MillerOctober 1989 FORM: OM-1578

Effectlye With Serial Number JK697875

MODEL: AUTOMATIC 1 DA

Gas/Current Sensing Control

Hub & Spindle Assembly

Spool Support

OWNER�S MANUAL

IMPORTANT: 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 onlyby persons trained and experienced in the safe operation of welding equipment. Do not allow untrained persons to install, operate, or maintain this unit.

Contact your distributor if you do not fully understand these instructions.

MILLER ELECTRIC Mfg. Co.A Mifler Group Ltd. Company

P.O. Box 1079

Appleton, WI 54912 USA

Tel. 414-734-9821

PRINTED IN U.S.A

LIMITED WARRANTY

EFFECTIVE: MARCH 15, 1989

L

This warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.

�7

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 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 originalpurchase, except Tecumseh and Onan engines which have a

two year warranty.

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 includ

ing nozzles and nozzle insulators where failure does not result

from defect in workmanship or material.

Miller shall be required to honorwarrarity 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: -

1. Arc welders, power sources, robots, and 1 year

components2. Loadbanks lyear3. Original main power rectifiers 3 years

(labor � 1 year only)4. All welding guns, feeder/guns and torches

..90 days

5. All other Millermatic Feeders 1 year6. Replacement or repair parts, exclusive of labor 60 days7. Batteries 6 months

provided that Miller is notified in writing within thirty (30) days of

the date of such failure.

As a matter of general policy only, Miller may honor daims

submitted by the original user within the foregoing periods.

In the case of Miller�s breach of warranty or any other dutywithrespect to the quality of any goods, the exclusive remedies

therefore shall be, at Miller�s option (1) repair or (2) replacementor, 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 orcreditforthe purchaseprice (less reasonable depreciation based upon actual use)upon return of the goods at Customer�s risk and expense.MILLER�s option of repairor replacementwill be F.O.B., FactoryatAppleton, 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 apparentdefect or failure, Miller shall instruct the claimant on the war

ranty claim procedures to be followed.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN

AND ANY IMPLIED WARRANTY, GUARANTY OR REPRE

SENTATION AS TO PERFORMANCE, AND ANY REMEDY

FOR BREACH OF CONTRACTWHICH, BUT FORTHIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF

LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN

CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR PURPOSE,WITH RESPECT TO ANY AND ALL EQUIPMENT FUR

NISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY

MILLER.

EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN

WRITING, MILLER PRODUCTS ARE INTENDED FOR ULTI

MATE PURCHASE BY COMMERCIAL/INDUSTRIAL USERSAND FOR OPERATION BY PERSONS TRAINED AND EXPE

RIENCED IN THE USE AND MAINTENANCE OF WELDING

EQUIPMENT AND NOT FOR CONSUMERS OR CON

SUMER USE. MILLER�S WARRANTIES DO NOT EXTEND

TO, AND NO RESELLER IS AUTHORIZED TO EXTEND

MILLER�S WARRANTIES TO, ANY CONSUMER.

�II�

ERRATA SHEET

July 19, 1990 FORM: OM-1578

After this manual was printed, refinements in equipment design occurred. This sheet lists exceptionsto data appearing iater in this manual.

AMENDMENT TO SECTION 4�INSTALLATiON

Amend Section 4-3E. INTERNAL CONNECTIONS: Flux Valve Connections

Connect power leads for 115VAC flux valve transformer to terminals 1TC and 2TD in the weld control (polarity is not

important).

The flux valve energizes when the weld control START switch is pressed and deenergizes at the end of post flow.

AMENDMENT TO SECTION 8� ELECTRICAL DIAGRAMS

Amend Diagram 8-4. Circuit Diagram For Voltage Control Board PCi (see Page 2 of this Errata Sheet)

AMENDMENT TO SECTION 9� PARTS LIST

Amend Parts List as follows:

Dia.**

Mkgs.Part ReplacedNo. With Description Quantity

37-i PCi 130 153 +137 693 CIRCUIT CARD, voltage control (Effw/KA743941) 1

39- 121 684 +121 684 CAPACITOR, (qty chg added C75) 2

39- 035 888 +035 888 RESISTOR, (qty chg deleted R78,93) 2

39- 035 826 +035 826 RESISTOR, (qty chg deleted R63,69) 5

39- R63,78 Added +097 110 RESISTOR, MF .25W 1K ohm 2

39- 009 173 +009 173 POTENTIOMETER, (qty chg added R103) 3

39- R69 Added +108 437 RESISTOR, MF .25W 4.75 K ohm 1

39- R93 Added +091 799 RESISTOR, MF .25W 8.25 K ohm 1

39- R103 082178 +Deleted

44- 070 183 137 152 CONTROL, gas/current sensing (Eli w/KA811372) 1

44-2 Reed 079687 136595 RELAY,current(Effw/KA8ii372) 1

44-3 057 091 Deleted Eli w/KA81 1372

44-4 604 525 Deleted Eli w/KA81 1372

44-11 602 934 602 934 FITTING, (qty chg) (Eff w/KA811372) 2

44-12 079 573 602 920 FITTING, pipe galv nipple L .250 NPT x 2 (Eli w/KA811372) 2

44-13 079 686 136 851 CASE SECTION, bottom/front/sides (Eli w/KA811372) ...1

45-9 085 980 135 205 NUT, stl slf 1kg hex reg .625-11 1

**FirSt digit represents page no - digits following dash represent item no.

+Circuit card components (Fig 9-4) remain the same with listed exceptions.BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

CircuitDiagramNo.

C-133836

Diagram8-4.

CIrcuitDiagramFor

VoitageControiBoardPCi

EffectiveWithSerlaiNo.

KA743941

OM-1 578� 10/89

RECEIVING-HANDLING

Before unpacking equipment, check carton for any dam- Use the following spaces to record the Model Designaage that may have occurred during shipment. File any tion and Serial or Style Number of your unit. The infor

claims for loss or damage with the delIverIng carrier. mation is located on the data card or the nameplate.Assistance for filing or settling claims may be obtained

from the distributor and/or the equipment manufactur- Model_______________________________

er�s Transportation Department.Senal or Style No.

____________________

When requesting information about this equipment, al

ways provide the Model Description and Serial or Style Date of Purchase_____________________

Number.

TABLE OF CONTENTS

Section No. Page No.

SECTION 1 � SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE

1-1. Introduction 1

1-2. General Precautions 1

1-3. Arc Welding 4

1-4. Standards Booklet Index 5

SECTION 2� SAFETY PRECAUTIONS AND SIGNAL WORDS

2-1. General Information And Safety 6

2-2. Safety Alert Symbol And Signal Words 6

SECTION 3� SPECIFICATIONS

3-1. Description 7

SECTION 4� INSTALLATION

4-1. Site Selection 9

4-2. Equipment Installation 9

4-3. Internal Connections 10

4-4. Wire Drive Motor Speed Calibration Selection 12

4-5. Weld Control Interconnections 13

4-6. Gas/Current Sensing Control Interconnections 14

4-7. Welding Wire Installation 15

SECTION 5- OPERATOR CONTROLS

5-1. Power Switch And Pilot Light 15

5-2. Retract - Advance Switch And Jog Switch 15

5-3. Purge Switch 16

5-4. Start Switch 16

5-5. Stop Switch 16

5-6. Error Reset Button 16

5-7. Press To Set Buttons 16

5-8. Digital Meters 17

5-9. Run In Wire Speed Control 17

5-10. Weld Wire Speed Control 17

5-11. Weld Voltage Control 17

Section No. Page No.

SECTION 5� OPERATOR CONTROLS (Continued)

5-12. Crater & Jog Wire Speed Control 17

5-13. Crater Voltage Control 17

5-14. Preflow Time Control 17

5-15. Spot - Continuous Switch 18

5-16. Spot Time Control 18

5-17. Crater Time Control 18

5-18. Burnback Control 18

5-19. Postflow Time Control 18

5-20. Optional Run In Controls 18

SECTION 6� SEQUENCE OF OPERATION

6-1. Gas Metal Arc Welding (GMAW) And

Flux Cored Arc Welding (FCAW) - Continuous 19

6-2. Gas Metal Arc Welding (GMAW) And

Flux Cored Arc Welding (FCAW) - Spot 19

6-3. Shutting Down 19

SECTION 7� MAINTENANCE & TROUBLESHOOTING

7-1. Routine Maintenance 20

7-2. Overload Protection 20

7-3. Hub Reinstallation 20

7-4. Circuit Board Handling Precautions 21

7-5. Troubleshooting 21

SECTION 8� ELECTRICAL DIAGRAMS

Diagram 8-1. Circuit Diagram 23

Diagram 8-2. Wiring Diagram 24

Diagram 8-3. Circuit Diagram For Models With Run In Option 26

Diagram 8-4. Circuit Diagram For Voltage Control Board PCi 27

Diagram 8-5. Circuit Diagram For Motor Control Board PC2 28

Diagram 8-6. Circuit Diagram For Timer Board PC3 29

Diagram 8-7. Circuit Diagram For Tach Board PC4 30

Diagram 8-8. Circuit Diagram For Low Speed Calibration Board PC8 30

SECTION 9� PARTS LIST

Figure 9-1. Control Box 32

Figure 9-2. Meter, Digital Volt 35

Figure 9-3. Panel, W/Components 36

Figure 9-4. Circuit Card, Voltage Control PCi 38

Figure 9-5. Circuit Card, Motor Speed PC2 40

Figure 9-6. Timer PC3 42

Figure 9-7. Circuit Card 43

Figure 9-8. Control, Gas/Current Sensing 44

Figure 9-9. Hub & Spindle Assembly 45

LIST OF CHARTS AND TABLES

Table 3-1. Specifications 7

Table 3-2. Weld Parameters 7

Table 7-i. Troubleshooting 21

SECTION 1 � SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE

1-1. INTRODUCTION

We learn by experience. Learning safety through personal experience, like a child touching a hot stove is

harmful, wasteful, and unwise. Let the experience of oth

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, operation, 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 requiretechnical 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 safetyare also available for additional and more complete procedures than those given in this manual. They are listed

in the Standards Index inthis manual. ANSI Z49.1 is the

most complete.

The National Electrical Code, Occupational Safety andHealth Administration, local industrial codes, and local

inspection requirements also provide a basis for equipment 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 electrode manufacturers Material Safety Data Sheets (MSDSs) for

specific technical data and precautionary measuresconcerning 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 flaps, and wear cuffless trousersto avoid 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

welding or cutting, (and chipping) to protect the eyesfrom 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 workpiecesshould never be handled without gloves.

Medical first aid and eye treatment. First aid facilities and

a qualified first aid person should be available for each

shift unless medical facilities are close by for immediate

treatment of flash burns of the eyes and skin burns.

Ear plugs should be worn when working on overhead or

in a confined space. A hard hat should be worn when

others work overhead.

Flammable hair preparations should not be used by persons intending to weld or cut.

B. Toxic Fume Prevention

Severe discomfort, illness or death can result from

fumes, vapors, heat, or oxygen enrichment or depletionthat welding (orcutting) may produce. Prevent them with

adequate ventilation as described in ANSI Standard

Z49.1 listed 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. Adequatelocal exhaust ventilation must be used, or each person in

the area as well as the operator must wear an air-supplied respirator. For beryllium, both must be used.

Metals coated with or containing materials that emit toxic

fumes should not be heated unless coating is removedfrom 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 respirato r.

Gas leaks in a confined space should be avoided.

Leaked gas in large quantities can change oxygen concentration dangerously. Do not bring gas cylinders into aconfined space.

Leaving confined space, shut OFF gas supply at source

to prevent possible accumulation of gases in the space if

downstream valves have been accidentally opened or

left open. Check to be sure that the space is safe before

re-entering it.

Vapors from chlorinated solvents can be decomposedby the heat of the arc (or flame) to form PHOSGENE, a

highly toxic gas, and other lung and eye irritating products. The ultraviolet (radiant) energy of the arc can also

decompose trichloroethylene and perchloroethylenevapors to form phosgene. DO NOT WELD or cut wheresolvent vapors can be drawn into the welding or cuttingatmosphere or where the radiant energy can penetrate

OM-1 578 Page 1

to atmospheres containing even minute amounts of

trichioroethylene or perchloroethylene.

C. Fire and Explosion Prevention

Causes of fire and explosion are: combustibles reached

by the arc, flame, flying sparks, hot slag or heated mate

rial; 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 tires 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 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 extin

guishing equipment during and for some time afterweld

ing or cutting if:

a. appreciable combustibles (including buildingconstruction) 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 orwalls

within 35 feet may expose combustibles to

sparks

d. combustibles adjacent to walls, ceilings, roofs,or metal partitions can be ignited by radiant or

conducted heat.

Hot work permit should be obtained before operation to

ensure supervisor�s approval that adequate precautionshave 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 firstbeen cleaned as described in AWS Standard A6.O, listed7 in Standards Index.

This includes: a thorough steam or caustic cleaning (orasolvent or water washing, depending on the combustible�s solubility) followed by purging and inerting with ni

trogen or carbon dioxide, and using protective equip-

ment as recommended in A6.O. Waterlilling just below

working level may substitute for inerting.

A container with unknown contents should be cleaned

(see preceding paragraph). Do NOT depend on sense of

smell or sight to determine if it is safe to weld or cut.

Hollow castings or containers must be vented before

welding or cutting. They can explode.

Explosive atmospheres. Never weld or cut where the air

may contain flammable dust, gas, or liquid vapors (suchas gasoline).

D. Compressed Gas EquIpment

Standard precautions. Comply with precautions in this

manual, and those detailed in CGA Standard P-i, SAFEHANDLING OF COMPRESSED GASES IN CYLIN

DERS, listed 11 in Standards Index.

1. Pressure Regulators

Regulator relief valve is designed to protect only the

regulator from overpressure; it is not intended to protectany downstream equipment. Provide such protectionwith one or more relief devices.

Never connect a regulator to a cylinder containing gasother than that for which the regulator was designed.

Remove faulty regulatorfrom service immediately for re

pair (first close cylinder valve). The following symptomsindicate a faulty regulator:

Leaks-it 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 pinwhen pressurized, nor returns to stop pin after pressurerelease.

Repair. Do NOT attempt to repair. Send faulty regulatorsfor 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 includingthird rails, electrical wires, or welding circuits. They can

produce short circuit arcs that may lead to a serious accident. (See 1-3C.)

ICC or DOT marking must be on each cylinder. It is an

assurance of safety when the cylinder is properly handled.

Identifying gas content. Use only cylinders with name of

gas marked on them; do not rely on color to identify gascontent. Notify supplier if unmarked. NEVER DEFACEor alter name, number, or other markings on a cylinder, Itis illegal and hazardous.

Empties: Keep valves closed, replace caps securely;mark MI; keep them separate from FULLS and return

promptly.OM-1578 Page 2

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 orcradie. 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 130°F. Cool with water spray

where such exposure exists.

Protect cylinders particularly valves from bumps, falls,

falling objects, and weather. Replace caps securelywhen moving cylinders.

Stuck valve. Do NOT use a hammer orwrench to open a

cylinder valve that can not be opened by hand. Notify

your supplier.

Mixing gases. Never try to mix any gases in a cylinder.

Never refill any cylinder.

Cylinder fittings should never be modified or exchanged.

3. Hose

Prohibited use. Never use hose other than that designedfor 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 tubing splices. Use only standard brass fit

tings to splice hose.

Avoid long runs to prevent kinks and abuse. Suspendhose off ground to keep it from being run over, steppedon, or otherwise damaged.

Coil excess hose to prevent kinks and tangles.

Protect hose from damage by sharp edges, and bysparks, slag, and open flame.

Examine hose regularly for leaks, wear, and loose con

nections. Immerse pressured hose in water; bubbles in

dicate leaks.

Repair leaky or worn hose by cutting area out and splicing (1-2D3). Do NOT tape.

4. Proper Connections

Clean cylinder valve outlet of impurities that may clogorifices and damage seats before connecting regulator.Except for hydrogen, crack valve momentarily, pointing

outlet away from people and sources of ignition. Wipewith a clean lintless cloth.

Match regulator to cylinder. Before connecting, check

that the regulator label and cylinder marking area, and

thatthe regulatorinlet and cylinderoutlet match. NEVERCONNECT 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.

lighten. If connection leaks, disassemble, clean, and

retighten using property fitting wrench.

Adapters. Use a CGA adapter (available from your sup

plier) between cylinder and regulator, if one is required.usetwowrenchestotighten adaptermarked RIGHTandLEFT HAND threads.

Regulatoroutlet (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 allowingseat 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 (gaugereaches regulator maximum) leave cylinder valve in fol

lowing position: For oxygen, and inert gases, open fullyto 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 regularlythere-after. Brush with soap solution (capfull of Ivory Liquid* or equivalent per gallon of water). Bubbles indicate

leak. Clean off soapy water after test; dried soap is com

bustible.

E. User ResponsibilitIes

Remove leaky or defective equipment from service im

mediately for repair. See User Responsibility statement

in equipment manual.

F. Leaving Equipment Unattended

Close gas supply at source and drain gas.

C. Rope Staging-Support

Rope staging-support should not be used for welding or

cutting operation; rope may burn.

*Trademark of Proctor & Gamble.

OM-1 578 Page 3

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 in

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. Burn Protection

Comply with precautions in 1-2.

The welding arc is intense and visibly bright. Its radiation

can damage eyes, penetrate lightweight clothing, reflect

from light-colored surfaces, and burn the skin and eyes.Skin burns resemble acute sunburn, those from gas-shielded arcs are more severe and painful. DON�T GET

BURNED; COMPLY WITH PRECAUTIONS.

1. Protective Clothing

Wear long-sleeve clothing (particularly for gas-shieldedarc) in addition to gloves, hat, and shoes (1 -2A). As nec

essary, use additional protective clothing such as

leatherjacket or sleeves, flame-proof apron, and fire-re

sistant leggings. Avoid outer garments of untreated cot

ton.

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 shadeno. 12 ordenser must be used when welding. Place overface 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 replacedIMMEDIATELY. Replace clear cover plate when broken,pitted, or spattered.

Flash goggles with side shields MUST be worn underthe helmet to give some protection to the eyes should thehelmet not be lowered over the face before an arc isstruck. Looking at an arc momentarily with unprotectedeyes (particularly a high intensity gas-shielded arc) cancause a retinal burn that may leave a permanent darkarea 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, sur

round the operation with low-reflective, non-combustible screens or panels. Allow for free air circulation, particularly at floor level.

Viewing the weld. Provide face shields for all personswho will be looking directly at the weld.

Others working in area. See that all persons are wearingflash 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 weldingequipment. 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 ves

sel. It creates a brittle area that can cause a violent nipture or lead to such a rupture under rough handling.

D. Compressed Gas Equipment

Comply with precautions in 1-2D.

E. Shock Prevention

Exposed hot conductors or other bare metal in the weld

ing circuit, or in ungrounded, electrically-HOT equipment can fatally shock a person whose body becomes a

conductor. DO NOT STAND, SIT, LIE, LEAN ON, ORTOUCH a wet surface when welding, without suitable

protection.

To protect against shock:

Wear dry insulating gloves and body protection. Keepbody 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

can not be avoided. Sweat, sea water, or moisture between body and an electrically HOT part or groundedmetal reduces the electrical resistance, and could enable dangerous and possibly lethal currents to flow

through the body.

A 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, electrical tools, work benches, welding power source cases,

workpieces, etc. Never touch the electrode and anymetal object unless the welding power source Is off.

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 WeldingAnd Cutting.�

When installing, connect the frames of each unit such as

welding power source, control, worktable, and watercirculatorto the building ground. Conductors must be ade

quate to carry ground currents safely. Equipment madeOM-1578 Page 4

electrically HOT by stray current may shock, possibly fa

tally. Do NOT GROUND to electrical conduit, orto a pipecarrying ANY gas or flammable liquid 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 equipment ground lead to the third (live) wire, or the equipment 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 equipmentframes 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-prongplug 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 three-

prong plug, connect to a grounded mating receptacle.Never remove the ground prong from a plug, or use a

plug with a broken off ground prong.

2. Electrode Holders

Fully insulated electrode holders should be used. Do

NOT use holders with protruding screws.

3. Connectors

Fully insulated lock-type connectors should be used to

join welding cable lengths.

4. Cables

Frequently inspect cables for wear, cracks and damage.IMMEDIATELY REPLACE those with excessively wornor 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 protectedfrom 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 (contactor)

Welding power sources for use with the gasmetal arc welding (GMAW), gas tungsten arc

welding (GTAW) and similar processes nor

mally are equipped with devices that permit onoff 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 object in contact with the electrode circuit unless

the welding power source is off.

b. Equipment without output on/off control (nocontactor)

Welding power sources used with shielded

metal arc welding (SMAW) and similar processes may not be equipped with welding poweroutput 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 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

pull all 115 volts line-cord plugs.

Do not open power circuit or change polarity while weld

ing. If, in an emergency, it must be disconnected, guardagainst 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.

F. Protection For Wearers of Electronic Life Support Devices (Pacemakers)

Magnetic fields from high currents can affect pacemakeroperation. Persons wearing electronic life supportequipment (pacemaker) should consult with their doctor

before going near arc welding, gouging, or spot weldingoperations.

1-4. STANDARDS BOOKLET INDEX

For more information, refer to the following standards or

their latest revisions and comply as applicable:

1. ANSI Standard Z49.1, SAFETY IN WELDING AND

CUTTING obtainable from the American WeldingSociety, 550 N.W. LeJeune Rd, Miami, FL 33126.

2. NIOSH, SAFETY AND HEALTH IN ARC WELDING

AND GAS WELDING AND CUTTING obtainable

from the Superintendent of Documents, U.S. Gov

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 obtainablefromthe AmericanNational Standards Institute, 1430 Broadway, New

York, NY 10018.

5. ANSI Standard Z41.1, STANDARD FOR MEN�S

SAFETY-TOE FOOTWEAR obtainable from the

American National Standards Institute, 1430 Broad

way, New York, NY 10018.

6. ANSi Standard Z49.2, FIRE PREVENTION IN THE

USE OF CUTTING AND WELDING PROCESSES

OM-1578 Page 5

obtainable from the American National Standards

Institute, 1430 Broadway, New York, NY 10018.

7. AWS Standard A6.0, WELDING AND CUTTING

CONTAINERS WHICH HAVE HELD COMBUS

TIBLES obtainable from the American Welding So

ciety, 550 N.W. LeJeune Rd, Miami, FL 33126.

8. 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.

9. NFPA Standard 70, NATIONAL ELECTRICAL

CODE obtainable from the National Fire Protection

Association, Batterymarch Park, Quincy, MA

02269.

10. NFPA Standard 51B, CUTTING AND WELDING

PROCESSES obtainable from the National Fire

Protection Association, Batterymarch Park, Qul ncy,MA 02269.

11. CGA Pamphlet P-i, SAFE HANDLING OF COM

PRESSED GASES IN CYLINDERS obtainable

fromthe Compressed Gas Association, 1235 Jeffer

son Davis Highway, Suite 501, Arlington, VA 22202.

12. CSA Standard W117.2, CODE FOR SAFETY IN

WELDING AND CUTTING obtainable from the Ca

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 SupplyAssociation, 1900 Arch Street, Philadelphia, PA

19103.

14. American Welding Society Standard AWSF4.1,RECOMMENDED SAFE PRACTICES FOR THE

PREPARATION FOR WELDING AND CUTTING

OF CONTAINERS AND PIPING THAT HAVE HELD

HAZARDOUS SUBSTANCES, obtainable from the

American Welding Society, 550 N.W. LeJeune Rd,

Miami, FL 33126.

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 equipmentdesign, installation, operation, maintenance, and

troubleshooting which should be read, understood, and

followed for the safe and effective use of this equipment.

B. Safety

The installation, operation, maintenance, and trouble

shooting of arc welding equipment requires practicesand procedures which ensure personal safety and the

safety of others. Therefore, this equipment is to be in

stalled, operated, and maintained only by qualified persons in accordance with this manual and all applicablecodes such as, but not limited to, those listed at the end

of Section 1 � Safety Rules For Operation Of Arc Weld

ing Power Source.

2-2. SAFETY ALERT SYMBOL AND SIGNAL

WORDS

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 signalwords WARNING and CAUTION to call atten

tion to the safety statements.

a WARNING statements identify procedures or

practices which must be followed to avoid senous personal injury or loss of life.

a CAUTION statements identify procedures or

practices which must be followed to avoid minor

personal injury or damage to this equipment.

IMPORTANT statements identify special instructions

necessary for the most efficient operation of this equipment.

OM-1578 Page 6

SECTION 3- SPECIFICATIONS

Table 3-1. SpecIfications

Component

Dimensions Weight

Height Width Depth Net Ship

Weld Control17-1/2 in.

(445 mm)

14 in.

(355 mm)8in.�

(203 mm)

32-1/2 lbs.

(14.7 kg)

Total 80 Ibs.*

(36 kg)

Gas/Current

Sensing Control

4-1/2 in.

(108 mm)5-1/2 in.

(140 mm)

10-1/2 in.

(267 mm)4-1/2 lbs.

(2.0 kg)

Spool SupportAssembly÷

13-31/2 in.

(343 mm)8-3/4 in.

(222 mm)

8-1/2 in.

(216 mm)

6 lbs.

(2.7 kg)

� Add 1 in. (25 mm) for control knobs. +Spool Support without optional wire reel.

* Includes weight of wire drive assembly.

Al D-2 Al D-4

50-780 ipm(1.8-19.8 mpm).023-3/32 in. wire

Wire Feed

Speed Range

(0.6-2.4 mm wire)

Al D-2L Al D-4L. 15-200 ipm

(0.4-5.1 mpm)5/64-5/32 in. wire

(2.0-4.0 mm wire)

Weld Voltage AndAmperage Capacity

.

Limited by welding power source.

3-1. DESCRIPTION

This weld control is designed to automatically cyclewelding events while maintaining constant wire feed

speed. This unit is to be used with a DC constant voltage(CV) welding power source having remote contactor and

voltage control capabilities for Gas Metal Arc Welding(GMAW) or Submerged Arc Welding (SAW).

The standard weld control has provisions to set weld

parameters according to Table 3-2. Spot weld controls

are also standard.

Normally-open and normally-closed relay contacts that

work in conjunction with the weld cycle are available to

interface with other equipment (such as fixtures).

Optional controls include run in voltage and time, and

water valve.

Table 3-2. Weld Parameters

Weld Cycle

Controls

Wire Speed Voltage. Time

Preflow X

Run-In X � �

Weld X X

Crater (Jog) X X X

Burnback X

Postflow X

X = Standard � Optional

For information on the wire drive assembly, see Owner�sManual supplied with the wire drive assembly.

A gas/current sensing control, wire spool hub, and

spindle support are provided with the weld control. Thewire reel is optional.

OM-1578 Page 7

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

Figure 3-1. DImensional Views

19-080 486-C

TA-080 485-A

*Add 1 in. (25 mm)for front panel controls.

TC-070 484-E

AUTOMATIC IDA Weld Control Gas/Current Sensing Control

TA-080 429

OM-1578 Page 8

SECTION 4-INSTALLATION

4-1. SITE SELECTION (Figure 3-1 And Figure 4-1)

Select an installation site which provides the following:

1. Correct input power supply (see unit nameplate)

2. Shielding gas supply (if applicable)

3. Water supply (if applicable)

4. Adequate ventilation and fresh air supply

5. No flammables

6. A clean and dry area

7. Proper temperature that avoids extremes of heat or

cold

8. Proper airflow around unit

9. Adequate space to open and remove cover and

wrapper for installation, maintenance, and repairfunctions.

Mounting holes provide the capability to install and se

cure the system components in a permanent location.

Figure 3-1 gives overall dimensions and mounting hole

layout.

4-2. EQUIPMENT INSTALLATION

A. Supplied Equipment

The following equipment is supplied as standard and re

quires installation or assembly:

1. Weld Control

2. Gas/Current Sensing Control

3. Hub and Spindle Assembly

4. Spindle Support

5. 10 ft. (3 m) Weld Control � Gas/Current SensingControl Interconnecting Cord

~ ,Weld Control

Control fl I ~

L_J_~~~ 1 J:1~..-wire Drive

L i ~j Assembly

~ rLI1

Welding Ir~Power Source

I

Typical Side

Beam ApplicatIon

I

6. 25 ft. (8 m) Weld Control � Welding Power Source

Interconnecting Cord

7. 5ft.(1.5 m) Motor Cord

8. 25 ft. (8 m) Voltage Sensing Cord

9. lOft.(3m)GasHose

B. EquIpment Location (FIgure 4-1)

When deciding on equipment location, consider the fol

lowing:

1. The equipment must be mounted to a structure ca

pable of supporting the weight of the equipment.

2. The lead lengths of the cords supplied with the

equipment will limit the area in which the equipmentcan be located. Some cords can be extended by using optional extension cords (check with weldingequipment distributor).

3. The interconnecting cords must be routed so that

they are not caught, pinched, or strained duringwelding operations.

4. One weld output cable must be routed to the Gas/

Current Sensing control.

5. Welding wire must be routed so that it does not con

tact the weld control or any other grounded equipment.

C. EquIpment InstallatIon

Obtain appropriate mounting brackets or adapter platesas necessary and mounting hardware. Prepare struc

ture for equipment installation. Secure weld control,Gas/Current Sensing control, and all other equipmentonto structures in the welding area.

Weld

I

Welding Power

Source

TC-131 138

Figure 4-1. Equipment Location Diagram

OM-1578 Page 9

D. Hub And Spindle installation To Spindle Sup

port (Figure 4-2)

1. 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 dependson wire spool size. Be sure 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 Section 4-6.

4-3. INTERNAL CONNECTIONS

There are fourtermi nal strips in the weld control to which

external equipment can 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

welding application.

External customer supplied remote start/stop devices

can be connected to the weld control. External customer

supplied devices (such as fixtures) can access relaycontacts that change state in conjunction with the weld

cycle. An automatic flux valve can be connected to the

weld control for Submerged Arc Welding (SAW). The optional water valve can be reconnected to operate simul

taneously with the gas valve. (See Section 4-6 for nor

mal operation of optional water valve.)

Determine the need for these connections based on the

welding application, and proceed as follows:

4~ WARNING: ELECTRIC SHOCK can kill.

� Do not touch live electrical parts.

� Shut down weld control and welding power

source, and disconnect input power employinglockout/tagging procedures before inspecting orins falling.

Lockout/tagging procedures consist of padlocking line disconnect switch in open position,removing fuses from fuse box, or shutting off and

red-tagging circuit breaker or other disconnect

ing device.

ELECTROSTATIC DISCHARGE (ESD) can

damage circuit boards.

� Put on properly grounded wrist strapBEFORE working near circuit boards.

� Perform work only 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

tion is complete.

A. Remote Start/Stop Switch Connections

(Figure 4-3)

Two momentary-contact push-button switches are re

quired for remote start/stop control. A normally-openswitch is required for start control while a normally-closed switch is required for stop control.

1. Install remote switches at desired location, obtain

proper length cable, and make connections to re

mote switches.

3. Connect leads from normally-open start switch to

1TF (common) and 1TH.

4. Connect leads from normally-closed stop switch to

1TF (common) and 1TG.

B. Remote Start/Stop Relay (Maintained Contact)Connections (Figure 4-3)

A set of contacts from a suitable relay can be used for

start/stop control of the weld cycle. Closing the relaycontact (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 lengthcable, and make connections to the normally-openset of contacts.

2. Locate terminal strip 1 Tin the weld control, and re

move jumper link between 1TE and 1TF.

3. Connect leads to 1TF (common) and 1TH.

Retaining RingWire Retainer*

-Washer

Fiber

Was her

*Optlonai

Washer

Figure 4-2. Hub And Spindle Installation

2. Locate terminal strip iT in weld control, and removeTD-045315-J

jumper link between 1TF and 1TG.

OM-1578 Page 10

Welding Start/Stop Connections

And Figure 4-4) (Uses Spot Time Con-

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 preflow and postf lowtimers determines the skip time (time between weld

cycles). The spot weld cycle repeats until the switch is

opened.Double-Pole

Single-Throw Switch

Figure 4-4. Skip Welding Switch Connections

1. Install switch at desired location, obtain proper

length cable, and make connections at switch (seeFigure 4-4).

2. Locate terminal strips 1 T and 2T in weld control, and

remove jumper link between 1TE and 1TF.

Motor SpeedDIP Switch S50

3. Connect switch common to 1 TF.

4. Connect remaining leads to lIE and 2TA.

5. Place the SPOT-CONTINUOUS switch inthe SPOT

position before starting skip welding.

D. Relay Contact Connections For Externai Equipment (Figure 4-3 And Figure 4-5)

A set of normally-open and normally-closed contacts are

provided to work in conjunction with the weld cycle timers. Forexample, if a fixture needs to start moving at arc

initiation and stop when the STOP switch is pressed, the

normally-open contacts of relay CR51 (at receptacleRC4, terminals F and H) would be used to control fixture

movement.

Connections can be made to the 3/16 in. male friction

terminals on timing board edge connector receptaclesRC4 and RC1 0. To gain access to these receptacles, the

timing circuit board needs to be removed.

1. Remove three screws securing timer panel.

2. Gently pull timer panel part way out.

3. Disconnect plugs PLG1 and PLG2 from the timer

circuit board.

4. Remove timer panel from weld control.

Terminal Strip iT

Board PC8

Receptacle RC1O

Receptacle RC4

Timing Circuit Board Assembly

liming

C. Skip(FIgure 43tro is)

Receptacle RC1 Location

Figure 4-3. Connection Strip Location

RC2 Location

Ret. TC-112 519

To Weld ControlTerminal Strips

2TA

1TE

1 TFS-0280

OM-1578 Page 11

5. 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 RC1 0.

6. After connections are made, reverse Steps 1

through 4 to reinstall timer panel.

E. Flux Valve Connections (FIgure 4-3)

Connect leads from flux valve to terminals 1 TC and ?TDin the weld control (polarity is not important).

The flux valve energizes when the weld control START

switch is pressed and deenergizes at the end of post-flow.

F. Reconnecting Water Valve Power (Figure 4-3)

If coolant flow is desired only in conjunction with shield

ing gas flow, reconnect power to the water valve as tot-

lows:

1. Locate terminal strips 11 and 21.

2. Locate lead 1 from gas/current sensing receptacleRC9 at 2TB and disconnect from 2TB.

3. Reconnect lead 1 at 1TC.

StartSwitchPressed

4-4. WIRE DRIVE MOTOR SPEED CALIBRATION

SELECTION (Figure 4-3)

a WARNING: ELECTRIC SHOCK can kill.

� Do not touch live electrical parts.

� Shut down weld control and welding power

source, and disconnect input power employinglockout/taggingprocedures before inspecting or

installing.

Lockout/tagging procedures consist of padlocking line disconnect switch in open position,removing fuses from fuse box, or shutting off and

red-tagging circuit breaker or other disconnect

ing device.

a CAUTION: ELECTROSTATIC DISCHARGE

(ESD) can damage circuit boards.

� Put on properly grounded wrist strapBEFORE handling circuit boards.

� Perform work only at a static-safe work area.

The weld control is shipped for use with a standard

speed wire drive motor (16.79:1 gear ratio). If a low

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:

Weld lime Or Spot Time

0-Infinity 0-2.5 Sec.

Crater lime0-2.5 SeC

Burnback Time

.

0-0.25 Sec.

0.

~~R5Q~ tCR5~ ~R5~ CR54 ~R% 1CR5~BT0 LE F

IH ~GvM

TL LK p yR xIw ~v CCTBB LM

RCIO

Fixture (Example explained in Section 4-3D.)

I,(

ICR56

CR55*

CR54*

CR5O*

CR51*

CR52

i��

- I III

� J ;

II.

F�

H

i~

Run inlime

Run In

Speed

PrefluxOrI- Preflow Tim

0-5 Sec.

I11

lime

SwitchPressed

*The dotted line condition indIcates the time during the weld cycle that the control relay is deenergized. The solid line condition Indicatesthe time during the weld cycle that the control relay Is energized. Ref. S.0271

FIgure 4-5. Weld Control Cycle

OM-1578 Page 12

1. Loosen screw securing door on upper panel of the

weld control, and open door.

2. Locate switch S50 on PC8. See Figure 4-3 for circuit

board location.

3. Place S50 in position 1 for low speed motor applications.

4. Close and secure weld control door.

If the switch is in the wrong position, the INCHES PER

MINUTE meter display is not accurate.

4-5. WELD CONTROL INTERCONNECTIONS

(FIgure 4-6 and FIgure 4-8)

a WARNING: ELECTRIC SHOCK can kill.

� Do not touch live electrical parts.

� Shut down weld control and welding power

source, and disconnect input power employinglockout�tagging procedures before inspecting orinstalling.

Lockout/tagging procedures consist of padlocking line disconnect switch in open position,removing fuses from fuse box, or shutting off and

red-tagging circuit breaker or other disconnect

ing device.

This unit is supplied with the necessary interconnectingcords. Examine and select the proper cord for each of

the following connections.

A. Drive Motor Connections

The 5 ft (1.5 m) motor cord has a 14-pin plug and

14-socket free-hanging receptacle. The 14-pin plug connects to the weld control. The 14-socket receptacle connects to the cord coming from the wire drive motor. To

make connections, align keyways, insert plugs into re

ceptacles, and rotate threaded collars fully clockwise.

B. Gas/Current SensIng Control Connections

The 10 ft. (3 m) interconnecting cord has a 14-pin plugand 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, alignkeyways, insert plugs into receptacles, and rotate

threaded collars fully clockwise.

C. Voltage Sensing Connection

Connect the 4-socket plug from the voltage sensing cordto the matching receptacle on the weld control as fol

lows: align keyway, insert plug into receptacle, and ro

tate threaded collar fully clockwise.

Connect the voltage sensing lead with ring terminal to

the wire drive assembly weld cable terminal. See wire

drive assembly Owner�s Manual for terminal location.

Connect the voltage sensing lead with clamp to the

workpiece. Be sure the clamp is connected to bare, drymetal.

D. ElectrIcal Input/Contactor ControlNoltage Control Connections

The 25 ft. (8 m) interconnecting cord has 14-socket and

14-pin plugs. The 14-socket plug connects to the weld

control. The 14-pin plug connects to the welding powersource. To make connections, align keyway, insert plugsinto receptacles, and rotate threaded collars fully clockwise.

Be sure remote contactor and voltage control switches

on the welding power source are in the correct position to

allow use of a remote control device.

FIgure 4-6. Cord Connections

IMPORTANT: If the supplied electrical input/contactorcontrol/voltage control cord does not match the weldingpower source remote control receptacle, obtain the nec

essary adapter cord from your welding equipment dis

tributor.

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: +10 volts dc with respect to Socket D re

quired from external source.

Socket D: Control circuit common for remote control

device from external source.

Socket E: Output Signal; 0 volts equals machine mini

mum; +10 volts equals machine maximum.

Socket G: 115 volts ac circuit common.

Socket I: Requires 115 volts ac, 60 Hz, with respectto socket G (circuit common).

Socket J: A contact closure from socket Ito socket J

completes the 115 volt circuit to the weldingpower source.

Socket K: Chassis ground.

IMPORTANT: The remaining sockets in the receptacleare not used.

�Voltage SensIng

Receptacle

~bIe Clamp

~WIre Drive

Sensing Control

Receptacle

Electrical lnput/Contactor Controi/

Voltage Control

Receptacle TC-070 484-E

OM-1578 Page 13

4-6. GAS/CURRENT SENSING CONTROL INTER

CONNECTIONS (FIgure 4-6)

A. Weld Output Connections

a WARNING: ELECTRIC SHOCK can kIll.

� Do not touch live electrical parts.

� Shut down weld control and welding powersource, and disconnect input power employinglockout/tagging procedures before inspecting orinstalling.

Lockout/tagging procedures consist of padlocking line disconnect switch in open position,removing fuses from fuse box, or shutting off and

red-tag9ing circuit breaker or other disconnect

ing device.

Select and prepare proper size and length weld cables

according to the welding power source Owner�s Manual.

Remove cover from Gas/Current Sensing control.

1. Electrode Positive/Reverse Polarity Connections

a. Connectaweldcabletothepositiveweld outputterminal 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 Owner�s Manual for terminal location.

d. Connect a weld cable from the negative weld

output terminal on the welding power source to

the workpiece.

e. Reinstall and secure Gas/Current Sensing control cover.

2. Electrode Negative/Straight Polarity Connections

Follow directions for Electrode Positive/Reverse

Polarity with the following exceptions:

a. Route weld cable from welding power source

negative weld output terminal through Gas/

Current Sensing control to wire drive assembly.

b. Connect weld cable from welding power source

positive weld output terminal to workpiece.

B. Shielding Gas Connections

The shielding gas fittings at the Gas/Current Sensingcontrol have 5/8-18 right-hand threads.

IMPORTANT: The gas flow must be accurately controlled by a regulator/flowmeter at the source.

1. Select and obtain shielding gas hose of suitable

length and type for connection between the shield

ing gas source and the Gas/Current Sensing control.

TA-080 484-B

Figure 4-7. Gas/Current Sensing Control

2. Connect gas hose from source to gas fitting on IN

panel of Gas/Current Sensing control.

3. Connect supplied 10 ft. (3 m) gas hose to remainingfitting on gas/current sensing control. Push remain

ing end of hose onto barbed fitting on wire drive as

sembly. See wire drive assembly Owner�s Manual

for location of barbed fitting.

Shielding gas flow is controlled by the preflow and post-flow timers in the weld control.

C. OptIonal Water Connections

4~ 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 coolantsystem is used.

� If using a water-cooled gun and recirculatingcoolant system, make connections from gundirectly to recirculating coolant system.

The water fittings at the Gas/Current Sensing control

have 5/8-18 left-hand threads.

1. Select and obtain water hose of suitable length and

type for connection between the water supply and

Gas/Current Sensing control.

2. Connect water hose from source to water fitting onIN panel of Gas/Current Sensing control.

3. Connect water in fitting from welding gun hose to re

maining fitting on Gas/Current Sensing control.

4. Route hose from gun water out fitting to a properdrain.

Water flows as soon as the weld control POWER switch

is placed in the ON position. Check system for properwater flow before welding.

OM-1578 Page 14

4-7. WELDING WIRE INSTALLATION (Figure 4-2)

A. Installation Of Spool-Type

1. Remove retaining ring.

2. Slide spool of wire onto hub so that wire feeds off the

bottom with minimum bend and sharp radius.

3. Rotate spool until hub guide pin is seated in hole in

spool. Be sure spool is seated against back flange of

hub.

4. Reinstall retaining ring.

B. instaiiation Of Reel-Type Wire Onto OptionalWire Reel

1. Remove retaining ring and wire reel assembly.

2. Lay wire reel assembly flat on table or floor.

3. Remove spanner nut from wire reel assembly.

4. Remove wire retainer, and install wire onto wire reel.

Be sure that wire feeds off 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 retaining ring onto hub.

C. Adjusting Hub Tension

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 backlash 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)

Placing the POWER switch in the ON position energizesthe weld control. The pilot light comes on whenever the

POWER switch is in the ON position and indicates that

the unit is receiving input power. Placing the POWER

switch in the OFF position shuts down the weld control

and turns off the pilot light.

IMPORTANT: The weldingpowersource must be energizedbefore the POWERswitch can be used to energizethe weld controL

5-2. RETRACT - ADVANCE SWITCH AND JOG

SWITCH (Figure 5-1)

With the RETRACT - ADVANCE switch in the RE

TRACT position, wire retracts into the gun at the speedset by the CRATER & JOG WIRE SPEED control when

the JOG switch is pressed.

With the RETRACT - ADVANCE switch in the AD

VANCE position, wire feeds from the gun at the speedset by the CRATER & JOG WIRE SPEED control when

the JOG switch is pressed.

25 ft. (8 mJ VoltageSensing Cord

(~ 5ft.(1.5m)MotorControl Cord

lOft. (3 mJ Gas/Current

Sensing Control Cord

25 ft. (8 m) Electrical

Input/ContactorControl/VoltageControl Cord

fi Accessory/ExternalControl Device

Connection

R&. 5-0261

FIgure 4-8. Connection Diagram

OM-1578 Page 15

Fuse

The JOG switch is a push-button switch. Pressing the

push button energizes the wire drive motorwithout ener

gizing the welding power source contactor or gas control

circuitry.

5-3. PURGE SWITCH (Figure 5-1)

The PURGE switch is a push-button switch. Pressingthe push button energizes the gas solenoid and purgesthe 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 preset weld 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.

5-5. STOP SWITCH (Figure 5-1 And Figure 4-5)

Pressing the STOP push-button switch initiates the preset crater, burnback, and postflow time events. See

Figure 4-5 for weld cycle events.

5-6. ERROR RESET BUTTON (Figure 5-1)

Pressing the ERROR RESET button stops the digitalvoltmeter display from flashing. The digital voltmeter

display flashes when the welding power source cannot

comply with the preset voltage parameters, or the volt

age sensing leads are not properly connected.

If the load voltage remains higher or lower than presetvoltage for more than 1 .5 seconds, the voltmeter displaybegins to flash. Once the display begins to flash, it con

tinues to do so even if the preset voltage can be ob

tained. Checkthe voltage sensing connections, readjustvoltage, and press ERROR RESET button before con

tinuing.

5-7. PRESS TO SET BUTTONS (Figure 5-1)

Depress and hold the PRESS TO SET button while set

ting RUN IN Voltage and Wire Speed or CRATER & JOG

Voltage and Wire Speed. The corresponding voltage or

wire speed is displayed on appropriate digital meter

while the PRESS TO SET button is held.

Error Reset

Switch

Circuit Breaker

(see SectIon 7-2)

Retract-Advance

Switch

Power

Switch

DigitalVoltmeter

Minute Meter

PurgeButton

Press to Set

Weld

Voltage

Weld Wire

Speed

Run-in Wire

Speed

StopSwitch

Start

Switch

Crater & JogWire Speed

Figure 5-1. Upper Front Panel Controls

Crater

Voltage

TQ-a70 4B4-~

OM-1578 Page 16

5-8. DIGITAL METERS (FIgure 5-1)

The digital VOLTS meter displays voltage to the nearest

tenth of a volt. The voltage displayed depends on what

portion of the weld cycle is running. At idle, the WELD

Voltage is displayed.

Thedigital INCHES PER MINUTE meteris shippedfromthe factory set to display wire speed in inches per min

ute. The wire speed displayed depends on what portionof the weld cycle is running. At idle, the WELD Wire

Speed is displayed.

IMPORTANT: The meter displays maybe erratic duringrun in and crater due to the short time of these weld

events. The preset voltage and wire speed are beingsupplied but the meters cannot stabilize fast enough to

show it.

5-9. RUN IN WIRE SPEED CONTROL (Figure 5-1)

The RUN IN WIRE SPEED control allows presetting of

the wire feed speed that applies to the time between the

end of pref low and arc initiation. After arc initiation, the

wire feed speed is set by the WELD WIRE SPEED con

trol.

The RUN IN SPEED control acts independently of the

other speed controls and can therefore be set above or

below the value set by the other controls.

Rotating the control clockwise increases run in wire feed

speed.

5-10. WELD WIRE SPEED CONTROL (Figure 5-1)

The WELD WIRE SPEED control allows presetting of

the wire feed speed for the weld event.

Rotating the control clockwise increases wire feed

speed.

5-11. WELD VOLTAGE CONTROL (Figure 5-1)

The WELD VOLTAGE control allows presetting of the

voltage for the weld event in the weld cycle.

5-12. CRATER & JOG WIRE SPEED CONTROL

(Figure 5-1)

The CRATER & JOG WIRE SPEED control allows pre

setting of the wire feed speed for crater fill. Wire retracts

or advances at the speed set by this control when the

JOG switch is pressed.

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 other controls.

Rotating the control clockwise increases wire feed

speed.

5-13. CRATER VOLTAGE CONTROL (FIgure 5-1)

The CRATER VOLTAGE control allows presetting of the

voltage for the crater event in the weld cycle.

5-14. PREFLOW TIME CONTROL (FIgure 5-2)

An adjustable 0 to 5 second PREFLOWTIME control al

lows presetting of the time shielding gas flows before arc

initiation. Pref low time starts when the START switch is

pressed.

The scale around the PREFLOW TIME control is

marked in seconds. Rotating the control clockwise in

creases preflow time.

TC-070 484-E

Pre-Flow

lime

Post-Flow

Time

Figure 5-2. Timer Panel View

OM-1578 Page 17

5-15. 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 atimed weld using the SPOT TIME control. Placing the

switch in the CONTINUOUS position provides a normal

untimed weld event. Both weld cycles have the followingevents: pref low, run in, weld (spot time oruntimed), cra

ter, burnback, and postflow.

5-16. SPOT TIME CONTROL (Figure 5-2)

The adjustable 0 to 2.5 second SPOT TIME control al

lows presetting of the spot weld time. Spot time starts at

arc initiation.

The scale around the SPOT TIME control is marked in

seconds. Rotating the control clockwise increases spottime.

5-17. CRATER TIME CONTROL (Figure 5-2)

An adjustable 0 to 2.5 second CRATER TIME control al

lows presetting of crater time. Crater time starts when

the STOP switch is pressed or the SPOT TIME control

times out.

The scale around the CRATER TIME control is marked

in seconds. Rotating the control clockwise increases

crater time.

5-18. BURNBACK CONTROL (Figure 5-2)

An adjustable 0 to 0.25 second BURNBACK control al

lows presetting of the time the wire remains electricallyenergized after the drive motor stops. Burnback starts

after the CRATER TIME co~troI times out.

The scale around the BURNBACK control is marked in

seconds. Rotating the control clockwise increases burn-

back time.

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

burnbacktime. lfthewirefreezesinthecontacttube,de

crease burnback time.

5-19. 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. Postflow time starts after the BURNBACK

timer times out.

The scale around the POSTFLOW TIME control is

marked in seconds. Rotating the control clockwise in

creases postflow time.

5-20. OPTIONAL RUN IN CONTROLS (Figure 5-1)

A. RUN IN TIME Control

An adjustable 0 to 2.5 second RUN IN TIME control al

lows presetting of the time between arc initiation and the

main weld sequence.

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 VOLTAGE Control

The RUN IN VOLTAGE control allows presetting of the

voltage for the run in event in the weld cycle.

SECTION 6-SEQUENCE OF OPERATION

a WARNING: ELECTRIC SHOCK can kill;MOVING PARTS can cause serious Injury;IMPROPEI~ AIRFLOW AND EXPOSURE TOENVIRONMENT can damage Internal parts.� Do not touch live electrical parts.

� Keep all covers and panels in place while

operating.

Warranty is void if the weld control is operatedwith any portion of the outer enclosure opened or

removed.

ARC RAYS, SPARKS, AND HOT SURFACEScan burn eyes and skin; NOISE can damagehearing.� Wear correct eye, ear, and body protection.

FUMES AND GASES can seriously harm

your health.

� Keep your head out of the fumes.

� Ventilate to keep from breathing fumes and

gases.

� If ventilation is inadequate, use approvedbreathing device.

WELDING WIRE can cause puncturewounds.

� Do not point gun toward any part of the body,any conductive surface, or other personneL

HOT METAL, SPATTER, AND SLAG can

cause fire and burns.

� Watch for fire.

� Keep a fire extinguisher nearby, and know

how to use it.

� Do not use near flammable material.

� Allow work and equipment to cool before

handling.

MAGNETIC FIELDS FROM HIGH CURRENTScan affect pacemaker operation.� Wearers should consult their doctor before

going near arc welding, gouging, orspot weldingoperations.

See Section 1 - Safety Rules For Operation OfArc Welding Power Source for basic weldingsafety information.

OM-1578 Page 18

6-1. GAS METAL ARC WELDING (GMAW) AND

FLUX CORED ARC WELDING (FCAW) -

CONTINUOUS (Figure 6-1)

a WARNING: Read and follow safety Information at begInnIng of entire Section 6 before

proceeding.

1. Install and connect weld control and supplied associated equipment according to Section 4.

2. Install and connect remaining equipment (gun, drive

motor, etc.) according to the applicable Owner�s

Manual.

3. Place SPOT-CONTINUOUS switch in CONTINU

OUS position.

4. Turn on shielding gas at the source.

5. Energize welding power source.

6. Place the weld control POWER switch inthe ON po

sition (see Section 5-1)

7. Program the desired weld cycle by setting the con

trols as instructed in Section 5.

8. Wear dry insulating gloves and clothing, and wear

welding helmet with proper filter lens according to

ANSI Z49.1.

9. Prepare for welding as follows:

a. Connect work clamp to clean, bare metal at

workpiece.

b. Select and obtain proper welding wire, and

thread according to wire drive assembly Own

er�s Manual.

10. Purge gas hose by pressing the PURGE switch for

one minute.

11. Press weld control START switch.

12. To stop the weld cycle and start crater, press the

STOP switch.

6-2. GAS METAL ARC WELDING (GMAW) AND

FLUX CORED ARC WELDING (FCAW) - SPOT

a WARNING: Read and follow safety informalion at beginning of entire Section 6 before

proceeding.

1. Install and connect weld control and supplied associated equipment according to Section 4.

2. 1 nstall and connect remaining equipment (gun, drive

motor, etc.) according to the applicable Owner�s

Manual.

3. Place SPOT - CONTINUOUS switch in the SPOT

position.

4. Rotate SPOT TIME control to desired position (seeSection 5-16).

5. Turn on shielding gas at source.

6. Energize welding power source.

7. Place the weld control POWER switch in the ON po

sition (see Section 5-1)

8. Program the desired weld cycle by setting the con

trols as instructed in Section 5.

9. Wear dry insulating gloves and clothing, and wear

welding helmet with proper filter lens according to

ANSI Z49.1.

10. Prepare for welding as follows:

a. Connect work clamp to clean, bare metal at

workpiece.

b. Select and obtain proper welding wire, and

thread according to wire drive assembly Owner�s Manual.

11. Purge gas hose by pressing the PURGE switch for

one minute.

12. Press weld control START switch.

13. The weld event automatically stops and crater starts

when the SPOT TIME control times out.

6-3. SHUTFING DOWN

1. Place weld control POWER switch in the OFF position.

2. Turn off all associated equipment.

3. Turn off shielding gas and water, if applicable, at

source.

a WARNING: HIGH CONCENTRATION OFSHIELDING GAS can harm health or kill.

� Shut off gas supply when not in use.

I Connect PersonalI I IdIngL_J

GasLJ SampleL�I

Prepare ForI Equipment Safety 1ł1E~~r~�ntLJ SetControlsThread Purge Do

_____

ControlsAndiInstall & ~ Put On Readjust I

~See Section 4 Equipment& Gas 1(See Section 5~ W~jre Line Weld Production i

FIgure 6-1. Sequence Of Operation

OM-1578 Page 19

SECTION 7- MAINTENANCE & TROUBLESHOOTING

7-1. ROUTINE MAINTENANCE A. Drive Motor Circuit Breaker CB1 (Figure 5-1)

IMPORTANT: Every six months inspect the labels on WARNING: Read and follow safety informathis unit for legibility. All precautionary labels must be tion at beginning of entire Section 7-2 before

maintained in a clearly readable state and replaced proceeding.

when necessary. See Parts List for part number of

precautionary labels.The drive motor is protected from damage due to over-

Usage and shop conditions determine the frequency load by circuit breaker CB1. if CB1 should open, the wire

and type of maintenance. At minimum, inspect equip- feed motor would stop.

ment every three months as follows:Should a motor overload occur and CB1 open, proceedas follows:

~ WARNING: ELECTRIC SHOCK can kill.

� Do not touch live electrical parts. 1. Check for jammed wire or clogged gun liner, and

correct problem. If wire jams often, replace gun liner.� Shut down weld control and welding powersource, and disconnect input power employing 2. If motor overload occurs often, repair or replace wirelockout�tagging procedures before inspecting, drive motor.maintaining, or servicing.

Lockout/tagging procedures consist of pad- 3. Check for binding drive gear or misaligned drive

locking line disconnect switch in open position, rolls, and correct problem.removing fuses from fuse box, or shutting off and

red-tagging circuit breaker or other disconnect- 4. Reset circuit breaker by depressing the button. A

ing device. cooling period may be necessary before the circuit

MOVING PARTS can cause serious injury,breaker can be reset.

� Keep away from moving parts. 5. Resume operation.

HOT SURFACES can cause severe burns,B. Main Fuse Fl (Figure 5-1)

� Allow cooling period before servicing.

a WARNING: Read and follow safety lnformaMaintenance to be performed only by qualifiedtion at beginning of entire Section 7-2 before

persons.proceeding.

1. Repair or replace, as required, all hose and cable; The weld control is protected from damage due to an in-

give particular attention to frayed and cracked insu- ternal short or excessive overload by fuse Fl. If Fllation and areas where it enters equipment. should open, the weld control would completely shut

down. To Replace Fl, proceed as follows:2. Remove grease and grime from components; mois

ture from electrical parts and cable. 1. Depress and rotate fuse holder cover counterclock

wise.7-2. OVERLOAD PROTECTION

2. Pull out fuse with cover when fuse holder cover is~ WARNING: ELECTRIC SHOCK can kill, free.

� Do not touch live electrical parts.3. Insert new fuse into fuse holder cover.

� Shut down weld control and welding powersource, and disconnect input power employing 4. Install fuse holder cover back into unit.

lockout/tagging procedures before inspecting,maintaining, or servicing. 5. Depress and rotate fuse holdercoverclockwise until

Lockout/tagging procedures consist of pad-cover is secure.

locking line disconnect switch in open position, 7-3. HUB REINSTALLATION (Figure 4-2)removing fuses from fuse box, or shutting off and

red-tagging circuit breaker or other disconnect- If it becomes necessary to replace all or part of the hubing device,

and spindle assembly, see Figure 4-2, and proceed as

INCORRECT FUSE can damage unit, follows:

� Use only replacement fuse ofsame size, type,and rating (see Parts List).

1. Remove hub assembly from spindle support, and

disassemble, discarding worn or broken parts.

OM-1578 Page 20

2. Slide the following items onto the spindle supportshaft in order given.

a. Spring

b. Keyed Washer

c. Fiber Washer

d. Brake Washer

e. Hub

f. Brake Washer

g. Fiber Washer

3. Align keyway, and insert spindle support shaft

through selected hole in hub support.

4. Install hex nut onto spindle support shaft. Tightenhex nut until a slight drag is felt while turning hub.

5. Install welding wire according to Section 4-7.

7-4. CIRCUIT BOARD HANDLING PRECAUTIONS

a WARNING: ELECTRIC SHOCK can kill.

� Do not touch live electrical parts.

� Shut down weld control and welding power

source, and disconnect input power employinglockout/tagging procedures before inspecting,maintaining, or servicing.

Lockout/tagging procedures consist of padlocking line disconnect switch in open position,removing fuses from fuse box, or shutting off and

red-tagging circuit breaker or other disconnect

ing device.

AA CAUTION: ELECTROSTATIC DISCHARGE

(ESD) can damage circuit boards.

� Put on propeily grounded wrist strapBEFORE handling circuit boards.

� Transport circuit boards in proper static-

shielding carriers or packages.

� Perform work only at a static-safe work area.

INCORRECT INSTALLATION or misalignedplugs can damage circuit board.

� Be sure that plugs are properly installed and

aligned.

EXCESSIVE PRESSURE can break circuit

board.

� Use only minimal pressure and gentle movement when disconnecting or connecting board

plugs and removing or installing board.

7-5. TROUBLESHOOTING

a WARNING: ELECTRIC SHOCK can kill.

� Do not touch live electrical parts.

� Shut down weld control and welding power

source, and disconnect input power employinglockout/tagging procedures before inspecting,maintaining, or servicing.

Lockout/tagging procedures consist of padlockinQ line disconnect switch in open position,removing fuses from fuse box, or shutting off and

red-tagging circuit breaker or other disconnect

ing device.

MOVING PARTS can cause serious injury.� Keep away from moving parts.

HOT SURFACES can cause severe burns.

� Allow cooling period before servicing.

Troubleshooting to be performed only byqualified persons.

It is assumed that the unit was properly installed accord

ing to Section 4 of this manual, the operator is familiar

with the function of controls, the weld control was work

ing properly, and that the trouble is not related to the

welding process.

The following table is designed to diagnose and provideremedies for some of the troubles that may develop in

this weld control. Use this table in conjunction with the

circuit diagram while performing troubleshooting procedures. If the trouble is not remedied after performingthese procedures, contact the nearest Factory Author

ized Service Station. In all cases of equipment malfunc

tion, strictly follow the manufacturer�s procedures and

instructions.

Table 7-1. Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Pressing the START button POWER switch Si. Energize welding power source.

does not start weld cycle.Electrode wire is not

energized and shieldinggas (or flux if applicable)does not flow.

Place Si in ON position.

Check Si and replace if necessary.

Main fuse Fl. Check and replace Fi according to

Section 7-2.

Circuit breaker CB1. Reset CB1 according to Section 7-2.

input power plug is not secure

on weld control or welding pow

in receptacleer source.

Secure connections (see Section

4-4D).

OM-1 578 Page 21

Table 7-1. Troubleshooting (Continued)

TROUBLE PROBABLE CAUSE REMEDY

Wire feeds, shielding gas

flows, but electrode wire

is not energized.

Contactor control plug is not secure in

receptacle on weld control or weldingpower source.

Secure connections (see Section

4-4D).

Welding power source. See Troubleshooting Section in weld

ing power source Owner�s Manual.

Erratic meter display(s). Incorrect or loose voltage sensingconnections.

Check connections, and be sure theyare correct and secure (see Section

4-4C).

Voltage control plug is not secure in

receptacle on weld control or weldingpower source.

Secure connections (see Section

4-4D).

Fixture movement erratic or

not as desired, if applicable.Control relays. Check and replace relays on Timer

Board PC3.

Loose or incorrect connections to terminal

strips.Check and secure connections.

See Section 4-3 for proper terminal

strip connections.

Motor does not run, or

motor runs erratically while

welding or jogging wire upor down.

Motor control board PC4.

.

Check and replace PC4 if necessary

(see Section 7-4).

OM-1578 Page 22

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3,11,

)D~RC~6

-c~~=._�.CRATER

45

CR

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PLG5~

~

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241/DC.

24V

FLUX

VALVE

_____

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4FV2

I

IPTILVAAL.�_._...L

.1

Diagram8-3.

CircuitDiagramFor

ModelsWithRunIn

Option

2T580A

/98c

49246E .180F

3/

9

0

6

H

CircuitDiagramNo.

C-128251

PG

HER/GlOVESNETSFOR

CHIPS

ASS

4.+155

Il��ISV

851

8-8155.4�ISV

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8-8155.4.�ISV

853

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Diagram8-4.

CircuitDiagramFor

VoltageControlBoardPCi

CircuitDiagramNo.

C-130150

0 �4 cD I�)

CircuitDiagramNo.

D-083388

CGCXPOINTJ

EXCEPTH.

ElOPE

'

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_JIIIIIIL_J~IIL~I1~

Diagram8-5.

CircuitDiagramFor

MotorControlBoardPC2

p..CO

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OM-1578 Page 29

Diagram 8-7. Circuit Diagram For Tach Board PC4

B

A

C

Circuit Diagram No. A-094 456

Circuit Diagram No. A-119 481

Diagram 8-8. Circuit Diagram For Low Speed Calibration Board PC8

OM-1578 Page 30

SECTION 9� PARTS LIST

OM-1578 Page 31

(0I.-�

LC)

x

0(0

C,

a)

(0N

(0

0,

U..

0N

OM-1578 Page 32

Item Dia. PartNo. Mkgs. No. Description Quantity

Figure 9-1. Control Box

1 079 844 SPRING, holddown-relay 1

2 CR2 095 033 RELAY, end 24VAC 4PDT 1

3 027 811 SOCKET, relay 14 pin 1

4 048 029 CLIP, retaining-skt relay 1

5 070 370 METER, digital volt (Fig 9-2) 2

6 109 474 CIRCUIT CARD, low-speed calibration (consisting of) 1

R50 039 360 POTENTIOMETER, cermet 20/T .5W 25K ohm 1

RC18 079 794 TERMINAL, hdr 3 pin 1

S50 109 285 . SWITCH, dip SPDT 1

PLG18 079796 HOUSING,termhdr3pin 1

7 PLG6,15 081 379 HOUSING, term hdr 12 pin 2

8 009 335 STAND-OFF, No. 4-40 X 5/8 4

9 010 855 RETAINER, screw No. 2 1

10 CB1 011991 CIRCUITBREAKER,1P1.5A250V 1

11 51 011 611 SWITCH,t91DPDT15A125V 1

12 S2,3 011 043 SWITCH, tgl DPDT 6A 125V 2

13 +128 959 CABINET, control (consisting of) 1

14 073487 �NUT,speedNo.2 1

15 123 154 LABEL, warning general precautionary 1

16 024 376 BLANK, snap-in 5/8 mtg hole 2

17 057 084 BUSHING, snap 1/4 ID x 3/8 mtg hole 1

18 079683 HEATSINK I

19 030949 HEATSINK 1

20 010 193 TUBING, 3/8 OD x l8ga wall x 1/4 4

21 R2 030941 RESISTOR, WWfxd 100W5 ohm 1

22 056 170 SHIELD, resistor 1

23 010199 TUBING,.275IDx.O48waIIxl 2

24 �092 178 CABLE, volt-sensing (consisting of) 1

25 073 686 PLUG, 4skt MS-3106A-14S-2S 1

26 039 828 CLAMP, cable AN-3057-6 1

27 600 848 WiRE, stranded l2ga (order by ft) 3Oft

28 604 109 . WIRE, stranded l6ga (order by ft) 7ft

29 600 750 TERMINAL, ring tongue 1.2 stud 1

30 601 226 . INSULATOR, vinyl clamp 1

31 601 228 CLAMP, universal 25A 1

32 �092 176 CABLE, motor (consisting of) I

33 PLG7 047 636 HOUSING PLUG & PINS (consisting of) 1

079 535 . TERMINAL, male 1 pin sz 16 18-14w 14

34 079 739 CLAMP, cable strain relief sz 17 2

35 073 139 CABLE, No. 16 6/c (order by ft) 1 Oft36 PLG8 071 892 . RECEPTACLE W/SOCKETS, (consisting of) 1

079 534 . TERMINAL, female lskt 14-18w 14

048 144 . TERMINAL, male-plug keying (located in plug) 2

37 �071 005 CABLE, interconnecting (consisting of) 1

38 PLG9 047 636 HOUSING PLUG & PINS, (consisting of) 1

079 535 TERMINAL, male lskt sz 16 18-14w 14

39 079 739 CLAMP, cable strain relief sz 17 240 073 139 CABLE, No. 16 6/c (order by ft) lift41 PLG16 048 598 . HOUSING PLUG & SOCKETS, (consisting of) 1

079 534 . . TERMINAL, female lskt 14-18w 16048 144 . TERMINAL, male 1 pin plug keying 1

42 .121 595 CABLE, interconnecting 25ft (consisting of) 143 111 122 . HOUSING PLUG & PINS, (consisting of) 1

109 770 TERMINAL, male 1 pin sz 45 16-22w 1444 116 964 CLAMP, cable 97-3057-i 012 245 110 015 CABLE, port No. 18 7/c (order by ft) 25ft

OM-1578 Page 33

Item Dia. PartNo. Mkgs. No. Description Quantity

Figure 9-1. Control Box (Continued)

46 111 123 HOUSING PLUG & SOCKETS, (consisting of) 1

109 771 TERMINAL, female lskt 16-22w sz 45 14

47 070 371 BLANK, snap-in 1-3/32 - 1-1/8 1

48 115 104 CONNECTOR, clamp-cable 1/2 in 1

49 010311 CLAMP,3/4diaxl/2wide 1

50 RC7,9 047 637 HOUSING RECEPTECLE & SOCKETS, (consisting of) 2

079 534 TERMINAL, female lskt 14-18w 14

51 RC11 094 480 RECEPTACLE, 14 pin MS-3102A-20-27P 1

52 RCI2 076 624 RECEPTACLE, 4 pin MS-3102A-14S-2P 1

048 144 TERMINAL, male 1 plug keying 4

53 C2,3 028291 CAPACITOR,cer.1uf500VDC 2

54 Fig 9-3 PANEL, w/components 1

55 PB1 011 232 SWITCH, PB SPDT 1

56 R4-6,22,23 603 856 POTENTIOMETER, WW 10/T 2W 10K ohm 5

57 128 449 DOOR, cabinet 1

58 NAMEPLATE (order by model arid serial number) 1

59 PB4 070 530 SWITCH W/BUTTON, red (consisting of) 1

60 071 222 SWITCH, PB MC SPDT 3A 125VAC 1

61 071 223 BUTTON, switch-red 1

62 PC3 085 268 TIMER (Fig 9-6) 1

63 071 226 BARRIER, switch-end 2

64 071 225 BARRIER, switch-center 1

65 PB3 070 531 SWITCH W/BUTTON, green (consisting of) 1

66 071 224 BUTTON, switch-green 1

67 071 222 SWITCH, PB MC SPDT 3A 125VAC 1

68 097 922 KNOB, pointer 5

69 057 359 BLANK, snap-in nyl .375 mtg hole 2

70 PB2,5,6 070 529 SWITCH W/BUTTON, white (consisting of) 3

71 071 227 . SWITCH, PB MC SPDT3A 125VAC 1

72 071 228 BUTTON, switch white 1

73 Fl *012 655 FUSE, minat gI 1OA 250V 1

74 010853 FASTENER,screwNo.2 1

75 046 432 HOLDER, fuse minat 1

76 071 230 BEZEL/FILTER 2

.056 462 HOSE ASSEMBLY, gas (consisting of) 1

056 851 FITTING, hose-barbed nipple 3/1 6TBG I

010 606 FITTING, hose-brs nut 5/8-18RH 1

056 108 FITTING, hose-brs ferrule .425 ID 1

604550 HOSE, No.1 (order by ft) lift

*Recommended Spare Parts.

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

�These items are not included with control box.BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-1578 Page 34

Item Dia.No. Mkgs.

PartNo.

070 370 FIgure 9-2. Meter, Digital Volt (Fig 91 Item 5)

Figure 9-2. Meter, Digital Volt

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

Description Quantity

C50

051

C52

C53

C54

D50 ,5 1

DD5O-52

lC5O

1051

050-52

R50

R51

R52

R53

R54

R55

T50

VR5O

I

2

3

071 200

000348

038 585

031 643

005 023

071 229

026 202

084 028

071 239

071 238

037201

009 172

082 178

071 231

071 237

035825

039 327

092 648

071 617

071 248

072944

071 219

081 381

071 670

070 026

CIRCUIT CARD, volt meter (consisting of)CAPACITOR, tantlm .47uf 35V

CAPACITOR, mylar .22uf 50V

CAPACITOR, cer disc .O1uf500VDC

CAPACITOR, tantlm 2.2uf 20V

CAPACITOR, elctlt 470uf 16V

~DIODE,1A400VSPLED, 2676

IC, interface 3162

IC, interface 3161

TRANSISTOR, 200MA 40V PNP

POTENTIOMETER, cermet 20/T .5W 50K ohm

POTENTIOMETER, cermet 25/T .5W 10K ohm

RESISTOR, MF .5W 1 meg ohm

RESISTOR, MF .5W 110K ohm

RESISTOR, CF .25W 1K ohm

RESISTOR, CF .25W 220 ohm

RESISTOR, WW fxd zero ohm

TRANSFORMER, control 115V

IC, linear 78M05

HEAT SINK, voltage regulatorCABLE, ribbon 11 positionTERMINAL, hdr 12 pinBRACKET, mtg-circuit card

STAND-OFF, No. 6-32

1

1

1

1

1

1

2

3

1

1

3

1

1

1

1

1

1

1

1

1

1

1

1

1

3

T8-070 451-A

OM-1578 Page 35

it Cc C Co Ca3

-&

CD C)03V0 CD -0 01

0-40 a ~7~

Item Dia. PartNo. Mkgs. No. Description Quantity

Figure 9-3. Panel, W/Components (Fig 9-1 item 54)

1 Pci 130 153 CIRCUIT CARD, voltage control (Fig 9-4) 1

2 009 335 STAND-OFF, No. 4-40 x .625 Ig 2

3 083 147 GROMMET, scr8-10 6

4 006 426 CLAMP, capacitor 2 in 1

5 Ci 031 692 CAPACITOR, elctlt 750uf 200VDC 1

6 PC2 071 642 CIRCUIT CARD, motor speed (Fig 9-5) 1

7 RC5 117374 HOUSING,connector22posn 1

8 CR1 127312 RELAY,encI24VACDPDT 1

9 092 897 PANEL, mtg-components 1

10 1T,2T 038659 BLOCK,term2OA8P 2

601 219 LINK, jumper-term block 5

11 Ti 082 629 TRANSFORMER, control 1i5/36V 1

12 T2 036 135 TRANSFORMER, control i15-24VAC 1

13 080 191 STRIP, insulator-block term 1

14 RC1O 079 784 TERMINAL, hdr i2skt 1

15 010 301 BUSHING, 9/64 ID x 1/400 x 5/16 2

16 R3 079 497 RESISTOR, WW fxd 25W 2K ohm 1

17 PLG2 079 797 HOUSING, term 4 pin 1

18 PLG1 079 798 HOUSING, term 13 pin 1

048 027 PLUG, connector-keying 1

19 RC4 079 783 TERMINAL, hdr i4skt 1

20 057 544 SPRING, compression 8

21 SRi 035 704 RECTIFIER, integ 30A 600V 1

22 Ri 030 651 RESISTOR, WW fxd 25W 10 ohm 1

23 PLG14 079 748 HOUSING, term hdr 18 1

24 073 914 WASHER, centering .437 4

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-1578 Page 37

OM-1578 Page 38

B-130 15~

Figure 9-4. CircuIt Card, Voltage Control PCi

Dia.

Mkgs.

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

PartNo. Description Quantity

PCi 130 153 FIgure 9-4. Circuit Card, Voltage Control (Fig 9-3 Item 1)

A50 096275 IC,Iinear324 1

A51-53 009159 lC,iinear358 3

C50,60,69-73 000 340 CAPACITOR, cer .Oluf 50V 7

C51 028 294 CAPACITOR, mylar luf 200VDC 1

C52 031 677 CAPACITOR, tantim 5.6uf 35VDC 1

C53,55-59,68 122 723 CAPACITOR, cer mono .luf 5OVDC 7

C54 000 861 CAPACITOR, elctlt 33uf 35V 1

C61 005 023 CAPACITOR, tantim 2.2uf 20V 1

C62 009 577 CAPACITOR, tantlm 27uf 35V 1

C63 053 992 CAPACITOR, cer .OOluf 1000V 1

C64,65 118 460 CAPACITOR, elctlt 330uf 5OVDC 2

C66,74 000 348 CAPACITOR, tantlm .47uf 35V 2

C67 121 684 CAPACITOR,polyemetfilm.47uflOOV 1

CR50 093 558 RELAY, end 12OVAC 4PDT 1

091 861

079 844

SOCKET, relaySPRING, holddown-relay

1

1

D51-54 026202 DIODE, 1A400V SP 4

D55-66 028 351 DIODE, sig .02A 75V SP 12

J1-15 092648 RESISTOR,WWfxdzeroohm 15

0C50 047 034 IC, interface 4N26 1

050 035 842 TRANSISTOR, 6A 40V PNP 1

051 -53 037 200 TRANSISTOR, 200MA 40V NPN 3

R51 ,80,86,87 039 331 RESISTOR, CF .25W 4.7K ohm 4

R52,78,91 ,93 035 888 RESISTOR, CF .25W 2.2K ohm 4

R53,73 078 431 RESISTOR, C .25W 330 ohm 2

R54 039 332 RESISTOR, CF .25W 15K ohm 1

R55-57,64,85 035 827 RESISTOR, CF .25W 10K ohm 5

R58,61 039 336 RESISTOR, CF .25W 220K ohm 2

R59,60,63,69,95-97 035 826 RESISTOR, CF .25W 6.8K ohm 7

R62,68,82 035 825 RESISTOR, CF .25W 1K ohm 3

R66,74 009 173 POTENTIOMETER, cermet 20/T .5W 5K ohm 2

R67,76 089 175 RESISTOR, MF .25W 10K ohm 2

R71 000 038 POTENTIOMETER, cermet trmr 25/T .5W 2K ohm 1

R75,89 052137 RESISTOR, CF .25W5.lKohm 2

R77 039 333 RESISTOR, CF .25W 18K ohm 1

R79 039 330 RESiSTOR, CF .25W 3.9K ohm 1

R81 035 886 RESISTOR, CF .25W 22K ohm 1

R83 084 205 RESISTOR, CF .25W 3.3K ohm 1

R84 000 885 RESISTOR, CF .25W 10K ohm 1

R88,92R90

081 833

035 885

RESISTOR, CF .25W 2.7 meg ohm

RESISTOR, CF .25W 68K ohm

2

1

R94 035 823 RESISTOR, CF .25W 100 ohm 1

R98 039 329 RESISTOR, CF .25W 2.7K ohm 1

R99 108433 RESISTOR,CF.25W2.4Kohm 1

R100 117 134 RESISTOR, CF .25W 24K ohm 1

R102 121 714 RESISTOR, CF 25W51K ohm 1

R103 082 178 POTENTIOMETER, cermet trmr 25/T .5W 10K ohm 1

RC1

Si

VR5O

079 749

092 367

081 832

TERMINAL, hdr 18 pinSWITCH, dip SPST 2 posnIC, linear 75M15

1

1

1

VR51 046932 IC,Iinear7gl5 1

OM-1578 Page 39

OM-1578 Page 40

Figure 9-5. CircuIt Card, Motor Speed PC2

C-093 300.U

Dia. Part

Mk~s. No. Descnption Quantity

PC2 071 642 Figure 9-5. Circuit Card, Motor Speed (Fig 9-3 Item 6)

A50-53 009159 IC,iinear358 3

C50 039 482 CAPACITOR, eictlt lOOuf 35VDC 1

C51 031 699 CAPACITOR, mylar .0022uf 200VDC 1

C52,61 073 739 CAPACITOR, cer luf 50V 2

C53,62 035 833 CAPACITOR, mylar .033uf 100VDC 2

C54 005 023 CAPACITOR, tantlm 2.2uf 20V 1

C55,66-75,77 031 643 CAPACITOR, cer .Oluf 500VDC 12

C56 073 549 CAPACITOR, mylar .Ol5uf 200V 1

C57 007 742 CAPACITOR, elctlt lOut 35V 2

C60 035 561 CAPACITOR, mylar 4ut 200V 1

C63,64 044 602 CAPACITOR, poly film .47uf 400VDC 2

C65 031 721 CAPACITOR, mylar .22ut 200VDC 1

CR50 095 033 RELAY, end 24VAC 4PDT 1

091 861 SOCKET, relay 1

079 844 SPRING, holddown-relay 1

D50-54,56-60 026 202 DIODE, 1A 400V SP 10

D55 080 910 DIODE, zener 15V 5W 1

IC5O 081 800 IC, interface 2907 1

050,53 037 200 TRANSISTOR, 200 MA 40V NPN 2

Q51 037 824 THYRISTOR, SCR 74A 200V 1

052 039 355 TRANSISTOR, unijunction 15MA 40V 1

R50 030 839 RESISTOR, WW fxd 5W 220 ohm 1

Note 1 035 827 RESISTOR, CF .25W 10K ohm 10

R52,56,61 052 138 RESISTOR, CF .25W 20K ohm 3

R53 039 332 RESISTOR, CF .25W 15K ohm 1

Note 2 035 884 RESISTOR, CF .25W lOOK ohm 8

R59 030 007 POTENTIOMETER, cermet 15/T .75W 50K ohm 1

R60,87,88 039 335 RESISTOR, CF .25W 47K ohm 3

R63,79 039 106 RESISTOR, CF .25W 470 ohm 2

R64 039 331 RESISTOR, CF .25W 4.7K ohm 1

R70 049 015 RESISTOR, CF .25W 1 meg ohm I

R73,83 039 328 RESISTOR, CF .25W 1.5K ohm 2

R77 052 142 RESISTOR, CF .25W 120K ohm 1

R78 039 108 RESISTOR, CF .25W82K ohm 1

R80 035 886 RESISTOR, CF .25W 22K ohm 1

R81 ,84 035 825 RESISTOR, CF .25W 1K ohm 2

R85 030 937 RESISTOR, C .5W 10 ohm 1

R86 030 090 RESISTOR, C .5W 47 ohm 1

092 648 RESISTOR, WW fxd zero ohm 15

T50 085 399 TRANSFORMER, pulse 1

VR5O 081799 IC,Iinear78LO8 1

VR51 047 272 IC, linear 78L12 1

NOTE 1: R51 ,54,55,57,67,68,74,75,82,89NOTE 2: R58,62,65,66,71 ,72,76,90BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-1578 Page 41

Description Quantity

PC3 085 268 FIgure 9-6. TImer (Fig 9-1 Item 62)

097 922 KNOB, pointer080 242 PLATE, md

079 684 BRACKET, mtg-timerFigure 9-7 CIRCUIT CARD

Item Dia.No. Mk~s.

PartNo.

9-7-

3

2

1

1

2

3

4

FIgure 9-6. TImer PC3

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

5

I

1

1

TD-083 368-A

OM-1578 Page 42

Desciiption Quantity

Figure 9-7. Circuit Card (Fig 9-6 Item 4)

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

Dia.

Mkgs.Part

No.

009 159

039 482

005 023

031 677

073 714

095521

091 861

079 844

026 202

037 449

073 535

039 332

082 708

030 018

iC,iinear358CAPACITOR, elcilt lOOuf 35VDC

CAPACITOR, tantim 2.2uf 20V

CAPACITOR, tantlm 5.6uf 35VDC

CAPACITOR, tantim .22uf 35V

RELAY, end 24VDC 4PDT

SOCKET, relaySPRING, hoiddown-relayDIODE, 1 A 400V SP

DIODE, zener 15V 1W SP

TRANSISTOR, 100MA 30V NPN

RESISTOR, CF .25W 15K ohm

POTENTIOMETER, WW 1W 1 meg ohm

RESISTOR, C 1W 820 ohm

A50-52

C50

C51 ,52,54

C53,55C56

CR5O-56

D50-57,59-71D58

050-55

R50,64,68R51,81-84

R52

R53,59-62,65,

71-73,77,80R54,63,69,70,78,79R55,56

R57,58,66,67,74,75R76

RC1

RC2

RC3

s50

035 827 RESISTOR, CF .25W 10K ohm

035 886 RESISTOR, CF .25W 22K ohm

035 823 RESISTOR, CF .25W 100 ohm

3

1

3

2

I

7

7

7

21

1

6

3

5

1

11

6

2

6

1

2

1

1

1

1

1

605 912

053572

092 648

079 795

079 793

079 794

079 722

010915

RESISTOR, C .25W 4700 ohm

RESISTOR, CF .25W 12K ohm...

RESISTOR, CF .25W zero ohm

TERMINAL, hdr 13 pinTERMINAL, hdr 4 pinTERMINAL, hdr 3 pinSWITCH, tgl SPDT 4A 2-4VDC...

WASHER, fiat brs .250 ID x .625 OD

Figure 9-7. CIrcuit Card

D~O97 726-B

OM-1578 Page 43

Item Dia.No. Mkgs.

PartNo.

070 183 Figure 9-8. Control, Gas/Current Sensing

RECEPTACLE W/PINS, (consisting of)� TERMINAL, male 1 pin sz 16 18-14w

RELAY, current (consisting of)SWITCH, reed SPST

� CABLE, No. 18 2/c (order by ft)WRAPPER

LABEL, warning general precautionaryBUSHING, snap 1-3/8 ID x 1-3/4 mtg hole

BUSHING, snap 1 ID 1-3/8 mtg hole

BLANK, snap-in 7/8 in

FITTING, hose-brs bushing 1/4NPT x 5/8-18RH

FITTING, pipe-galv coupling 1/4NPT

FITTING, pipe-galv nipple L 1I4NPT x 6

CASE SECTION, bottom/front/sides

BRACKET, mtg-componentVALVE, 115VAC 2 way 1/4 IPS port 1/8 orifice...

2

2

1

1

1

2

1

Figure 9-8. Control, Gas/Current Sensing

Ret: TC-080 365-R

+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-1578 Page 44

Description Quantity

1 RC16 090246

079 535

2 Reed 079687

3 057091

4 604525

5 +079 682

6 123154

7 010494

8 057358

9 601 158

10 010604

11 602934

12 079573

13 079686

14 079574

15 GS1 003538

1

9

1

1

1 ft

1

1

2

2

1

1£

15

�4

Item PartNo. No. Description

FIgure 9-9. Hub & Spindle Assembly

Quantity

2 058427

3 072292

4 010233

5 057971

6 010191

7 058628

8 058428

9 085980

10 092989

121 316

11 �108 008

12 124200

13 124905

14 124904

i-When ordering a component originally displaying a precautionary label, the label should also be ordered.� Optional EquipmentBE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

1

1

1

1

1

2

2

1

1

I

1

I

1

1

1

072 094 HUB & SPINDLE, (consisting of)RING, retainingSHAFT, spool supportSPRING, compressionWASHER, flat keyed 1-1/2 dia

WASHER, fiber 5/8 ID x 1-1/2 OD x 1/8

WASHER, brake

CHUB, spoolNUT, hex-jam 5/8-11

SUPPORT, spindle (consisting of)LABEL, warning general precautionaryREEL, wire (consisting of)SUPPORT, reel-supportRETAINER, spool-supportNUT, spanner-spool

1

I

Figure 9-9. Hub & Spindle Assembly

Ret: TD-045 31 5-J

OM-1578 Page 45

Dia. Part

Mkgs. No. Descnption Quantity

Optional Equipment

070 814 VOLTAGE CONTROL, run in (consisting of) 1

CR5 095 521 RELAY, end 24VDC 4PDT 1

049 970 BRACKET, mtg-relay 1

027811 CONNECTOR, 14 pin 1

048 029 CLIP, retaining-skt relay 1

079 844 SPRING, holddown-relay I

PB6 084 096 SWITCH, w/white button 1

PLG3 079 796 HOUSING, term hdr 3 posn 1

R24 603 856 POTENTIOMETER, WW lOfT 2W 10K ohm 1

R25 028 770 POTENTIOMETER, C l/T 2W 1 meg ohm 1

097 922 KNOB, pointer 2

080 594 WATER CONTROL KIT, (consisting of) 1

WS1 003 538 VALVE, 2 way 1/4 IPS port 1/8 orifice 1

010 605 FITTING, hose-bushing 1/4 NPTx 5/8-18 2

602 934 FITTING, pipe-coupling 1/4NPT 1

079 573 FITTING, pipe-nipple L 1/4NPT x 6 1

080 596 LOCKING COVER, (consisting of) 1

080 581 COVER, locking-control box 1

080 584 TAB, locking 1

108 008 REEL, wire (see Fig 9-9) 1

041 546 AUTOMATIC SHUTDOWN, (consisting of) 1

005303 TUBING,phen.l4OIDx.2500D 2

046 565 CIRCUIT CARD, drop out (consisting of) 1

C50,51 000 348 CAPACITOR, tantlm .47u1 35V 2

CR50 039 346 RELAY, end 24VDC DPDT 1

D50 028 293 DIODE, zener 6.2V 1W 1

050 022 135 THYRISTOR, SCR 4A 200V SP-67 1

R50 039 106 RESISTOR, CF .25W 470 ohm 1

R51 035 888 RESISTOR, CF .25W 2.2K ohm 1

026837 . INSULATOR,termnyl 3

073 756 . . STAND-OFF, No. 6-32 x .625 Ig 2

121 694 TOOL, extraction pin amp No. 91 037-2-0 1

117 567 TOOL, extraction Amphenol 1

121 481 TOOL, extraction pin molex 1

048 471 TOOL, extraction-pin amp No. 305183 1

OM-1578 Page 46