
vapors to form phosgene. DO NOT WELD or cut where
solvent vapors can be drawn into the welding or cutting
atmosphere or where the radiant energy can penetrate
OM-1548
Page
1
to atmospheres containing even minute
tnchloroethylene or perchloroethylene.
C.
amounts of
Explosion Prevention
Fire and
Causes of fire and explosion are: combustibles reached
by the arc, flame, flying sparks, hot slag or heated mate
nal; misuse of compressed gases and cylinders; and
short circuits.
flying sparks or falling slag can pass
through cracks, along pipes, throughwindows ordoors,
and through wall or floor openings, out of sight of the
goggled operator. Sparks and slag can fly 35 feet.
BE AWARE THAT
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, venti
lators. If the work cannot be moved, move combustibles
at least 35 feet away out of reach of sparks and heat; or
protect against ignition with suitable and snug-fitting,
fire-resistant
Walls
covers or
touching combustibles on opposite sides should
(or cut). Walls, ceilings, and floor near
should be protected by heat-resistant covers or
shields.
standing by with suitable fire extin
guishing equipment during and for some time afterweld
ing or cutting it:
Fire watcher must be
appreciable combustibles (including building
construction) are within 35 feet
a.
b.
appreciable
combustibles
feet but
be
can
are
d.
further than 35
ignited by sparks
openings (concealed orvisible)
c.
level may substitute for
A container with unknown contents should be cleaned
(see preceding paragraph). Do NOT depend on sense of
smell
sight
or
castings or containers must be
welding or cutting. They can explode.
Explosive atmospheres.
Never weld
may contain flammable dust, gas,
as
or
or
vented before
cut where the air
liquid vapors (such
gasoline).
D.
Compressed Gas Equipment
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-i, SAFE
HANDLING OF COMPRESSED GASES IN CYLIN
DERS, listed ii in Standards Index.
1.
Pressure
Regulators
Regulator relief valve is designed to protect only the
regulator from overpressure; it is not intended to protect
any downstream equipment. Provide such protection
with one
or more
relief devices.
in floors orwalls
Remove faulty regulatorfrom service immediately for re
pair (first close cylinder valve). The following symptoms
indicate a faulty regulator:
Leaks-if gas leaks externally.
Excessive Creep-if delivery pressure continues to rise
with downstream valve closed.
Faulty Gauge-if gauge pointer does not move off stop pin
when pressurized, nor returns to stop pin after pressure
release.
Do NOT attempt to
Repair.
sparks
2.
adjacent to.walis, ceilings, roofs,
partitions can be ignited by radiant or
combustibles
repair. Send faulty regulators
for repair to manufacturers designated repair center,
where special techniques and tools are used by trained
personnel.
metal
to determine if it is safe to weld or cut.
Hollow
within 35 feet may expose combustibles to
or
Waterfilling just below
inerting.
Never connect a regulator to a cylinder containing gas
other than that for which the regulator was designed.
shields.
not be welded on
work
ment as recommended in A6.O.
working
Cylinders
Cylinders must be handled carefully to prevent leaks
damage to their walls, valves, or safety devices:
and
conducted heat.
Avoid electrical circuit contact with
Hot work
permit should be obtained before operation to
supervisors approval that adequate precautions
ensure
have been taken.
dent.
After work is done, check that area is free of
glowing embers, and flames.
sparks,
An
empty container that held combustibles, or that can
produce flammable or toxic vapors when heated, must
never
be welded
been cleaned
as
on or
cut, unless container has first
described in AWS Standard A6.O, listed
7 in Standards Index.
or
OM-1548
carbon dioxide, and
Page
2
ICC
(See 1-3C.)
or
DOT
assurance
marking must be on each cylinder. It is an
safety when the cylinder is properly han
of
dled.
Identifying gas content. Use only cylinders with name of
gas marked on them; do not rely on color to identify gas
Notify supplier if unmarked. NEVER DEFACE
alter name, number, or other markings on a cylinder. It
is illegal and hazardous.
content.
or
This includes: athorough steamorcausticcleaning(ora
solvent or water washing, depending on the combusti
bles solubility) followed by purging and inerting with ni
trogen
cylinders including
third rails, electrical wires, or welding circuits. They can
produce short circuit arcs that may lead to a serious acci
using protective equip-
Empties: Keep valves closed, replace caps securely;
keep them separate from FULLS and return
promptly.
mark MT;
Prohibited use. Never use a cylinder or its contents for
other than its intended use, NEVER as a support or
outlet away from people and
with a clean lintless cloth.
sources
of
ignition. Wipe
roller.
Locate
or secure
cylinders
so
they
cannot be knocked
over.
Passageways and work areas. Keep cylinders
where they may be struck.
clear of
Match regulator to cylinder. Before connecting, check
that the regulator label and cylinder marking area, and
thatthe regulator inlet and cylinderoutlet match. NEVER
CONNECT a regulator designed for a particular gas or
gases to
a
cylinder containing any
other gas.
areas
Transporting cylinders. With a crane, use a secure sup
port such as a platform orcradle. 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 al
low contents to exceed 130F.
where such exposure exists.
Cool with water spray
Protect
cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when moving cylinders.
Stuck valve. Do NOT use a hammer or wrench to open a
cylinder valve that can not be opened by hand. Notify
your supplier.
Mixing
gases. Never try to mix any gases in
Never refill any
a
cylinder.
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 ordi
nary wire or other substitute) as a binding to connect
hoses to fittings.
No copper
tings
to
tubing splices. Use only
splice hose.
standard brass fit
Avoid long runs to prevent kinks and abuse. Suspend
hose off ground to keep it from being run over, stepped
on, or otherwise
Coil
retighten using properly fitting
excess
damaged.
hose to prevent kinks and
Adapters. Use a CGA adapter (available from your sup
plier) between cylinder and regulator, if one is required.
usetwowrenchestotighten adaptermarked RIGHTand
LEFT HAND threads.
Regulatoroutiet (or hose) connections may be identified
by right hand threads for oxygen and left hand threads
(with grooved hex on nut or shank) for fuel gas.
5.
Pressurizing Steps:
Drain regulator of residual gas through suitable vent be
fore opening cylinder (or manifold valve) by turning ad
justing screw in (clockwise). Draining prevents exces
sive compression heat at high pressure seat by allowing
engaged slightly
pressurization. Leave adjusting
on single-stage regulators.
screw
Open cylinder valve slowly so that regulator pressure in
creases slowly. When gauge is pressurized (gauge
reaches regulator maximum) leave cylinder valve in fol
lowing 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 (capfuli of Ivory Liq
uid* or equivalent per gallon of water). Bubbles indicate
leak. Clean off soapy water after test: dried soap is com
bustible.
tangles.
E.
Protect hose from damage by
sparks, slag, and open flame.
Examine hose
sharp edges,
and
regularly for leaks, wear, and loose con
pressured hose in water; bubbles in
area
out and
splic
Clean cylinder valve outlet of impunties that may clog
orifices and damage seats before connecting regulator.
Except for hydrogen,
crack valve
momentarily, pointing
Leaving Equipment
Close gas
G.
Proper Connections
Responsibilities
Remove leaky or defective equipment from service im
mediately for repair. See User Responsibility statement
in equipment manual.
F.
Repair leaky or worn hose by cutting
ing (1-2D3). Do NOT tape.
User
by
nections. Immerse
dicate leaks.
4.
wrench.
Stand to side of regulator while opening cylinder valve.
Hose
Prohibited
con
nections, clean and smooth seats where necessary.
Tighten. If connection leaks, disassemble, clean, and
seat to open on
cylinder.
Cylinderfittings should never be modified or exchanged.
3.
Tighten connections. When assembling threaded
supply
Unattended
at source and drain gas.
Rope Staging-Support
Rope staging-support should not be
cutting operation; rope may burn.
used for
welding
or
*Trademark of Proctor & Gamble.
OM-1548
Page
3
Viewing the
ARC WELDING
1-3.
Comply with precautions in 1-1, 1-2, and this section.
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, ulUavioiet and in
Arc
frared energy radiates, weldments are hot, and com
pressed gases may be used. The wise operator avoids
unnecessary risks and protects himself and others from
accidents. Precautions are described here and in stan
dards referenced in index.
A.
Others working in
flash
B.
precautions
Comply with precautions
FIre and
Skin burns resemble acute sunburn, those from gasshielded arcs are more severe and painful. DONT GET
BURNED; COMPLY WITH PRECAUTIONS.
cause a
Clothing
Wear long-sleeve clothing (particularly for gas-shielded
arc) in addition to gloves, hat, and shoes (1 -2A). As nec
essary, use additional protective clothing such as
leather jacket or sleeves, flame-proof apron, and f ire-re
sistant
Avoid outer garments of untreated cot
leggings.
ton.
Bare skin protection. Wear dark, substantial clothing.
Button collar to protect chest and neck and button pock
ets to prevent entry of sparks.
2.
Eye and Head Protection
flaps
or
in 1 -2B.
Explosion Prevention
Comply with precautions
Equipments
equipment.
Protective
wearing
Generator engine exhaust must be vented to the outside
air. Carbon monoxide can kill.
in 1-2.
is intense and
arc
are
goggles.
visibly bright. Its radiation
can damage eyes, penetrate lightweight clothing, reflect
from light-colored surfaces, and burn the skin and eyes.
The welding
See that all persons
Toxic Fume Prevention
C.
with
area.
Before starting to weld, make sure that screen
bay doors are closed.
Burn ProtectIon
Comply
1.
weld. Provide face shields for all persons
at the weld.
looking directly
who will be
in 1 -2C.
rated capacity. Do not overload arc welding
it may overheat cables and cause a fire.
Loose cable connections may overheat
fire.
or
flash and
an arc on a cylinder or other pressure ves
sel. It creates a brittle area that can cause a violent nip
ture or lead to such a rupture under rough handling.
Never strike
D.
Compressed
Comply
E.
with
Gas
Equipment
precautions
in 1-20.
Shock Prevention
Exposed hot conductors or other bare metal in the weld
ing circuit, or in ungrounded, electrically-HOT equip
ment 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.
Protect eyes from exposure to
electric arc without protection.
arc.
NEVER look at
an
To protect
against shock:
dry insulating gloves and body protection. 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 dampness or sweat
Wear
containing a filter plate shade
no. 12 or denser must be used when welding. Place over
face before striking arc.
helmet
Welding
Protect filter
shield
or
plate
with
a
clear cover
be avoided. Sweat, sea water, or moisture be
and an electrically HOT part or grounded
metal reduces the electrical resistance, and could en
can not
plate.
tween
Cracked
or
broken helmet
worn; radiation can pass
or
shield should NOT be
to cause burns.
through
must be
replaced
plates
Replace clear cover plate when broken,
spattered.
Cracked, broken,
or
loose filter
IMMEDIATELY.
pitted,
Flash
or
goggles with side shields MUST be worn under
give some protection to the eyes should the
the helmet to
helmet not be lowered
struck.
eyes
Looking
over
the face before
(particularly
a
retinal burn that may leave a
area in the field of vision.
cause a
3.
Protection of
Enclosed
an arc
is
momentarily with unprotected
high intensity gas-shielded arc) can
at an arc
welding
Nearby
permanent dark
Personnel
For
production welding,
a
sepa
rate room or enclosed bay is best. in open areas, sur
round the operation with low-reflective, non-combusti
ble
screens or
area.
panels.
ticularly
at floor level.
OM-1548
Page
4
Allow for free air circulation, par
body
able dangerous and possibly lethal
through the body.
currents to flow
voltage will exist between the electrode and any con
ducting object in the work circuit. Examples of conduct
ing objects include, but are not limited to, buildings, elec
trical tools, work benches, welding power source cases,
workpieces, etc. Never touch the electrode and any
metal object unless the welding power source is off.
A
1.
Grounding
the
Equipment
Arc welding equipment must be grounded according to
the National Electrical Code, and the work must be
grounded according to ANSI Z49.1 Safety In Welding
And
Cutting.
installing, connect the frames of each unit such as
welding power source, control, worktable, and water cir
culator to the building ground. Conductors must be ade
quate to carry ground currents safely. Equipment made
When
electrically HOT by stray current may shock, possibly I atally. Do NOT GROUND to electrical conduit, orto a pipe
carrying ANY gas or flammable liquid such as oil or fuel.
Welding
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.
output on-off control devices. With such equip
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 re
ceptacle, the ground lead must be connected to the
ground prong only. If the line cord comes with a threeprong plug, connect to a grounded mating receptacle.
Never remove the ground prong from a plug, or use a
plug with a broken off ground prong.
2.
power sources used with shielded
metal arc welding (SMAW) and similar proc
esses may not be equipped with welding power
ment 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
Safety
devices such as interlocks and circuit breakers
should not be disconnected or shunted out.
Before installation, inspection, or service, of equipment,
shut OFF all power and remove line fuses (or lock or red-
tag switches) to prevent accidental turning ON of power.
Disconnect all cables from welding power source, and
all 115 volts tine-cord plugs.
pull
Do not open power circuit or change polarity while weld
it must be disconnected, guard
ing. If, in an emergency,
against shock burns, or
Fully insulated
3.
electrode holders should be used. Do
holders with protruding screws.
should be used to
Cables
Frequently inspect cables for wear,
cracks and
damage.
IMMEDIATELY REPLACE those with excessively
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
from hot metal and
F.
Protection For Wearers of Electronic Life
port Devices (Pacemakers)
the
Sup
Magnetic fields from high currents can affect pacemaker
operation. Persons wearing electronic life support
equipment (pacemaker) should consult with their doctor
before going near arc welding, gouging, or spot welding
operations.
1-4.
metal
power sources for
use
NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING obtainable
from the Superintendent of Documents, U.S. Gov
b.
ernment
Printing Office, Washington,
D.C. 20402.
3.
OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the Superintendent of
Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
4.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainable from the American
with the gas
welding (GMAW), gas tungsten arc
welding (GTAW) and similar processes nor
mally are equipped with devices that permit on
off control of the welding poweroutput. When so
equipped the electrode wire becomes electri
cally HOT when the power source switch is ON
and the welding gun switch is closed. Never
touch the electrode wire or any conducting ob
ject in contact with the electrode circuit unless
the welding power source is off.
or
2.
Equipment with output on/off control (contactor)
Welding
standards
appiicable:
ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126.
sparks.
Electrode
following
as
1.
protected
Terminals And Other Exposed Parts
a.
STANDARDS BOOKLET INDEX
For more information, refer to the
their latest revisions and comply
Terminals and other exposed parts of electrical units
should have insulating covers secured before operation.
6.
near
source.
worn
or
5.
power
Connectors
Fully insulated lock-type connectors
join welding cable lengths.
4.
arcing.
Leaving equipment unattended. Always shut OFF and
disconnect all power to equipment.
welding
use
flash from switch
Power disconnect switch must be available
Electrode Holders
NOT
Devices
arc
Equipment without output
contacto r)
on/off control (no
National Standards Institute, 1430 Broadway, New
York, NY 10018.
5.
ANSI Standard Z41.1, STANDARD FOR MENS
SAFETY-TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430 Broad
way, New York, NY 10018.
6.
ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES
OM-1 548
Page
5
7.
obtainable from the American National Standards
Institute, 1430 Broadway, New York, NY 10018.
from the Compressed Gas Association, 1235 Jeffer
son Davis Highway, Suite 501, Arlington, VA 22202.
AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUS
TIBLES obtainable from the American Welding So
ciety, 550 N.W. LeJeune Ad, Miami, FL 33126.
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the Ca
NFPA Standard 51, OXYGEN-FUEL GAS SYS
TEMS FOR WELDING, CUTTING, AND ALLIED
PROCESSES obtainable from the National Fire
Protection Association, Batterymarch Park, Quincy,
MA 02269.
8.
Standard 70, NATIONAL ELECTRICAL
CODE obtainable from the National Fire Protection
NFPA
9.
Association,
Batterymarch
Park,
Quincy,
MA
02269.
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association,
Batterymarch Park, Qui ncy,
MA 02269.
11. CGA
Pamphlet P-i, SAFE HANDLING OF COM
PRESSED
GASES
IN
obtainable
CYLINDERS
nadian Standards Association, Standards Sales,
178 Rexdale Boulevard, Rexdale, Ontario, Canada
M9W 1R3.
13. NWSA booklet, WELDING SAFETY BIBLIOGRA
PHY obtainable from the National Welding Supply
Association, 1900 Arch Street, Philadelphia, PA
19103.
Welding Society Standard AWSF4.1,
RECOMMENDED SAFE PRACTICES FOR THE
PREPARATION FOR WELDING AND CUTTING
OF CONTAINERS AND PIPINGTHAT HAVE HELD
HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd,
Miami, FL 33126.
14. American
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA
TORY PROTECTION, obtainable from the Ameri
can National Standards Institute, 1430 Broadway,
New York, NY 10018.
SECTION 2- SAFETY PRECAUTIONS AND SIGNAL WORDS
2-1.
GENERAL INFORMATION AND SAFETY
A. General
Information presented in this manual and
on
various la
bels, tags, and plates on the unit pertains to equipment
design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed for the safe and effective
B
.
use
of this
The installation, operation, maintenance, and trouble
shooting of arc welding equipment requires practices
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be in
stalled, operated, and maintained only by qualified per
Sons fl accordance with this manual and all applicable
codes such as, but not limited to, those listed at the end
of Section 1
Safety Rules For Operation Of Arc Weld
ing Power Source.
Page
6
ALERT
SYMBOL
AND
SIGNAL
The following safety alert symbol and signal words are
used throughout this manual to call attention to and iden
tify different levels of hazard and special instructions.
4~
This safety alert symbol is used with the signal
words WARNING and CAUTION to call atten
tion to the safety statements.
4A
WARNING statements identify procedures or
practices which must be followed to avoid seri
ous personal injury or loss of life.
a
CAUTION statements identify procedures or
practices which must be followed to avoid minor
equipment.
Safety
OM-1548
2-2. SAFETY
WORDS
personal injury
or
damage
to this
equipment.
IMPORTANT statements identify special instructions
necessary for the most efficient operation of this equip
ment.
SECTION 3- SPECIFICATIONS
SpecIfications
Table 3-1.
Dimensions
Component
W e IdC ontI~O
Control
Spool Support
Assembly+
Add 1 in.
lncludes
Width
Height
Net
Ship
17-1/2iri.
14 in.
Bin.,
32~1I2 lbs.
(355 mm)
(203 mm)
(14.7 kg)
4-1/2 in.
5-1/2 in.
10-1/2 in.
4-1/2 lbs.
Total 80 lbs.*
(108 mm)
(140 mm)
(267 mm)
(2.0 kg)
(36 kg)
13-31/2 in.
8-3/4 in.
8-1/2 in.
6 lbs.
(343 mm)
(222 mm)
(216 mm)
(2.7 kg)
Spool Support
(25 mm) for control knobs.
weight
Depth
(445 mm)
Gas/Current
Sensing
Weight
of wire drive
without
optional wire reel.
assembly.
A1D-4
50-780 ipm
(1 .8-19.8 mpm)
.023-3/32 in. wire
A1D-2
(0.6-2.4
Wire Feed
mm
AID-4L
A1D-2L
Speed Range
wire)
15-200
1pm
(0.4-5.1 mpm)
5/64-5/32 in. wire
(2.0-4.0
Weld
Voltage And
Amperage Capacity
3-1.
mm
wire)
.
Limited
by welding power
DESCRIPTION
source.
Table 3-2. Weld Parameters
Controls
This weld control is
designed to automatically cycle
while maintaining constant wire teed
welding events
speed. This unit is to be used with the Puistar DC con
stant voltage (CV) welding power source having remote
contactor and voltage control capabilities for Gas Metal
Arc Welding (GMAW), Gas Metal Arc Welding-Pulsed
(GMAW-P), or Submerged Arc Welding (SAW).
Weld
Wire
Cycle
Speed
Background
Voltage
Peak
Amperage
Pref low
.~..ime
X
Run-In
X
,
Weld
X
X
,
X
Crater
The standard weld contiDl has
provisions
Burnback
parameters according to Table 3-2. Spot weld controls
are
x
(Jog)
to set weld
also standard.
X
Postf low
X
Normally-open and normally-closed relay contacts that
work in conjunction with the weld cycle are available to
interlace with other equipment (such as fixtures).
Standard
For information
Manual
=
on
supplied
Optional
the wire drive
assembly, see Owners
assembly.
with the wire drive
A
Optional
controls include run in
water valve.
voltage
and time, and
gas/current sensing control, wire spool hub, and
spindle support are provided with the weld control. The
wire reel is optional.
OM-1548
Page
7
14 In.
7-3/4
ln.~~ ,~-~~~5-1/2
in.
(140 mm)
(197 mm)
(89 mm)
2
TA-060 485-A
In.
TOP VIEW
2.7/8 In.
__J
TE
(73 mm)
I
TA.0~ 440
4-1/2 in.
mm)
Diameter 2 Hol
8in.
(203 mm)
Add 1 In.
for front
(25 mm)
panel controls.
(267 mm)
TC-098 619-A
AUTOMATIC IDA-PS Weld Control
TA-080 429
Gas/Current
Sensing Control
Overall Dimensions And
Mounting Hole Layout
Inches
Millimeters
A
21-7/8
556
B
13-3/4
349
C
3
76
D
2-1/2
63.5
E
3.1/2
88.9
F
4-1/2
114
G
10-11/16
275
TB-080 486-C
Figure
OM-1 548
Page
8
3-1. Dimensional Views
SECTION 4INSTALLATION
4-1. SITE SELECTION
Select
installation site which
an
And
(Figure 3-1
provides
Figure 4-1)
the
Correct input power supply (see unit nameplate)
2.
Shielding
3.
Water
4.
Adequate
5.
No flammables
6.
A clean and
7.
Proper temperature that avoids
supply (if applicable)
supply (if applicable)
ventilation and fresh air
dry
10 ft. (3 m) Weld Control
Gas/Current
Control Interconnecting Cord
6.
Two 25 ft. (8 m) Weld Control
Source Interconnecting Cords
7.
5ft.(1.5m)
8.
lOft.(3m)GasHose
B.
Equipment
following:
1.
gas
5.
supply
When
deciding
lowing:
area
extremes of heat or
Proper airflow
9.
Adequate space to open and remove cover and
wrapper for installation, maintenance, and repair
functions.
Mounting
cure
holes
the
capability
to install and se
4-2.
A.
following equipment is supplied as standard and
quires installation or assembly:
1.
Weld Control
2.
Gas/Current
3.
Hub and
4.
Spindle Support
equipment location, consider the fol
3.
The
interconnecting cords must be routed so that
they are not caught, pinched, or strained during
welding operations.
4.
One weld output cable must be routed to the Gas/
Current Sensing control.
5.
The
on
(Figure 4-1)
The lead
EQUIPMENT INSTALLATION
Supplied Equipment
Location
2.
the system components in a permanent location.
3-1 gives overall dimensions and mounting hole
Figure
layout.
Motor Cord
The equipment must be mounted to a structure ca
pable of supporting the weight of the equipment.
around unit
provide
Power
Welding
1.
cold
8.
Sensing
lengths of the cords supplied with the
equipment will limit the area in which the equipment
can be located. Some cords can be extended by us
ing optional extension cords (check with welding
equipment distributor).
Welding wire
must be routed so that it does not con
tact the weld control or any other
ment.
re
C.
Equipment
grounded equip
InstallatIon
Obtain
appropriate mounting brackets or adapter plates
necessary and mounting hardware. Prepare struc
ture for equipment installation. Secure weld control,
Gas/Current Sensing control, and all other equipment
Sensing Control
as
Spindle Assembly
onto structures in the
welding
area.
W Id
Drive
~
/HJ
Assembly
:~-~T:~
Welding
Power Source
Typical Side
Application
Beam
Welding
Power
Source
I
I
I
TC-13I 138
FIgure
4-1.
EquIpment Location
DIagram
OM-1 548
Page
9
Spindle Installation
port (Figure 4-2)
D.
Hub And
To
WARNING: ELECTRIC SHOCK
Spindle Sup-
Replace hex nut and tighten
turning hub.
2.
until
Shut down weld control and welding power
input power employing
locko ut/tagging procedures before inspecting or
a
slight drag
source, and disconnect
installing.
Lockout/tagging procedures consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
is felt
while
3.
Install
welding
wire
according
to Section 4-7.
ELECTROSTATIC DISCHARGE
Retainina
Retalner*
Ring
kill.
Do not (ouch live electrical parts.
Remove hex nut from spindle support shaft, align
keyway, and insert shaft through one of the sets of
holes in the spindle support. Hole selection depends
on wire spool size. Be sure the brake washers are
properly seated in the hub.
1.
can
(ESD)
can
damage circuIt boards.
Put on properly grounded wrist
BEFORE working near circuit boards.
Reei
Perform work
only
strap
at a static safe work area.
To access the terminal strips, open control panel door.
Loosen screws from cabinet door on the weld control,
and open door. Route incoming cables through strain re
lief provided on right side of weld control. Close and se
cure control door, and tighten strain relief when installa
Spindle Support
tion is
A.
complete.
Remote
Start/Stop
Switch
Connections
(Figure 4-3)
Two momentary-contact push-button switches are re
quired for remote start/stop control. A normally-open
switch is required for start control while a normallyclosed switch is required for stop control.
Washer
spring
Fl
1.
Was her
*Optlonai)
Install remote switches at desired location, obtain
proper length cable, and make connections to re
mote switches.
Washer
2.
TD-045 31 5-J
Locate terminal strip 1 Tin weld control, and
link between 1TG and 1TH.
remove
jumper
Figure
4-3.
There
4.2. Hub And
Spindle
Installation
INTERNAL CONNECTIONS
in the weld control to which
be connected or at which inter
nal reconnections can be made. The use of these termi
nal strips depends on the welding system set-up and
are
external
four terminal
equipment
cycle. An automatic flux valve can be connected to the
weld control for Submerged Arc Welding (SAW). The op
tional water valve can be reconnected to operate simul
taneously with the gas valve. (See Section
mal operation of optional water valve.)
B. Remote Start/Stop Relay (Maintained
Connections (FIgure 4-3)
Contact)
relay can be used for
start/stop control of the weld cycle. Closing the relay
contact (energizing the relay) starts the weld cycle.
Opening
the contact stops the weld event and crater
starts.
1.
Install relay at desired location, obtain proper length
cable, and make connections to the normally-open
set of contacts.
4-6 for nor
Determine the need for these connections based
and proceed as follows:
10
Connect leads from normally-closed stop switch to
1TG (common) and 1TH.
A set of contacts from a suitable
External customer supplied remote start/stop devices
be connected to the weld control. External customer
supplied devices (such as fixtures) can access relay
contacts that change state in conjunction with the weld
Page
4.
strips
can
OM-1548
Connect leads from normally-open start switch to
1TG (common) and 1TJ.
can
welding application.
welding application,
3.
on
2.
Locate terminal strip 1 T in the weld control, and
move jumper link between 1TF and 1TG.
3.
Connect leads to 1TG
the
(common)
and 1TJ.
re
Motor
Speed
DIP Switch S50
Digital
inches
Per Minute Meter
PC8
Receptacle RC1O
liming
Receptacle
RC4
Receptacle RC2 Location
Ref. TC-112 519
Figure 4-3. Connection Strip Location
C.
Connections
Skip
Welding
Start/Stop
(Figure 4-3 And Figure 4-4) (Uses Spot Time Con
trols)
A
double-pole, single-throw, maintained-contact switch
is required for skip welding. Closing the switch starts the
spot weld cycle. The setting of the pref low and postf low
timers determines the skip time (time between weld
cycles). The spot weld cycle repeats until the switch is
opened.
Double-Pole
Switch
Single-Throw
S~O28O
2.
Connect
5.
remaining leads
Place the SPOT-CONTINUOUS switch in the SPOT
position before starting skip welding.
D.
Relay Contact Connections For External Equip
(Figure 4-3 And Figure 4-5)
ment
A set of normally-open and normally-closed contacts are
provided to work in conjunction with the weld cycle tim
ers. For example, if a fixture needs to start moving at arc
SkIp Weiding Switch Connections
Connections can be made to the 3/16 in. male friction
terminals on timing board edge connector receptacles
RC4 and RC1 0. To gain access to these receptacles, the
timing circuit
board needs to be removed.
1.
Remove three
Install switch at desired location, obtain proper
length cable, and make connections at switch (see
2.
Gently pull
Figure 4-4).
3.
Locate terminal
remove
to 1 TF and 2TA.
1 TF
ITG
1.
4.
to 1 TG.
common
movement.
To Weld Control
Terminal Strips
4-4.
Connect switch
initiation and stop when the STOP switch is pressed,the
normally-open contacts of relay CR51 (at receptacle
RC4, terminals F and H) would be used to control fixture
2TA
Figure
3.
jumper
IT and 21 in weld control, and
link between 1TF and 11G.
Disconnect
screws
timer
securing
panel part
plugs PLG1
timer
panel.
way out.
and PLG2 from the timer
circuit board.
strips
4.
Remove timer
panel from weld
control.
OM-1548
Page
11
5.
6.
E.
4-4.
Route leads from external equipment to desired ter
minals at RC4 and RC1O. Leads from external
equipment must have 3/16 female friction terminals
to connect to RC4 and Ad 0.
Steps
After connections are made, reverse
through 4 to reinstall timer panel.
Flux Valve Connections
WIRE DRIVE MOTOR SPEED CALIBRATION
SELECTION
a
1
flow,
If coolant flow is desired
only
in
a
(Figure 4-3)
conjunction
with shield
ing gas flow, reconnect power to the water valve
lows:
as
ELECTROSTATIC DISCHARGE
CAUTION:
damage circuit boards.
Put on properly grounded wrist
BEFORE handling circuit boards.
(ESD)
fol
can
Perform work
The weld control is
strips iT and
1.
Locate terminal
2.
Locate lead 1 from
2T.
Reconnect lead 1 at lTD.
I~ ~E
~
,
F
IH
at a static-safe work area.
shipped for use with a standard
(16.79:1 gear ratio). If a low
speed
speed motor (65.5:1 gear ratio) is used, it is necessary to
change the DIP switch position on the Low Speed Cali
bration board PC8. To check or change switch position,
proceed as follows:
gas/current sensing receptacle
~R5~
only
strap
wire drive motor
RC9 at 2TB and disconnect from 2TB.
3.
kill.
welding power
employing
locko ut/tagging procedures before inspecting or
installing.
Lockout/tagging procedures consist of pad
lockinQ line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
The flux valve energizes when the weld control START
switch is pressed and deenergizes at the end of post-
Power
can
Do not touch live electrical parts.
Shut down weld control and
(Figure 4-3)
Reconnecting Water Valve
WARNING: ELECTRIC SHOCK
source, and disconnect in put power
Connect leads from flux valve to terminals 1 TO and 2TD
in the weld control (polarity is not important).
F.
(FIgure 4-3)
L0
~
1CR5~
IL ii<
1CR5~
CR54
~
:
:1~
n
Iw
x
Lv
ccIBB LM
RC1 0
Fixture
(Example explained in Section 4-3D.)
I,
CR56
~
ITU
-III
CR55
I
CR54
CR50~
CR51
i~
t-
-
I
~
E~EEE
~
.
CR52
-,
Run In
Time
,
Weld Time 0-Infinity or
Spot Time 0-2.5 Sec.
Crater Time
0-2.5 Sec
Run In
I
Speed
I-
Burnback Time
0-0.25 Sec.
PrefluxOr
Preftow Tim
0-5Sec.
!015U)I
/ /
Start
Switch
Pressed
p
Poettlow Time
I.
0.5
Sec.-4~
Time
Stop
Switch
Pressed
The dotted line condition indicates the time during the weld cycle that the control
the time during the weld cycle that the control relay is energized.
Figure
OM-1548 Page 12
/
I
4-5. Weld Control
relay is deenergized. The solid line condition indIcates
Cycle
Ref. S-0271
Loosen
1.
securing door
screw
on
upper panel of the
weld control, and open door.
PC8. See
2.
Locate switch S50
board location.
3.
Place S50 in position 1 for low
tions.
on
Figure 4-3 for circuit
control. The 14-pin plug connects to the welding power
source. To make connections, align keyway, insert plugs
into receptacles, and rotate threaded collars fully clock
wise.
Be
Close and
4.
secure
speed
motor
applica
sure
power
remote contactor control switch on the welding
is in the correct position to allow use of a
source
remote control device.
weld control door.
If the switch is in the wrong position, the INCHES PER
MINUTE meter display is not accurate.
4-5.
CONTROL
WELD
(Figure
INTERCONNECTIONS
Figure 4-8)
4-6 and
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Shut down weld control and welding power
input power employing
locko ut/tagging procedures before inspecting or
source, and disconnect
installing.
Cable
Lockout/tagging procedures consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing
Clamp
Wire Drive
Motor
device.
Receptacle
Gas/Current
Control
supplied with the necessary interconnecting
cords. Examine and select the proper cord for each of
the following connections.
Sensing
Receptacle
This unit is
Electrical
Drive Motor Connections
A.
lnput/Contactor
Receptacle
Control
Voltage/Amperage
Receptacle
Control
The 5 ft (1 .5 m) motor cord has a 14-pin plug and
14-socket free-hanging receptacle. The 14-pin plug con
nects to the weld control. The 14-socket
receptacle con
TC-098 619-A
from the wire drive motor. To
make connections, align keyways, insert plugs into re
ceptacles, and rotate threaded collars fully clockwise.
nects to the cord
Gas/Current
B.
coming
Sensing Control
Connections
The 10 ft. (3 m) interconnecting cord has a 14-pin plug
and 16-socket plug. The 14-pin plug connects to the
weld control. The 16-socket plug connects to the Gas/
Current Sensing control. To make connections, align
keyways,
insert
threaded collars
C.
plugs into receptacles, and
fully clockwise.
rotate
Background Voltage/Peak Amperage Control
Connections
The 25 ft.
(8 m) interconnecting cord has a 10-socket
and a 10-pin plug. The 10-socket plug connects to the
weld control. The 10-pin plug connects to the welding
power source. To make connections, align keyways, in
plugs into receptacles, and rotate threaded collars
Figure
IMPORTANT:
Be
power
the remote output control switch on the welding
is in the proper position to allow use of a
source
The
following socket information is included in case the
supplied cord is not suitable, and it is necessary to wire a
plug or cord to interface with the welding power source
REMOTE 14 receptacle.
Socket C:
Socket D:
Electrical
Socket E:
Control circuit
common
for remote control
Input command signal from wiper of
remote
control potentiometer; 0 volts equals ma
chine minimum; +10 volts equals machine
maximum.
Socket G:
115
volts
circuit
ac
also
common;
connected to welding power source chas
sis.
Socket I:
Up to 15 amperes 01115 volts ac, 60 Hz,
with respect to socket G (circuit common).
Input/Contactor Control Connections
The 25 ft. (8 m) interconnecting cord has 14-socket and
14-pin plugs. The 14-socket plug connects to the weld
+10 volts dc with respect to Socket D.
device.
remote control device.
D.
suppiled electrical input/contactor
tributor.
clockwise.
sure
If the
control/voltage control coid does not match the welding
power source remote controireceptacle, obtain the nec
essary adapter cord from your welding equipment dis
sert
fully
4.6. Cord Connections
OM-1548
Page
13
control to energize weld contactor for
115 volts ac weld control. A contact closure
from socket Ito socket J completes the 115
Socket J:
Input
IMPORTANT: The gas flow must be accurately
trolled by a regulator/flowmeter at the source.
1.
volt circuit.
Socket K:
Weld control chassis.
IMPORTANT: The remaining sockets in the
are not used.
con
Select and obtain shielding gas hose of suitable
length and type for connection between the shield
ing gas source and the Gas/Current Sensing con
trol.
receptacle
Panel
GAS/CURRENT SENSING CONTROL INTER
CONNECTIONS (FIgure 4-6, FIgure 4-7 and Figure
Gas/Current
4-6.
4-8)
A.
Weld
4A
Output Connections
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Shut down weld control and
welding power
input power employing
lockouttagging procedures before inspecting or
source, and disconnect
installing.
Opening
Lockout/tagging procedures
consist of
pad
Optional Water
Fitting Location
line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
lockin9
Fitting
TA-080 484-8
ing device.
Figure
Select and prepare proper size and length weld cables
according to the welding power source Owners Manual.
Remove cover from Gas/Current Sensing control.
1.
Electrode Positive/Reverse
Connect aweld cable to the positive weld output
terminal on the welding power source.
b.
Route cable through weld cable opening on
gas/current sensing control IN panel, and
through reed relay.
c.
Connect end of cable coming from Gas/Current
Sensing control to weld cable terminal on wire
drive assembly. See wire drive assembly Own
ers Manual for terminal location.
d.
Connect
a
weld cable from the
output terminal
the
e.
2.
on
the
negative
welding power
Electrode
Negative/Straight Polarity
b.
IN
3.
Connect supplied 10 ft. (3 m) gas hose to remaining
fitting on gas/current sensing control. Push remain
ing end of hose onto barbed fitting on wire drive as
sembly. See wire drive assembly Owners Manual
for location of barbed fitting.
Shielding gas flow is controlled
flow timers in the weld control.
C.
Optional
4A
fitting
on
by the preflow and post-
Water Connections
CAUTION:
OVERHEATING Gas Metal Arc
Welding (GMAW) gun
can
damage gun.
Do not use water connections on the Gas
Current Sensing control if a recirculating coolant
system is used.
weld
If using a water-cooled gun and recirculating
coolant system, make connections from gun
directly to recirculating coolant system.
source to
Sensing con
The water fittings at the Gas/Current
have 5/8-18 left-hand threads.
Connections
1.
Follow directions for Electrode Positive/Reverse
Polarity with the following exceptions:
a.
Sensing Control
Connect gas hose from source to gas
panel of Gas/Current Sensing control.
workpiece.
Reinstall and secure Gas/Current
trol cover.
4-7. Gas/Current
2.
Polarity Connections
a.
Gas In
In
Route weld cable from welding power source
negative weld output terminal through Gas/
Current Sensing control to wire drive assembly.
Connect weld cable from welding power source
positive weld output terminal to workpiece.
Sensing
Select and obtain water hose of suitable
type for connection between the
Gas/Current
water
length and
supply and
Sensing control.
2.
Connect water hose from source to water
IN panel of Gas/Current Sensing control.
3.
Connect water in
maining fitting
4.
control
fitting from welding gun
on
fitting
on
hose to
re
Gas/Current
Route hose from gun water
Sensing control.
out fitting to a proper
drain.
B.
ShIeldIng Gas Connections
The shielding gas fittings at the Gas/Current
control have 5/8-18 right-hand threads.
OM-1548
Page
14
Sensing
Water flows as soon
is placed in the ON
water flow before
as
the weld control POWER switch
position. Check system
welding.
for proper
AUTOMATiC 1 DA.PS
Weld Control.
fi
5ft.(1.5m)Motor
Control Cord
10 ft. (3 mj Gas/Current
Control Cord
Sensing
25 ft.
(8 m) Electrical
Input/Contactor
Control Cord
Sensing
Assembly
WELDING WIRE INSTALLATION
4-8. ConnectIon
(Figure 4-2)
1.
Remove
2.
Slide spool of wire onto hub so that wire feeds off the
bottom with minimum bend and sharp radius.
Rotate
B.
Reinstall
retaining ring.
Installation Of
Reel-Type
Wire Onto
Optional
Wire Reel
1.
Remove
2.
Lay
3.
Remove spanner nut from wire reel
retaining ring
wire reel
Diagram
Remove wire retainer, and install wire onto wire reel.
sure that wire feeds oft bottom of reel.
5.
Reinstall wire retainer and spanner nut onto wire
reel.
6.
Slide wire reel assembly onto hub, and rotate as
sembly until hub guide pin is seated in reel. Be sure
reel assembly is seated against back flange of hub.
7.
Reinstall
C.
Adjusting Hub Tension
guide pin is seated in hole in
spool is seated against back flange of
hub.
4.
4.
until hub
sure
Control Device
Connection
Spool-Type
retaining ring.
spool
Accessory/External
Be
Installation Of
spool. Be
(~
Ref. S.O2~3
A.
3.
25 ft. (8 m) Voltage
Control Cord
Drive
Control
Figure
4-7.
(D
and wire reel
assembly flat
on
table
assembly.
or
floor.
assembly.
retaining ring
onto hub.
Check hub tension by slowly pulling wire toward the feed
roll. The wire should unwind freely, but hub tension
should be sufficient to keep wire taut and prevent back
lash when wire feed stops. If adjustment is required,
loosen or tighten hex nut on end of hub support shaft ac
cordingly.
SECTION 5- OPERATOR CONTROLS
5-1.
POWER
SWITCH
AND
PILOT
LIGHT
(Figure 5-1)
set
by the CRATER & JOG WIRE SPEED
pressed.
control when
the JOG switch is
Placing the POWER switch in the ON position energizes
the weld control.
position
Placing
the POWER switch in the OFF
shuts down the weld control.
With the RETRACT
-
ADVANCE switch in the AD
VANCE
IMPORTANT: The welding powersource must be ener
gizedbefore the POWER switch can be used to energize
set
by
position, wire feeds from the gun at the speed
the CRATER & JOG WIRE SPEED control when
the JOG switch is
pressed.
the weld controL
RETRACT
ADVANCE
SWITCH (Figure 5-1)
5-2.
-
With the RETRACT
TRACT
position,
SWITCH
AND JOG
ADVANCE switch in the RE
wire retracts into the gun at the speed
-
The JOG switch is a push-button switch. Pressing the
push button energizes the wire drive motorwithout ener
gizing the welding power source contactor orgas control
circuitry.
OM-1548
Page
15
Fuse Fl
(see
Retract/Advance
Voltage
Inches Per
Crater & Jog
Wire
FIgure
5-3.
PURGE SWITCH
5-1.
Upper
(FIgure 5-1)
Meter
TD-098 619~A
Minute Meter
Speed
Front Panel Controls
on
appropriate digital
meter while the PRESS TO SET
button is held.
The PURGE switch is a push-button switch. Pressing
the push button energizes the gas solenoid and purges
the shielding gas line to the gun.
5-4.
START SWITCH
(FIgure
5-1 And
FIgure 4-5)
Pressing the START push-button switch starts the pre
cycle. See Figure 4-5 forweld cycle events. The
weld cycle continues until the STOP push-button switch
is pressed or the SPOT TIME times out.
set weld
5-5.
IMPORTANT: The PEAK AMPERAGE meter does not
illuminate if the welding power source Mode selector
switch is in the STANDARD position.
5-7.
DIGITAL METERS (Figure 5-1)
The digital INCHES PER MINUTE meter is
shipped from
display wire speed in inches per min
ute. The wire speed displayed depends on what portion
of the weld cycle is running. At idle, the WELD wire is dis
played.
the
factory
set to
STOP SWITCH (Figure 5-1 And Figure 4-5)
digital BACKGROUND VOLTAGE meter displays
voltage to the nearest tenth of a volt. The voltage dis
played depends on what portion of the weld cycle is run
ning. At idle, the WELD Background Voltage is dis
played.
The
the STOP
Pressing
push-button switch initiates the pre
set crater, burnback, and postflow time events. See
Figure 4-5 for weld cycle events.
5-6.
PRESS TO SET BUTTONS (Figure 5-1)
The
Depress and hold the PRESS TO SET button while set
ting RUN IN or CRATER & JOG parameters. The corre
sponding voltage, amperage,
OM-1548
Page
16
or
wire
speed is displayed
digital PEAK AMPERAGE
meter
displays amper
age to the nearest ampere. The amperage displayed de
pends on what portion of the weld cycle is running. At
idle, the WELD Peak Amperage is displayed.
IMPORTANT: The PEAK AMPERAGE meter does not
illuminate if the welding power source Mode Selector
switch is in the STANDARD position.
IMPORTANT: The meterdisplays maybe erratic during
run in and crater due to the short time of these weld
events. The preset voltage, amperage, and wire speed
are being suppiled, but the meters cannot stabilize fast
enough to show ft~
5-8.
RUN IN WIRE SPEED CONTROL
(FIgure 5-1)
5-14. CRATER PEAK AMPERAGE CONTROL
(Fig
ure5-1)
The CRATER PEAK AMPERAGE control allows preset
ting of the peak amperage for the crater portion of the
weld cycle.
5-15. PREFLOW TiME CONTROL
(FIgure 5-2)
adjustable 0 to 5 second PREFLOW TIME control al
lows presetting of the time shielding gas flows before arc
An
initiation. Pref low time starts when the START switch is
pressed.
The RUN IN WIRE SPEED control allows presetting of
the wire feed speed that applies to the time between arc
initiation and the main weld portion of the weld cycle. Af
ter run in, the wire feed speed is set by the WELD WIRE
The scale around the PREFLOW TIME control is
marked in seconds. Rotating the control clockwise in
creases pref low time.
SPEED control.
5-16. SPOT
-
CONTiNUOUS SWITCH (Figure 5-2)
The SPOT CONTINUOUS switch allows selection of
either a normal untimed weld cycle or a timed spot weld
cycle. Placing the switch in the SPOT position provides a
timed weld using the SPOT TIME control. Placing the
switch in the CONTINUOUS position provides a normal
untimed weld event. Both weld cycles have the following
events: pref low, run in, weld (spot time or untimed), cra
-
The RUN IN SPEED control acts
other
speed
independently of the
controls and can therefore be set above
by the other controls.
or
below the value set
Rotating the control clockwise increases
run
in wire feed
speed.
5-9.
WELD WIRE SPEED CONTROL
(Figure 5-1)
The WELD WIRE SPEED control allows
the wire feed speed for the weld event.
Rotating
presetting
ter, burnback, and postf low.
of
the control clockwise increases wire feed
WELD BACKGROUND VOLTAGE CONTROL
(FIgure 5-1)
The WELD BACKGROUND VOLTAGE control allows
presetting of the background voltage forthe weld portion
of the weld cycle.
5-11. WELD PEAK AMPERAGE CONTROL
(Figure 5-2)
adjustable 0 to 2.5 second SPOT TIME control al
lows presetting of the spot weld time. Spot time starts at
arc initiation.
The
speed.
5-10.
5-17. SPOT TIME CONTROL
(Figure
The scale around the SPOT TIME control is marked in
seconds. Rotating the control clockwise increases spot
time.
5-18. CRATER TIME CONTROL
An
(Figure 5-2)
adjustable 0 to 2.5 second CRATER TIME control al
lows
presetting
of crater time. Crater time starts when
pressed or the SPOT TIME control
the STOP switch is
5-1)
times out.
The WELD PEAK AMPERAGE control allows presetting
of the peak amperage for the weld portion of the weld
The scale around the CRATER TIME control is marked
in seconds. Rotating the control clockwise increases
crater time.
cycle.
5-19. BURNBACK CONTROL
5-12.
CRATER & JOG WIRE SPEED CONTROL
(Figure 5-2)
adjustable 0 to 0.25 second BURNBACK control al
presetting of the time the wire remains electrically
energized after the drive motor stops. Burnback starts
An
(FIgure 5-1)
lows
The CRATER & JOG WIRE SPEED control allows pre
setting of the wire feed speed for crater fill. Wire retracts
advances at the speed set
JOG switch is pressed.
or
by
this control when the
The scale around the BURNBACK control is marked in
seconds.
The CRATER & JOG WIRE SPEED control acts inde
pendently of the other speed controls and can therefore
be set above or below the value set by the othercontrols.
Rotating
after the CRATER TIME control times out.
the control clockwise increases wire feed
speed.
CON
The CRATER BACKGROUND VOLTAGE control allows
presetting of the background voltage for the crater por
tion of the weld cycle.
control clockwise increases burn-
By adjusting the control properly, the wire neither
freezes in the weld puddle nor in the contact tube of the
gun. If the wire freezes in the weld puddle, increase
burnback time. If the wire freezes in the contact tube, de
crease
5-13. CRATER BACKGROUND VOLTAGE
TROL (Figure 5-1)
Rotating the
back time.
burnback time.
5-20. POSTFLOW TIME CONTROL
(Figure 5-2)
An
adjustable 0 to 5 second POSTFLOW TIME control
allows presetting of the time shielding gas flows after
burnback. Postf low time starts after the BUANBACK
timer times out.
OM-1548
Page
17
The scale around the POSTFLOW TIME control is
marked in seconds. Rotating the control clockwise in
creases postflow time.
5-21. OPTIONAL RUN IN CONTROLS
A.
An
(Figure 5-1)
The scale around the RUN IN TIME control is marked 0
to 2.5 seconds. Rotating the control clockwise increases
run
in time.
B.
RUN IN BACKGROUND VOLTAGE Control
RUN IN TIME Control
adjustable 0 to 2.5 second RUN IN TIME control al
presetting of the time between arc initiation and the
lows
main weld sequence.
The RUN IN BACKGROUND VOLTAGE control allows
run in event
presetting of the background voltage for the
In the weld cycle.
Pre-Flow
Time
Spot.Contlnuous
Switch
Spot
lime
lime
Burnback
Post-Flow
lime
FIgure
SECTION 6
a
5-2. Timer Panel View
SEQUENCE OF OPERATION
WARNING:
ELECTRIC SHOCK can kill;
MOVING PARTS can cause serIous Injury;
IMPROPER AIRFLOW AND EXPOSURE TO
ENVIRONMENT can damage Internal parts.
Do not touch live electrical parts.
WELDING
wounds.
removed.
ARC RAYS, SPARKS, AND HOT SURFACES
burn eyes and skin; NOISE can damage
can
hearing.
WIRE
can
cause
puncture
Do not point gun toward any part of the body,
any conductive surface, or other personnel.
HOT
Keep all covers and panels in place while
operating.
Warranty is void if the weld control is operated
with any portion of the outer enclosure opened or
cause
METAL, SPATrER, AND SLAG
can
fIre and burns.
Watch for fire.
Keep a fire
how to use it.
Do not
extinguisher nearby,
use near
Allow work and
and know
flammable materiaL
equipment
to cool before
handling.
Wear correct eye, ear, and
FUMES AND GASES
your health.
can
Keep your head out of the
Ventilate to
TC.OQ8619~A
body protection.
seriously
harm
Wearers should consult their doctor before
fumes.
keep from breathing fumes and
gases.
If ventilation is
breathing device.
MAGNETIC FIELDS FROM HIGH CURRENTS
affect pacemaker operation.
can
going near arc we/ding, gouging, orspot we/ding
operations.
See Section 1
inadequate,
use
approved
Safety Rules For Operation Of
Welding Power Source for basic welding
safety information.
Arc
-
GAS METAL ARC WELDING (GMAW) AND
WELDING
ARC
CORED
FLUX
(FCAW)
CONTINUOUS (FIgure 6-1)
6-1.
1.
Install and connect weld control and supplied
ciated equipment according to Section 4.
2.
Install and connect remaining equipment (gun, drive
motor, etc.) according to the applicable Owners
-
4A
WARNING: Read and follow safety informa
tion at beginning of entire Section 6 before
proceeding.
asso
Manual.
3.
Place SPOT
-
CONTINUOUS switch in the SPOT
position.
1.
Install and connect weld control and supplied asso
ciated equipment according to Section 4.
4.
Rotate SPOT TIME control to desired position (see
Section 5-17).
remaining equipment (gun, drive
motor, etc.) according to the applicable Owners
5.
Turn
Manual.
6.
Energize welding power
7.
Place the weld control POWER switch in the ON p0sition (see Section 5-1)
Install and connect
2.
3.
Place SPOT-CONTINUOUS switch in CONTINU
OUS position.
4.
Turn
on
shielding gas
at the source.
8.
Energize welding power
6.
Place the weld control POWER switch in the ON p0sition (see Section 5-1)
7.
Program the desired weld cycle
trols as instructed in Section 5.
8.
dry insulating gloves and clothing, and wear
welding helmet with proper filter lens according to
by setting
9.
Connect work
a.
10.
by setting the
con
Prepare
to
welding
as
follows:
Connect work clamp to clean, bare metal at
Select and obtain proper welding wire, and
thread according to wire drive assembly Own
ers Manual.
b.
follows:
clamp
for
workpiece.
clean, bare metal at
11.
workpiece.
Purge gas
hose
by pressing
the PURGE switch for
minute.
one
Select and obtain proper welding wire, and
thread according to wire drive assembly Own
ers Manual.
b.
the desired weld cycle
instructed in Section 5.
ANSI Z49.1.
the con
ANSI Z49.1.
as
as
Wear dry insulating gloves and clothing, and wear
welding helmet with proper filter lens according to
a.
Prepare for welding
source.
source.
Wear
9.
at source.
Program
trols
5.
shielding gas
on
12. Press weld control START switch.
13. The weld event
automatically stops
and crater starts
when the SPOT TIME control times out.
10.
Purge gas
one
hose
by pressing the PURGE
switch for
6-3.
minute.
1.
11. Press weld control START switch.
SHUTTING DOWN
Place weld control POWER switch in the OFF
posi
tion.
12. To stop the weld
STOP switch.
cycle
and start crater, press the
GAS METAL ARC WELDING (GMAW) AND
FLUX CORED ARC WELDING (FCAW) SPOT
6-2.
2.
Turn off all associated
3.
Turn off
A~
I
I
I
a
Equipment
I
hl
~See Section 4~
I
Put On
Personal
Safety
Equipment
applicable,
I I
f
1E~r~ZitLJ
& Gas
FIgure
I~
5jj WeidingLSJ L__J SampuJ*I
SetControls
See Section
6-1.
at
WARNING:
HIGH CONCENTRATION OF
SHIELDING GAS can harm health or kill.
Shut off gas supply when not in
proceeding.
install &
Connect
and water, if
source.
-
WARNING: Read and follow safety Informa
tion at beginning of entire SectIon 6 before
shielding gas
equipment.
i
i
Thread
Purge
Wire
Gas
~
Do
______
_____
Weld
use.
Readlust
I
ControisAndi
For I
Production
Prepare
Sequence Of Operation
OM-1548
Page
19
SECTION 7
MAINTENANCE & TROUBLESHOOTING
IMPORTANT: Ever, six months inspect the labels on
this unit for legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
when necessary. See Parts List for part number of
precautionary labels.
Usage and shop conditions determine the frequency
and type of maintenance. At minimum, inspect equipment every three months as follows:
WARNING: ELECTRIC SHOCK
can
proCeeding.
The drive motor is protected from
load bycircuitbreakerCBl.If CB1
feed motor would stop.
Should
a
motor overload
Check for jammed wire
1.
Shut down weld control and
welding power
input power employing
lockout/tagging procedures before inspecting,
maintaining, or servicing.
source, and disconnect
consist of padin open position,
removin9 fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnecting device,
Lockoutltagging procedures
locking line disconnect switch
Keep
HOT SURFACES
Allow
burns.
performed only by qualified
Repair or replace, as required, all hose and cable;
give particular attention to frayed and cracked insulation and areas where it enters equipment.
ture from electrical
7-2.
WARNING: ELECTRIC SHOCK
Check for
3.
or
misaligned drive
Reset circuit breaker by depressing the button. A
be necessary before the circuit
breaker can be reset.
4.
cooling period may
5.
Resume
B.
Main Fuse Fl
operation.
(Figure 5-1)
a
WARNING:
Read and follow safety informa
tlonatbeglnningofentlre Sectlon7-2before
proceeding.
The weld control is
protected from damage due to an inexcessive overload by fuse Fl. If Fl
should open, the weld control would completely shut
down. To Replace Fl, proceed as follows:
ternal short
Depress
1.
or
and rotate fuse holder cover counterclock
can
2.
Pull out fuse with
free.
kill,
3.
Insert
4.
Install fuse holder
maintaining,
5.
or
servicing.
Lockout/tagging procedures
locking line disconnect switch
consist of
in open position,
red-tagging
ing device,
circuit breaker
INCORRECT FUSE
or
other disconnect-
7-3.
damage
unft.
Useonlyreplacement fuse of same size, type,
and rating (see Parts List).
when fuse holder
cover
is
fuse into fuse holder cover.
cover
back into unit.
is secure.
HUB REINSTALLATION
If it becomes necessary to
and
can
new
cover
Depress and rotate fuse holdercoverclockwise until
cover
pad
removin9 fuses from fuse box, or shutting off and
20
drive gear
binding
rolls, and correct problem.
Shut down weld control and welding power
source, and disconnect input power employing
lockout/tagging procedures before inspecting,
Page
repairorrepiacewire
wise.
Do not touch live electrical parts.
OM-1548
and
drive motor.
OVERLOAD PROTECTION
~
clogged gun liner,
or
cooling period before servicing.
Remove grease and grime from components; mois
parts and cable.
2.
proceed
problem. if wire jams often, replace gun liner.
If motoroverloadoccursoften,
2.
lnju~.
moving parts.
can cause severe
Maintenance to be
persons.
1.
serious
can cause
and CB1 open,
follows:
correct
away from
occur
damage due to overshouidopen,thewire
kill.
Do not touch live electrical parts.
MOVING PARTS
(Figure 5-1)
WARNING: Read and follow safety Informa
tion at beginning of entire Section 7-2 before
as
a
Drive Motor Circuit Breaker CB1
A.
ROUTINE MAINTENANCE
7-1.
spindle assembly,
see
(Figure 4-2)
replace all or part of the hub
Figure 4-2, and proceed as
follows:
1.
Remove hub assembly from spindle support, and
disassemble, discarding worn or broken parts.
2.
3.
Slide the following items onto the
shaft in order given.
a.
Spring
b.
Keyed
c.
Fiber Washer
d.
Brake Washer
e.
Hub
f.
Brake Washer
g.
Fiber Washer
break circuit
can
Use only minima/pressure and gentle move
ment when disconnecting or connecting board
plugs and removing or installing board.
Washer
7-5.
TROUBLESHOOTING
a
WARNING: ELECTRIC SHOCK
can
kill.
Do not touch ilve electrical parts.
Shut down weld control and welding power
input power employing
lockout/tagging procedures before inspecting,
-
and
Align keyway,
through selected
insert
spindle support
hole in hub
support.
maintaining,
Install hex nut onto spindle support shaft. Tighten
hex nut until a slight drag is felt while turning hub.
5.
Install
welding
according
wire
source, and disconnect
shaft
4.
7-4.
EXCESSIVE PRESSURE
board.
spindle support
consist of pad
in open position,
switch
line
disconnect
lockinQ
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
to Section 4-7.
WARNING: ELECTRIC SHOCK can kill.
MOVING PARTS
Do not touch live electrical parts.
welding power
input power employing
lockout/tagging procedures before inspecting,
maintaining, or servicing.
Shut down weld control and
or
other disconnect
device.
CAUTION:
ELECTROSTATIC DISCHARGE
can
Allow coolThg
Perform work
Troubleshooting to
qualified persons.
be
performed only by
It is assumed that the unit was properly installed accord
to Section 4 of this manual, the operator is familiar
with the function of controls, the weld control was work
only at
a
static-safe work
area.
INCORRECT INSTALLATION or mIsalIgned
can damage circuit board.
that
plugs
are
properly installed and
aligned.
Table 7-1.
trouble is not related to the
following table is designed to diagnose and provide
remedies for some of the troubles that. may develop in
this weld control. Use this table in conjunction with the
circuit diagram while performing troubleshooting proce
dures. if the trouble is not remedied after performing
procedures, contact the nearest Factory Author
ized Service Station. In all cases of equipment malfunc
tion, strictly follow the manufacturers procedures and
instructions.
these
Troubleshooting
REMEDY
PROBABLE CAUSE
TROUBLE
Pressing the START button
does not start weld cycle.
Electrode wire is not
energized and shielding
gas (or flux if applicable)
does not flow.
ing properly, and that the
welding process.
The
plugs
sure
period before servicing.
strap
Transport circuit boards in proper staticshielding carriers or packages.
Be
Injury.
ing
damage cIrcuit boards.
Put on properly grounded wrist
BEFORE handling circuit boards.
(ESD)
serious
HOT SURFACES can cause severe burns.
Lockout/tagging procedures consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
circuit breaker
can cause
Keep away from moving parts.
source, and disconnect
ing
servicing.
Lockout/tagging procedures
CIRCUIT BOARD HANDLING PRECAUTIONS
red-tag9ing
or
POWER switch Si.
Energize welding power source.
Place Si in ON position.
Check Si and replace if necessary.
Main fuse Fl.
Check and replace Fl
Section 7-2.
Circuit breaker CB1.
Reset CB1
Input power plug is not secure in receptacle
weld control or welding pow er source.
4-4D).
on
according
according
to
to Section 7-2.
Secure connections (see Section
OM-1 548
Page
21
Table 7-1.
Troubleshooting (Continued)
REMEDY
PROBABLE CAUSE
TROUBLE
Wire feeds, shielding gas
flows, but electrode wire
is not energized.
Contactor control plug is not secure in
receptacle on weld control or welding
power
source.
Welding power
Erratic meter display(s).
secure in
Fixture movement erratic or
not as desired, if applicable
See
Troubleshooting Section in weld
ing power source Owners Manual.
source.
Voltage and amperage control plug is
or
Secure connections (see Section
4-4D).
receptacle
welding power
Control
on
not
weld control
relays.
strips.
or
erratically while
welding or jogging wire up
motor runs
or
down.
OM-1548
Page
22
4-4C).
source.
Loose or incorrect connections to terminal
Motor does not run,
Secure connections (see Section
Motor control board PC4.
Check and replace
Board PC3.
relays
on
Timer
Check and secure connections.
See Section 4-3 for proper terminal
strip connections.
Check and replace PC4 if necessary
(see Section 7-4).
Cl) ii C) -~ 0 z 03
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CircuIt
8-3.
Diagram
388
0-083
No.
Diagram
CIrcuit
PC2
Board
Control
Motor
For
Diagram
CIrcuit
8-4.
Diagram
267
C-085
No.
Diagram
Circuit
{Th~R
v
ICAS5
PC3
Uffi..v TORC1O
1T~fltvY
PC10
Board
Timer
For
Diagram
v
~
v
~
fl~4GG
riii
RC,
Circuit
rrt.
8-5.
vv
10C .
tv_
PCi
Diagram
Circuit
Diagram
8-6. CircuIt
Diagram
Diagram
No. A-094 456
For Tach Board PC4
CE
BA(
131
CR56
II
co
114
CR55
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Circuit Diagram No. B-095 433
Diagram
8-7. Circuit
Diagram For Relay
Board PC5
OM-1548
Page
29
B
A
C
Circuit
Diagram
OM-1548
Page
30
8-8. CIrcuit
Diagram For
Low
Speed Calibration
Diagram
Board PC8
No. A-119 481
SECTION 9
PARTS LIST
OM-1 548
Page
31
0
N
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OM-1548
Page
32
Item
No.
Dia.
Mkgs.
Part
No.
Description
FIgure
1
095 546
2
3
4
5
6
7
8
9
10
SI
CB1
PB1
011 611
011 991
011 232
S2,3
011 043
095 696
095 427
095 426
109 474
009 335
081 379
073487
+128 959
123 154
024 376
057 084
079 683
030949
030 941
056 170
010 193
010199
047 838
115 104
092 176
047 636
079 535
079 739
073 139
071 892
079 534
048 144
PB3
PB4
PC8
11
12
PLG6,15,17
13
14
15
16
17
18
19
20
R2
21
22
23
24
25
26
27
28
29
30
PLG7
PLG8
.120
089
073
073
039
31
32
33
34
35
36
37
PLG9
38
39
40
PLG18
071
047
079
079
073
048
079
048
357
647
332
140
716
005
636
535
739
139
598
534
144
41
.114 290
42
111 123
43
44
45
46
47
RC7,9
RC11
109771
073 296
604 571
111 122
109 770
047637
079 534
048 144
094 480
Quant~y
9-1. Control Box
NAMEPLATE, (order by model & serial number)
DOOR, cabinet
SWITCH, tgl DPDT 15A 125V
CIRCUIT BREAKER, 1P 1.5A 125V
SWITCH, pb SPDT
SWITCH, tgl DPDT MC 6A 125V
GUARD, switch
SWITCH, pb MC SPST 20A 250VAC black
SWITCH, pb MC SPST 20A 250VAC red
CIRCUIT CARD, low speed motor calibration (Fig 9-11)
STAND-OFF, No. 4-40 x .625 Ig
HOUSING, term header 12 pin
1
1
i
i
1
2
1
1
1
1
2
3
NUT,speedNo.2
1
CABINET,control
LABEL, warning general precautionary
BLANK, snap-in 5/8 mtg hole
BUSHING, snap 1/4 ID x 3/8 mtg hole
HEAT SINK, resistor
1
2
HEATSINK
1
RESISTOR, WW fxd 100W 5 ohm
SHIELD, resistor
TUBING, 3/8 OD x 18 ga wall x 1/4
TUBING,.275IDx.O48waIIxl
BLANK, snap-in 1 in hole
CONNECTOR, clamp cable .500
CABLE, motor (consisting of)
HOUSING PLUG & PINS, (consisting of)
TERMINAL, male
CLAMP, cable strain relief size 17
CABLE, No. 16 6/c (order by 11)
RECEPTACLE W/SOCKETS, (consisting of)
TERMINAL, female
TERMINAL, male-plug keying
CABLE, interconnecting (consisting of)
PLUG, l0skt MS-3106A-18-1S
CLAMP, cable AN-3057-i 0
CABLE, No. 18 10/c (order by it)
PLUG, 10 pin MS-3106A-18-1P
CABLE, interconnecting (consisting of)
HOUSING PLUG & PINS, (consisting of)
TERMINAL, male
CLAMP, cable strain relief size 17
CABLE, No. 166/c (order by ft)
HOUSING PLUG & SOCKETS, (consisting of)
TERMINAL, female
TERMINAL, male 1 pin
CABLE, interconnecting power 25ft (consisting of)
HOUSING PLUG & SOCKETS, (consisting of)
~TERMlNAL,female
CLAMP, cable 97-3057-1 2-6
CABLE, port No. 18 4/c (order by ft)
HOUSING PLUG & PINS, (consisting of)
1
1
1
1
1
4
2
I
1
1
1
14
2
.
5ft
1
14
2
1
1
2
25ft
1
1
1
14
2
lift
1
16
2
1
1
14
2
25ft
1
TERMINAL, male
HOUSING RECEPTACLE & SOCKETS, (consisting of)
TERMINAL, female
TERMINAL, male 1 pin-plug keying
RECEPTACLE, 14 pin MS-3102A-20-27P
14
2
14
4
1
OM-1548
Page
33
Dia.
Item
No.
Part
No.
Mkgs.
Description
FIgure
RC22
48
49
50
51
52
53
PC3
(cont)
089 646
Fig 9-3
070370
085 268
071 230
RECEPTACLE, 10 pin MS-3102A-18-1P
PANEL, w/components
METER, volt-digital (Fig 9-2)
CIRCUIT CARD, timer (Fig 9-6)
3
1
BEZEL/FILTER
3
603 856
097 922
057 359
POTENTIOMETER, WW 10/T 2W 10K ohm
KNOB, pointer
BLANK, snap-in 3/8 mtg hole
HOLDER, fuse minat
FUSE, minat-gI 1OA 250V
SWITCH W/BUTTON, white (consisting of)
SWITCH, pb MC SPDT 3A 125 VAC
BUTTON, switch-white
FASTENER, scr No. 2
RETAINER,scrNo.2
HOSE, gas lOft (consisting of)
FITTING, hose brs nut .625-18RH
FITTING, hose brs ferrule .425 lOx .718 Ig
FITTING, hose brs barbed nipple 3/1 6TBG
7
16,22,23
046 432
012 655
Fl
070 529
071 227
071 228
010 853
010855
056 462
010 606
056 108
056 851
604 550
PB5,6
61
62
079 796
.i-When
ordering
a
HOSE, nprn brd No. 1 (order by ft)
HOUSING, term header 3 pin
1
component originally displaying
a
precautionary label,
34
I
1
2
I
1
1
1
1
1
I
1
1
the label should also be ordered.
item is not included w/control box.
Page
7
3
lift
Re~mmended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1548
1
R4-6,15
54
55
56
57
58
59
60
This
9-1. Control Box
Quantity
Item
Dia.
Mn
Mkos.
Part
No.
070 370
DD5O-52
IC5O
IC51
050-52
R50
071 200
000348
038585
031643
005 023
071 229
026202
084 028
071 239
071 238
037 201
009172
R51
082178
R52
R53
071 231
071 237
035825
039327
071617
071 248
072944
071 219
081 381
071 670
070 026
1
C50
C51
C52
C53
C54
D50,51
R54
R55
150
VR5O
2
3
Description
Quantity
Figure 9-2. Meter, Volt-Digital (Fig 9-1
Item
50)
CIRCUIT CARD, volt meter (consisting of)
1
CAPACITOR, tantim .47uf 35V
CAPACITOR, mylar .22uf 50V
CAPACITOR, cer .Oluf 500VDC
CAPACITOR, tantim 2.2uf 20V
CAPACITOR, eIctft 470uf 16V
DIODE,1A400VSP
LED, 2676
1
1
1
1
1
2
3
IC, interlace 3162
IC, interface 3161
1
1
TRANSISTOR, 200MA 40V PNP
POTENTIOMETER, cermet 20/1 .5W 50K ohm
3
cermet 25/1.5W 10K ohm
1
POTENTIOMETER,
1
RESISTOR, MF .5W 1 meg ohm
RESISTOR, MF .5W 110K ohm
RESISTOR, CF .25W 1K ohm
RESISTOR, CF .25W 220 ohm
TRANSFORMER, current 115V
IC, linear 78M05
HEAT SINK, voltage regulator
CABLE, ribbon llposn
TERMINAL, header 12 pin
BRACKET, mtg-circuit card
STAND-OFF, No. 6-32
1
1
1
1
1
1
1
1
1
1
3
2
TB-070 451
Figure
9-2.
Meter, Volt-DIgItal
OM-1548
Page
35
-4 C)
CD CO
(.3
CD
C) 0
0
CO
9.
It~~m
~
~
Description
Figure
1
2
3
4
5
6
PC5
PLG54
PLG53
PLG52
PLG5O
PLG1 51
7
8
9
10
PC2
RC5
11
12
Cl
13
14
15
16
17
IT
2T
CR1
T2
18
19
20
RC1O
21
Ri
22
R3
PLG2
RC4
23
24
25
26
27
SRi
094 818
079 748
072 669
079 760
048 104
079 798
048 027
083 147
071 642
117374
092 897
009 335
9-3.
Quantfty
Panel, W/Components (Fig 9-1 item 49)
CIRCUIT CARD, relay (Fig 9-5)
HOUSING, term header 18 pin
1
HOUSING, term header 9 pin
HOUSING, term header 12 pin
HOUSING, term header 7 pin
HOUSING, term header 13 pin
PLUG, connector-keying
GROMMET, scr8-10
CIRCUIT CARD, motor speed (Fig 9-4)
1
1
1
1
2
1
6
1
HOUS1NG,connector22posn
I
PANEL, mtg-components
STAND-OFF, No. 4-40 x .625 ig
2
031 692
CAPACITOR, elctlt 750u1 200VDC
1
006426
038 782
038 659
601 219
127312
128 511
080 191
079 784
010 301
030 651
079 497
079 797
079 783
057 544
035 704
073 914
CLAMP,capacitor2in
I
BLOCK, term 20A lop
BLOCK, term 20A 8P
LINK, jumper-term block 20A
RELAY,encI24VACDPDT
TRANSFORMER, control
STRIP, insulator-term block
TERMINAL, header i2skt
BUSHING, 9/64 ID x 1/4 00 x 5/16
RESISTOR, WW fxd 25W 10 ohm
RESISTOR, WW fxd 25W 2K ohm
HOUSING, term header 4 pin
TERMINAL, header l4skt
SPRING, compression
RECTIFIER, integ 30A 600V
WASHER, centering 7/16
1
1
1
7
1
I
1
1
2
I
I
1
1
8
1
4
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1548
Page
37
C-O~ 380
Figure
OM-1548
Page
38
9-4. Clrcuft
Card, Motor Speed PC2
Part
No.
Dia.
Mkr~s
PC2
071 642
A50-53
C50
C51
009
039
031
073
035
005
C52,61
C53,62
C54
055,66-75,77
C56
C57
C60
C63,64
C65
CR50
D50-54,56-60
D55
1C50
050,53
051
Q52
R50
Note 1
R52,56,61
R53
Note 2
R59
R60,87,88
R63,79
R64
R70
R73,83
R77
R78
R80
R81,84
R85
R86
T50
VR5O
VR51
NOTE 1: R51
031
073
007
035
044
031
095
091
079
026
080
159
482
699
739
833
023
643
549
742
561
602
721
Description
FIgure
9-4. CIrcuit
IC, linear 358
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
Quantity
Card, Motor, Speed (FIg 9-3 item 8)
3
elctlt lOOuf 35VDC
mylar .0022uf 200 VDC
cer luf 50V
861
SOCKET, relay
SPRING, holddown-relay
DIODE, 1A 400V SP
DIODE, zener 15V 5W
IC, interface 2907
TRANSISTOR, 200MA 40V NPN
THYRISTOR, SCR 7.4A 200V
TRANSISTOR, uni junction 15MA 40V
RESISTOR, WW fxd 5W 220 ohm
039 355
030 839
035827
052 138
039 332
035 884
030 007
039 335
039 106
039 331
049 015
039 328
052 142
039 108
035 886
035825
030 937
030 090
092 648
085 399
081 799
047272
end
RESISTOR,
I
12
1
1
1
2
i
24VAC 4PDT
RELAY,
081 800
037 200
037 824
1
2
2
mylar .033uf IOOVDC
tantim 2.2u1 20V
cer .Oluf 500 VDC
mylar .Ol5uf 200V
elctlt lOut 35V
mylar 4uf 200V
CAPACITOR, poly film .47uf 400 VOC
CAPACITOR, mylar .22uf 200VDC
033
844
202
910
1
1
1
1
10
1
1
2
I
I
1
.25W 10K ohm
10
.25W 20K ohm
.25W 15K ohm
.25W lOOK ohm
POTENTIOMETER, cermet 15/T .75W 50K ohm
RESISTOR, CF .25W 47K ohm
RESISTOR, CF .25W 470 ohm
RESISTOR, CF .25W 4700 ohm
RESISTOR, CF .25W 1 meg ohm
RESISTOR, CF .25W 1500 ohm
RESISTOR, CF .25W 120K ohm
RESISTOR, CF .25W 82K ohm
RESISTOR, CF .25W 22K ohm
RESISTOR, CF .25W 1K ohm
RESISTOR, C .5W 10 ohm
RESISTOR, C .5W 47 ohm
RESISTOR, CF .25W zero ohm
3
CF
RESISTOR, CF
RESISTOR, CF
RESISTOR, CF
1
8
1
3
2
I
1
2
1
1
I
2
I
1
15
TRANSFORMER, pulse
IC, linear 78L08
IC, linear 78L12
I
1
1
.54,55,57,67,68,14,75,82,89
NOTE 2: R58,62,65,66,71,72,,76,90
BE SURE TO PROVIDE MODEL
A~JD SERIAL NUMBER WHEN ORDERING
REPLACEMENT PARTS.
OM-1548
Page
39
Part
No.
Dia.
Mkas.
PC5
Description
Figure
094 818
CR51 ,52,55,56
CR53
CR54
R50
R51
RC5O
RC51
RC52
RC53
RC54
095
093
095
095
095
092
048
079
079
072
079
033
558
521
823
822
648
105
795
759
670
749
091 861
079 844
9-5. CircuIt
Quantity
Card, Relay (Fig 9-3 item 1)
RELAY, end 24VAC 4PDT
RELAY, end 12OVAC 4PDT
RELAY, end 24VAC 4PDT
RESISTOR, MF .25W 44.8K ohm
RESISTOR, MF .25W 5K ohm
RESISTOR, CF .25W zero ohm
TERMINAL, header 7 pin
TERMINAL, header 13 pin
TERMINAL, header 12 pin
TERMINAL, header 9 pin
TERMINAL, header 18 pin
SOCKET, relay
SPRING, holddown-relay
0
4
1
1
1
1
2
1
1
1
1
1
7
6
I)~-I
ABC
~Z
<<<~<<<
DEFG
1
ii
RC5OI
RC 51
CR5Z
RC52
BA
3B
3C
0
3E
BF
I
BG
I
3H
A55 Y
BJ
BK
BL
R CS 3
0
B094 819
FIgure
9-5. CIrcuit
Card, Relay
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1548
Page
40
Item
No.
Dia.
Mkas.
PC3
Part
No.
085 268
3
097 922
080 242
079 684
4
Fig9-7
1
2
Description
Quantity
Figure 9-6. Circuit Card,
Timer
(Fig 9-1
item
51)
KNOB, pointer
PLATE, md
BRACKET, mtg-timer
5
1
1
1
CIRCUITCARD
4Fig
9-7
2
18.080 368.A
Figure
9-6. Circuit
Card, Timer PC3
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1548
Page
41
Dia.
Mkos.
Part
No.
Description
PC3
A50-52
C50
C51 ,52,54
C53,55
C56
CR5O-56
D50-57,59-71
D58
050-55
R50,64,68
R51,81-84
R52
R53,59,60-62,65,
71-73, 77,80
R54,63,69,
70,78,79
R55,56
R57,58,66,
67,74,75
R76
-
S50
A~CO
FIgure
Quantity
9-7. CircuIt Card
(FIg
9-6 Item
4)
009 159
039 482
005 023
031 677
073 714
095 521
091 861
079 844
026 202
037 449
073 535
039 332
082 708
030018
IC, linear 358
CAPACITOR, elctlt lOOuf 35VDC
CAPACITOR, tantim 2.2uf 20V
CAPACITOR, tantlm 5.6uf 35VDC
CAPACITOR, tantim .22uf 35V
RELAY, end 24VDC 4PDT
SOCKET, relay l4skt
SPRING, hoiddown relay
DIODE, 1A 400V SP
DIODE, zener iSV 1W SP
TRANSISTOR, 100MA 30V NPN
RESISTOR, CF .25W 15K ohm
POTENTIOMETER, WW 1W 1 meg ohm
RESISTOR, C 1W820 ohm
035 827
RESISTOR, CF .25W 10K ohm
11
035 886
035 823
RESISTOR, CF .25W 22K ohm
RESISTOR, CF .25W 100 ohm
6
605912
053 572
092 648
079 795
079 793
079 794
079 722
RESISTOR,
RESISTOR,
RESISTOR,
TERMINAL,
TERMINAL,
TERMINAL,
6
~
3
1
3
2
1
7
7
7
21
I
6
3
5
1
2
C .25W 4700 ohm
CF .25W 12K ohm
WW fxd zero ohm
header 13 pin
header 4 pin
header 3 pin
SWITCH, tgi SPDT 4A 2-4VDC
G~
I
2
1
1
1
1
51
H
VW
Z~A
B6CC
Ref. D-097 726-8
FIgure
9-7. CIrcuit Card
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1548 Page 42
Item
1…1n
Dia.
Mkns.
Part
No.
070 183
I
2
RC16
Reed
3
4
5
6
7
8
9
10
11
12
13
14
15
GS1
090 246
079 535
079 687
604 525
057091
+079 682
123 154
010494
057 358
601 158
010 604
602 934
079 573
079 686
079574
003 538
Description
Quantity
FIgure 9-8 Control, Gas/Shunt
RECEPTACLE W/PINS, (consisting of)
TER.~INAL, male
RELAY, current (consisting of)
1
9
I
CORD, No. 18 2/c (order by ft)
SWITCH, reed SPST
ift
1
I
WRAPPER
LABEL, warning general precautionary
BUSHING, snap 1-3/8 ID x 1-3/4 mtg hole
BUSHING, snap 1 ID 1-3/8 mtg hole
2
BLANK, snap-in 7/8 in
2
FITTING, hose-brs bushing 1/4 NPT x 5/8-18 RH
FITTING, pipe-galv coupling 1/4 NPT
FITTING, pipe-galv nipple L 1/4 NPT x 6
2
1
2
1
1
CASE SECTION, bottom/front/sides
1
BRACKET, mtg-component
VALVE, 115VAC 2 way 1/4 IPS port 1/8 ort
2
1
6
Ret. TC-080 385-A
FIgure
9-8.
Control, Gas/Shunt
+When
ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1548
Page
43
Item
No.
Dia.
Mkas.
Part
No.
Description
Figure
072 094
058 428
1
2
058.628
010191
085 980
057 971
010 233
072 292
058 427
+092 989
3
4
5
6
7
8
9
10
121 316
9-9. Hub &
HUB & SPINDLE,
.
Quantity
Spindle Assembly
(consisting of)
1
HUB, spool
WASHER, steel-brake
WASHER,fiber5/8lDxl-1/200x 1/8
NUT, hex 5/8-11
1
2
2
1
WASHER, flat-keyed I -1/2dia
SPRING, compression
SHAFT, spool-Support
RING, retaining-spool
SUPPORT, spindle (consisting of)
LABEL, warning general precautionary
1
1
1
I
.
1
I
6 thru 9
10
18-070884
Figure
When
9-9. Hub &
Spindle Assembly
ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM.1548
Page
44
Item
No.
Part
Dia.
Mkcis.
108 008
124904
124905
124900
1
2
3
Quantity
Description
No
FIgure 9-10 Reel,
Wire
1
NUT, spanner spool support
RETAINER, spool support
SUPPORT, reel spool
-
1
-
1
-
2
3
If~2E
o
A
B C
ASSY
R50
TC-127
FIgure
0
o
9-10. Reel, Wire
_
RC I 8
A-tOO 475
Figure
9-11. CircuIt Card Low
Speed
Motor Calibration PC8
Dia.
RAL-ric
Part
No.
Description
Figure
R50
RC18
S50
039 360
079 794
109 285
9-11. CIrcuit Card Low
Quantity
Speed Motor Calibrati on (Fig
9-1 Item 10)
POTENTIOMETER, cermet trmr 20/T .5W 25K ohm
TERMINAL, header 3 pin
SWITCH, dip SPOT
1
1
I
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1548
Page
45
Part
No.
Dia.
Mkqs.
Description
Quantity
Optional Equipment
096
095
079
079
603
028
097
080
003
010
602
079
096
095
080
108
048
CR50
PLG3
Ri 7,24
R25
WS1
185
033
844
796
856
770
922
594
538
605
934
573
183
709
584
008
471
121 694
117567
START CONTROL, run-in adjustable (consisting of)
RELAY, end 24VAC 4PDT
SPRING, hoiddown relay
HOUSING, term header 3 pin
POTENTIOMETER, WW sltd sit 10/T 2W 10K ohm
POTENTIOMETER, C sltd sft lIT 2W 1 meg ohm
.
KNOB, pointer
Page
46
1
1
1
1
1
3
WATER CONTROL KI 1~ (consisting of)
VALVE, 115VAC 2 way 1/4 IPS 1/8 orf
FITTING, hose brs bushing 1/4 NPT x .625-18 LH
FITTING, pipe galv coupling .25ONPSC
FITTING, pipe galv nipple L .25ONPT x 6.000
2
COVER, locking (consisting of)
1
COVER, control box
TAB, locking
REEL, wire (see Fig 9-10)
TOOL, extraction pin amp No. 305183
TOOL, extraction pin amp No. 91037-2-0
TOOL, extraction Amphenol poke home
1
.
.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1548
1
1
1
1
1
1
1
1
1
1