Miller Electric AUTOMATIC 1D User manual

May
1981
FORM:
OM-1536
OWN
E
RS
MANUAL
1!I1,lI!rI!
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MILLER
ELECTRIC MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON,
WI
54912 USA
ADDITIONAL
COPY PRICE
90
CENTS
NWSA
CODE NO. 4579
PRINTED
IN
U.S.A.
Effective
With Serial
No.
JE1500222
MODEL
AUTOMATIC
1 D

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~. ~o
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LIMITED
WARRANTY
EFFECTIVE:
JUNE
1.
1979
This
warranty
supersedes
all
previous
MILLER warranties and
is
ex
clusive with
no
other
guarantees
or warranties
expressed
or
implied.
LIMITED
WARRANTY-Subject
to
the
terms
and conditions
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
hereof,
Miller Electric
Mfg.
Co.
Appleton,
Wisconsin
warrants
submitted
by
the
original
user
within
the
foregoing
periods.
to
its Distributor/Dealer
that all
new
and
unused
Equipment
(
furnished
by
Miller is free
from defect in
workmanship
and
In the
case
of
Millers
breach of
warranty
or
any
other
duty
material
as
of the time and
place
of
delivery
by
Miller.
No
war-
with
respect
to
the
quality
of
any
goods,
the exclusive
remedies
ranty
is
made
by
Miller with
respect
to
engines,
trade
ac-
therefore shall
be,
at
Millers
option
11)
repair
or (2)
replacement
cessories
or
other
items
manufactured
by
others. Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
engines,
trade accessories
and
other
items
are
sold
subject
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties of their
respective
manufacturers,
if
any
.
All
Miller
service station
or
(4)
payment
of
or
credit for
the
purchase
engines
are
warranted
by
their manufacturer for
one
year
from
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
date
of
original purchase,
return
of the
goods
at
Customers risk
and
expense.
Upon
receipt
of notice of
apparent
defect
or
failure,
Miller shall instruct
the clai-
Except
as
specified
below,
Millers
warranty
does
not
apply
mant
on
the
warranty
claim
procedures
to
be
followed.
to
components having
normal
useful life of
less than
one
lii
year,
such
as
spot
welder
tips, relay
and
contactor
points,
ANY
EXPRESS
WARRANTY
NOT PROVIDED
HEREIN
AND
MILLERMATIC
parts
that
come
in
contact
with the
welding
ANY
IMPLIED
WARRANTY,
GUARANTY
OR REPRESENTA-
?
wire
including
nozzles and nozzle
insulators
where failure does
TION
AS TO
PERFORMANCE,
AND
ANY REMEDY
FOR
not
result from defect in
workmanship
or
material.
BREACH OF
CONTRACT
WHICH,
BUT
FOR THIS
PROVISION,
MIGHT ARISE
BY
IMPLICATION,
OPERATION OF
LAW,
Miller shall be
required
to honor
warranty
claims
on war-
CUSTOM OF
TRADE
OR COURSE OF
DEALING,
INCLUDING
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
ANY
IMPLIED
WARRANTY OF
MERCHANTABILITY
OR OF
within the
following
periods
from the date of
delivery
of
Equip-
FITNESS
FOR PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ment
to
the
original
user:
ANY AND ALL
EQUIPMENT
FURNISHED
BY MILLER IS EX
CLUDED
AND DISCLAIMED
BY
MILLER.
1. Arc
welders,
power
sources
and
components
. .
1
year
2.
Original
main
power
rectifiers 3
years
EXCEPT AS
EXPRESSLY PROVIDED
BY
MILLER IN
(labor
-
1
year
only)
WRITING,
MILLER
PRODUCTS
ARE
INTENDED FOR
3.
All
welding
guns
and
feeder/guns
90
days
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
4. All
other Millermatic
Feeders
1
year
USERS
AND
FOR OPERATION
BY
PERSONS
TRAINED AND
5.
Replacement
or
repair
parts,
exclusive of labor
.
60
days
EXPERIENCED
IN THE USE AND
MAINTENANCE OF
d
6.
Batteries
6
months
WELDING EQUIPMENT
AND
NOT FOR CONSUMERS OR
CONSUMER USE.
MILLER
WARRANTIES DO NOT
EXTEND
provided
that Miller is notified
in
writing
within
thirty
(30)
days
TO,
AND
NO RESELLER
IS
AUTHORIZED TO EXTEND
of
the date
of
such failure.
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
j

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
3
1
-
4.
Standards
Booklet Index
4
SECTION
2
-
INTRODUCTION
2
-
1.
General
Information
And
Safety
5
2
-
2.
Receiving-Handling
5
2
-
3.
Description
5
SECTION
3
-
INSTALLATION
3-1. Location
6
3
-
2.
Shielding
Gas Connections
6
3
-3. Water
Connections
6
3
-
4. Remote
Start
And
Stop
Connections
7
3
-
5.
Normally-Open
And
Normally-Closed
Contacts
Available
For
Control
Of
Weld
Fixtures
7
3
-
6.
Weld Control
Interconnections
8
SECTION
4
-
FUNCTION OF
CONTROLS
4
-
1. Power
Switch
10
4
-
2.
Retract-Advance
Switch
And
Inch
Switch
10
4
-
3.
Purge
Push-Button
Switch
10
4
-
4.
Start Push-Button
Switch
10
4
-
5.
Stop
Push-Button
Switch
11
4
-
6.
Error
Reset
Button
11
4-7.
PressTo
Set
Buttons
11
4
-
8.
Digital
Voltmeter
11
4
-
9.
Digital
Inches Per
Minute
Meter
11
4-10. Weld
Voltage
Control
11
4-11.
WeldWireSpeedControl
11
4-12.
Run-In
Wire
Speed
Control
11
4-13.
Run-In
Voltage
Control
11
4-14.
RunlnlimeControl
12
4-15.
Crater
&
Inch
Wire
Speed
Control
12
4-16.
Crater
Voltage
Control
12
4-17.
Pre-FIow Time Control
12
4-18.
Spot-Continuous
Switch
12
4-19.
SpotlimeControl
12
4-20.
Crater
Time
Control
12
4-21.
BurnbackControl
12
4-22.
Post-Flow
Time
Control
12
4-23. Overload
Protection 12
SECTION
5
-
SEQUENCE
OF OPERATION
5
-
1.
Gas
Metal-Arc
Welding
& Flux Cored Arc
Welding
-
Continuous
13
5-2. Gas
Metal-Arc
Welding&Flux
Cored
Arc
Welding-Spot
13
5
-
3.
Shutting
Down
13
SECTION
6
-
MAINTENANCE
&
TROUBLESHOOTING
6-1.
Inspection
And
Upkeep
13
6-2.
General
14
6
-
3.
Troubleshooting
Chart
14

SECTION
1-SAFETY
RULES
FOR
OPERATION
OF
ARC
WELDING
POWER
SOURCE.
1-1.
INTRODUCTION
We
learn
by experience.
Learning
safety
through
personal
experience,
like
a
child
touching
a
hot
stove
is
harmful,
wasteful,
and unwise.
Let
the
experience
of
others teach
you.
Safe
practices
developed
from
experience
in
the
use
of weld
ing
and
cutting
are
described
in
this
manual.
Research,
devel
opment.
and
field
experience
have evolved reliable
equipment
and safe
installation,
operation,
and
servicing
practices.
Acci
dents
occur
when
equipment
is
improperly
used
or
main
tained.
The
reason
for
the
safe
practices
may
not
always
be
given.
Some
are
based
on common
sense,
others
may
require
technical
volumes
to
explain.
It
is
wiser
so
follow the rules.
Read
and
understand
these
safe
practices
before
attempting
so
install,
operate,
or
service
the
equipment. Comply
with
shese
procedures
es
applicable
to
she
particular equipment
used
and
their instruction
manuals,
for
personal
safety
and
for
she
safety
of
others.
Failure
so
observe
these
safe
practices
may
cause
serious
in
jury
or
death.
When
safety
becomes
a
habit,
the
equipment
can
be used
wish confidence.
These safe
practices
are
divided
into two
Sections:
1
-
General
Precautions,
common
to
arc
welding
and
cutting;
and
2
-
Arc
Welding
(and
Cutting((only(.
Reference standards:
Published Standards
on
safety
are
also
available for additional
and
more
complete
procedures
than
those
given
in this manual.
They
are
listed
in
she
Standards
Index
in
this
manual.
ANSI
Z49,1
is the
most
complete.
The National
Electrical
Code,
Occupational Safety
and
Health
Administration,
local
industrial
codes,
and local
in
spection
requirements
also
provide
a
basis
for
equipment
in
stallation,
use,
and
service.
GENERAL PRECAUTIONS
Burn
Prevention
Wear
protective clothing
-
leather
(or
esbestos(
gaunsles
gloves,
has,
and
high
safesy-soe
shoes. Button shirt collar and
pocket
flaps,
and
wear
cuffless
trousers
to
avoid
entry
of
sparks
and
slag.
Wear
helmet
wish
safety
goggles
or
glasses
with
side
shields
underneath,
appropriate
filter
lenses
or
plates
(prorected
by
clear
cover
glass(.
This
is
a
MUST
for
welding
or
cutting,
(and
chipping(
to
protect
the
eyes
from
radiant
energy
and
flying
mesal.
Replace
cover
glass
when
broken,
pitted,
or
spattered.
See
1-3A.2.
Avoid
oily
or
greasy
clothing.
A
spark
may
ignite
them.
Hot
metal
such
as
electrode
stubs
and
workpieces
should
never
be handled
without
gloves.
Medical first
aid end
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
she
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
inrending
to
weld
or
cut.
B. Toxic
Fume
Prevention
Adequate
ventilation. Severe
discomfort,
illness ordeath
can
result
from
fumes,
vapors,
heat
or
oxygen
enrichment
or
depletion
that
welding
(or
cutsing(
may
produce.
Prevent
them with
adequate
ventilation
aa
described
in
ANSI Stan
dard Z49.1
listed
1
in
Standards
index,
NEVER
ventilate
with
oxygen.
Lead
-.
cadmium
.,
zinc
.,
mercury
.,
and
beryllium
-
bearing
and
similar
materials,
when
welded
(or cus(
may
produce
harmful concentrations
of
toxic
fumes.
Adequate
local
exhaust
ventilation
must
be
used,
or
each
person
in
the
area
as
well
as
the
operator
must
wear
an
air-supplied
respirator.
For
beryllium,
both
must
be
used.
Metals
coated
with
or
containing
materials
that
emit
toxic
fumes
should
not
be
heated
unless
coating
is removed
from
the work
surface,
the
area
is
well
ventilated,
or
she
operator
wears an
air-supplied
respirator.
Work
in
a
confined space
only
while it
is
being
ventilated
and,
if
necessary,
while
wearing
an
air-supplied
respirator.
Gas
leaks
in
a
confined
space
should
be
avoided.
Leaked
gas
in
large
quantities
can
change
oxygen
concentration
danger
ously.
Do
not
bring
gas
cylinders
into
a
confined
space.
Leaving
confined
space,
shut
OFF
gas
supply
as
source
to
prevent
possible
accumulation of
gases
in
the
space
if
down
stream
valves
have been
accidently
opened
or
left
open.
Check
to
be
sure
that the
space
is safe
before
re-entering
it.
Vapors
from
chlorinated
solvenrs
can
be
decomposed
by
the
heat of the
arc
(or flame(
to
form
PHOSGENE, a
highly
toxic
gas,
and
other
lung
and
eye
irritating
products.
The
ultra
violet
(radiant(
energy
of
the
arc
can
also
decompose
tn
chloroeshylene
and
perchioroethylene
vapors
to
form
phos
gene.
DO
NOT
WELD
or
cut where
solvent
vapors
can
be
drawn
into
the
welding
or
cutting
atmosphere
or
where
the
radiant
energy
can
penetrate
to
atmospheres
containing
even
minute
amounts
of
tnichioroethylene
or
perchloroethylene.
C.
Fire
and
Explosion
Prevention
Causes
of
fire
and
explosion
are:
combustibles
reached
by
the
arc,
flame,
flying
sparks,
hot
slag
or
heated
material;
misuse
of
compressed
gases
and
cylinders;
and
short
circuits.
BE
AWARE
THAT
flying
sparks
or
falling
slag
can
pass
through
cracks,
along
pipes,
through
windows
or
doors,
and
through
wall
or
floor
openings,
out
of
sight
of
the
goggled
operator.
Sparks
and
slag
can
fly
35
feet.
To
prevent
fires
and
explosion:
Keep
equipment
clean
and
operable,
free of
oil,
grease,
and
(in
electrical
parts(
of
metallic
particles
that
can
cause
short
circuits.
If
combustibles
are
in
area,
do
NOT
weld
or
cut.
Move
the
work
if
practicable,
to
an
area
free of
combustibles. Avoid
paint
spray
rooms,
dip
tanks,
storage
areas,
ventilators. If the
work cannot be
moved,
move
combustibles
as
least
35 lees
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 sh
ould
not
be
welded
on
(or
cut(.
Walls,
ceilings,
and floor
near
work
should
be
protected
by
heat-resistant
covers
or
shields.
Fire
watcher
must
be
standing
by
with
suitable
fire
ex
tinguishing
equipment
during
and
for
some
time
after
weld
ing
or
cutting
if:
a.
appreciable
combustibles
(including
building
construc
sion(
are
within
35
feet
b.
appreciable
combustibles
are
further
than
35
feet
but
can
be
ignited
by sparks
c.
openings
(concealed
or
visible( in
floors
or
walls
within
35
feet
may
expose
combustibles
to
sparks
d.
combustibles
adjacent
to
walls,
ceilings,
roofs,
or
motel
partitions
can
be
ignited
by
radiant
or
conducted
heat.
Hot work
permit
should
be
obtained
before
operation
to
ensure
supervisors
approval
that
adequate
precautions
have
been taken.
After work
is
done,
check
that
area
is
free
of
sparks,
glowing
embers,
and
flames.
An
empty
container
that
held
combustibles,
or
that
can
pro
duce
flammable
or
toxic
vapors
when
heated,
must
never
be
welded
on
or
cut,
unless
container
has
first been
cleaned
as
described
in
AWS
Standard
A6.O,
listed
3
in
Standards
index.
1-2.
A.
OM-1536
Page
1

This
includes:
a
thorough
steam
or
caustic
cleaning
(or
a
solvent
or
water
washing, depending
on
the combustibles
solubility)
followed
by
purging
and
inerting
with
nitrogen
or
carbon
dioxide,
and
using
protective
equipment
at
recom
mended
in
A6,0.
Waterfilling
just
below
working
level
may
substitute for
inerting.
A
container
with
unknown
contents
should be
cleaned
(see
paragraph
above).
Do
NOT
depend
on sense
of smell
or
sight
to
determine
if
it is
safe
to
weld
or
cut
Hollow
castings
or
containers
must
be
vented before
welding
or
cutting,
They
can
explode,
Explosive
atmospheres.
Never
weld
or
cut
where
the air
may
contain
flammable
dust,
gas,
or
liquid
vapors
(such
as
gaso
line)
-
D.
Compressed
Gas
Equipment
Standard
precautions.
Comply
with
precautions
in
this
manual,
and
those
detailed
in
CGA Standard
P-i,
PRECAU
TIONS FOR SAFE HANDLING
OF
COMPRESSED GASES
IN
CYLINDERS,
listed 6
in
Standards
index.
1.
Pressure
Regulators
Regulator
relief
valve
is
designed
to
protect
only
the
regula
tor
from
overpressure;
it is
not
intended
to
protect
any
downstream
equipment.
Provide
such
protection
with
one or
more
relief
devices.
Never
connect
a
regulator
to
a
cylinder
containing
gas
other
than
that
for which
the
regulator
was
designed.
Remove
faulty
regulator
from
service
immediately
for
repair
(first
close
cylinder
valve).
The
following
symptoms
indicate
a
faulty
regulator:
Leaks
-
if
gas
leaks
externally,
Excessive
Creep
-
if
delivery
pressure
continues
to
rise
with
downstream
valve
closed.
Faulty
Gauge
-
if
gauge
pointer
does
not
move
off
stop
pin
when
pressurized,
nor
returns
to
stop
pin
after
pressure
release.
Repair.
Do
NOT
attempt
repair.
Send
faulty
regulators
for
repair
to
manufacturers
designated
repair
center,
where
special techniques
and
tools
are
used
by
trained
personnel.
2.
Cylinders
Cylinders
must
be
handled
carefully
to
prevent
leaks
and
damage
to
their
walls,
valves,
or
safety
devices:
Avoid
electrical
circuit
contact
with
cylinders
including
third
rails,
electrical
wires,
or
welding
circuits.
They
can
produce
short
circuit
arcs
that
may
lead
to a
serious
accident.
(See
i-3C.)
ICC
or
DOT
marking
must be
on
each
cylinder.
It
is
an
assurance
of
safety
when the
cylinder
is
properly
handled.
Identifying
gas
content
Use
only
cylinders
with
name
of
gas
marked
on
them;
do
not
rely
on
color
to
identify
gas
con
tent.
Notify
supplier
if
unmarked.
NEVER DEFACE
or
alter
name,
number,
or
other
markings
on
a
cylinder.
It
is
illegal
and hazardous.
Empties: Keep
valves
closed,
replace
caps
securely;mark
MT;
keep
them
separate
from FULLS
and
return
promptly.
Prohibited
use.
Never
use
a
cylinder
or
its
contents
for
other
than
its intended
use,
NEVER
as
a
support
or
roller.
Locate
or secure
cylinders
so
they
cannot
be knocked
over.
Passageways
and work
areas.
Keep
cylinders
clear of
areas
where
they
may
be
struck.
Transporting
cylinders.
With
a
crane,
use a
secure
support
such
as
a
platform
or
cradle.
Do
NOT
lift
cylinders
off the
ground
by
their valves
or
caps,
or
by chains,
slings,
or
mag
nets.
Do
NOT
expose
cylinders
to
excessive
heat,
sparks, slag,
and
flame,
etc.
that
may
cause
rupture.
Do not
allow
contents
to
exceed
130F.
Cool
with
water
spray
where
such
exposure
exists.
Protect
cylinders
particularly
valves
from
bumps,
falls,
falling
objects,
and weather.
Replace
caps
securely
when
moving
cylinders.
Stuck
valve.
Do
NOT
use
a
hammer
or
wrench
to
open
a
cylinder
valve
that
can
not
be
opened
by
hand.
Notify
your
supplier.
Mixing
gases.
Never
try
to
mix
any
gases
in
a
cylinder.
Never refill
any
cylinder.
Cylinder
fittings
should
never
be
modified
or
exchanged.
3.
Hose
Prohibited
use.
Never
use hose
other
than that
designed
for
the
specified
gas.
A
general
hose identification
rule
is:
red for
fuel
gas,
green
for
oxygen,
and black for inert
gases.
Use ferrules
or
clamps
designed
for
the hose
(not
ordinary
wire
or
other substitute)
as
a
binding
so
connect
hoses
to
fittings.
No
copper
tubing
splices.
Use
only
standard brass
fittings
to
splice
hose.
Avoid
long
runs
to
prevent
kinks
and abuse.
Suspend
hose
off
ground
to
keep
it from
being
run
over,
stepped
on,
or
other
wise
damaged.
Coil
excess
hose
to
prevent
kinks
and
tangles.
Protect hose from
damage
by
sham edges,
and
by
sparks,
slag,
and
open
flame.
Examine hose
regularly
for
leaks,
wear,
and
loose
connec
tions, Immerse
pressured
hose
in
water;
bubbles
indicate
leaks.
Repair
leaky
or worn
hose
by
cutting
area
out
and
splicing
)i-2D3).
Do NOT
use
tape.
4.
Proper
Connections
Clean
cylinder
valve
outlet of
impurities
that
may
clog
orifices
and
damage
seats
before
connecting regulator. Except
for
hydrogen,
crack
valve
momentarily,
pointing
outlet
away
from
people
and
sources
of
ignition.
Wipe
with
a
clean
lint-
less
cloth.
Match
regulator
to
cylinder.
Before
connecting,
check
that
the
regulator
label and
cylinder
marking
agree,
and that the
regulator
inlet
and
cylinder
outlet match.
NEVER CON
NECT
a
regulator
designed
for
a
particular
gas
or
gases
to
a
cylinder
containing
any
other
gas.
Tighten
connections,
When
assembling
threaded
connections,
clean and smooth
seats
where
necessary.
Tighten.
If
connec
tion
leaks,
disassemble, clean,
and
retighten
using
properly
fitting
wrench.
Adapters.
Use
a
CGA
adapter
(available
from
your
supplier)
between
cylinder
and
regulator,
if
one
is
required.
Use
two
wrenches
to
tighten
adapter
marked
RIGHT and LEFT
HAND
threads.
Regulator
outlet
(or
hose)
connections
may
be
identified
by
right
hand
threads
for
oxygen
and
left hand threads
(with
grooved
hex
on
nut
or
shank) for fuel
gas.
5.
Pressurizing
Steps;
Drain
regulator
of residual
gas
through
suitable
vent
before
opening
cylinder
(or
manifold valve)
by
turning
adjusting
screw
in
(clockwise).
Draining
prevents
excessive
compression
heat
at
high
pressure
seat
by
allowing
seat to
open
on
pressur
ization. Leave
adjusting
screw
engaged slightly
on
single-stage
regulators.
Stand
to side of
regulator
while
opening
cylinder
valve.
Open
cylinder
valve
slowly
so
that
regulator
pressure
in
creases
slowly.
When
gauge
is
pressurized
)gauge
reaches
regu
lator
maximum) leave
cylinder
valve
in
following
position:
For
oxygen,
and
inert
gases,
open
fully
so
seal
stem
against
possible
leak. For
fuel
gas,
open
to
less
than
one
turn
to
permit
quick
emergency
shutoff.
Page
2

Use
pressure
charts
(available
from
your
supplier)
for
safe
and
efficient,
recommended
pressure
sestings
on
regulators.
Check
for
leaks
on
first
pressurization
and
regularly
there
after.
Brush
with
soap
solution
(capful
of
Ivory Liquid
or
equivalent
per
gallon
of
water). Bubbles indicate
leak. Clean
off
soapy
water
after
test;
dried
soap
is
combustible.
E.
User
Responsibilities
Remove
leaky
or
defective
equipment
from
service
immed
iately
for
repair.
See
User
Responsibility
statement
in
equip
ment manual.
F.
Leaving
Equipment
Unattended
Close
gas
supply
at
source
and drain
gas.
G.
Rope Staging-Support
Rope
staging-support
should
not
be used for
welding
or
cut
ting
operation;
rope
may
burn.
1-3.
ARC
WELDING
Comply
with
precautions
in
1-1, 1-2,
and
this
section. Arc
Welding,
properly done,
is
a
safe
process,
but
a
careless
opera
tor
invites
trouble.
The
equipment
carries
high
currents at
significant voltages.
The
arc
is
very
bright
and
hot.
Sparks
fly,
fumes
rise,
ultraviolet
and
infrared
energy
radiates,
weld
ments
are
hot,
and
compressed
gases
may
be
used. The
wise
operator
avoids
unnecessary
risks
and
protects
himself
and
others
from
accidents.
Precautions
are
described
here and in
standards referenced
in
index.
A.
Burn
Protection
Comply
with
precautions
in
1-2.
The
welding
arc
is intense
and
visibly
bright
Its
radiation
can
damage
eyes,
penetrate
lightweight clothing,
reflect from
light-colored
surfaces,
and
burn the
skin
and
eyes.
Skin
burns
resemble
acute
sunburn,
those
from
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-shielded
arc)
in
addition
to
gloves,
hat,
and shoes
)1-2A).
As
necessary,
use
additional
protective
clothing
such
as
leather
jacket
or
sleeves,
flame-proof
apron,
and
fire-resistant
leggings.
Avoid
outergarments
of
untreated
cotton.
Bare
skin
protection.
Wear
dark,
substantial
clothing.
Button
collar
to
protect
chest
and neck and
button
pockets
to
pre
vent
entry
of
sparks.
2.
Eye
and Head
Protection
Protect
eyes
from
exposure
to
arc.
NEVER look
at
an
elec
tric
arc
without
protection.
Welding
helmet
or
shield
containing
a
filter
plate
shade
no.
12
or
denser
must
be
used
when
welding.
Place
over
face
before
striking
arc.
Protect filter
plate
with
a
clear
cover
plate.
Cracked
or
broken
helmet
or
shield should
NOT
be
worn;
radiation
can
pass
through
to
cause
burns.
Cracked,
broken,
or
loose
filter
plates
must
be
replaced
IM
MEDIATELY.
Replace
clear
cover
plate
when
broken,
pitted,
or
spattered.
Flash
goggles
with side
shields
MUST
be
worn
under the
helmet
to
give
some
protection
to
the
eyes
should
she
helmet
not
be lowered
over
the
face before
an arc
is
struck.
Looking
at
an arc
momentarily
with
unprotected
eyes
(particularly
a
high
intensity
gas-shielded
arc)
can cause
a
retinal
burn
that
may
leave
a
permanent
dark
area
in
the field
of vision.
3.
Protection
of
Nearby
Personnel
Enclosed
welding
area.
For
production
welding,
a
separate
room
or
enclosed
bay
is
best.
In
open
areas,
surround
the
operation
with
low-reflective,
non-combustible
screens
or
panels.
Allow
for free
air
circulation,
particularly
at
floor
level.
Viewing
the
weld.
Provide
face
shields
for all
persons
who
will
be
looking
direÆtly
at
the
weld.
Others
working
in
area.
See
that all
persons
are
wearing
flash
goggles.
Before
starting
to
weld,
make
sure
that
screen
flaps
or
bay
doors
are
closed.
B. Toxic Fume Prevention
Comply
with
precautions
in
1-2B.
Generator
engine
exhaust
must be
vented
to
the outside air.
Carbon
monoxide
can
kill.
C. Fire and
Explosion
Prevention
Comply
with
precautions
in
1-2C.
Equipments
rated
capacity.
Do
not
overload
arc
welding
equipment.
It
may
overheat cables
and
cause
a
fire.
Loose
cable
connections
may
overheat
or
flash and
cause
a
fire.
Never
strike
an
arc on
a
cylinder
or
other
pressure
vessel.
It
creates
a
brittle
area
that
can cause
a
violent
rupture
or
lead
to
such
a
rupture
later under
rough
handling.
D.
Compressed
Gas
Equipment
Comply
with
precautions
in
1-2D.
E. Shock
Prevention
Exposed
hot
conductors
or
other bare
metal
in
the
welding
circuit,
or
in
ungrounded,
electrically-HOT
equipment
can
fatally
shock
a
person
whose
body
becomes
a
conductor.
DO
NOT
STAND,
SIT,
LIE,
LEAN
ON,
OR
TOUCH
a
wet
sur
face when
welding,
without suitable
protection.
To
protect
against
shock:
Keep
body
and
clothing
dry,
Never work
in
damp
area
with
out
adequate
insulation
against
electrical
shock.
Stay
on
a
dry duckboard,
or
rubber
met
when
dampness
or
sweat
can
not
be
avoided.
Sweat,
sea
water,
or
moisture
between
body
and
an
electrically
HOT
part
-
or
grounded
metal
-
reduces
the
body
surface
electrical
resistance,
enabling
dangerous
and
possibly
lethal
currents
to
flow
through
the
body.
1,
Grounding
the
Equipment
When
installing,
connect
the frames
of
each
unit
such
as
welding
power
source,
control,
work
table,
and
watr
circula
tor to
the
building
ground.
Conductors
must
be
adequate
to
carry
ground
currents
safely. Equipment
made
electrically
HOT
by
stray
current
may
shock,
possibly fatally.
Do
NOT
GROUND
to
electrical
conduit,
or
to
a
pipe
carrying
ANY
gas
or
a
flammable
liquid
such
as
oil
or
fuel.
Three-phase
connection,
Check
phase
requirement
of
equip
ment 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
electri
cally
HOT
-
a
dangerous
condition
that
can
shock,
possibly
fatally.
Before
welding,
check
ground
for
continuity.
Be
sure
conduc
tors
are
touching
bare
metal
of
equipment
frames
at
connec
tions.
If
a
line
cord
with
a
ground
lead is
provided
with
the
equip
ment
for
connection
to
a
switchbox,
connect
the
ground
lead
to
the
grounded
switchbox.
If
a
three-prong
plug
is
added
for
connection
to
a
grounded
mating
receptacle,
the
ground
lead
must be connected
to the
ground
prong
only.
If
the
line
cord
comes
with
a
three-prong
plug,
connect
to
a
grounded
mating
receptacle.
Never
remove
the
ground
prong
from
a
plug,
or
use
a
plug
with
a
broken
off
ground
prong.
Trademark
of
Proctor
&
Gamble.
OM-1536
Page
3

2.
Electrode
Holders
Fully
insulated
electrode
holders
should
be
used.
Do NOT
use
holders
with
protruding
screws.
3.
Connectors
Fully
insulated
lock-type
connectors
should
be
used
to
join
welding
cable
lengths.
4.
Cables
Frequently
inspect
cables
for
wear,
cracks and
damage.
IMMEDIATELY
REPLACE
those
with
excessively
worn
or
damaged
insulation
to avoid
possibly
-
lethal
shock
from
bared
cable. Cables with
damaged
areas
may
be
taped
to
give
resistance
equivalent
to
original
cable.
Keep
cable
dry,
free
of
oil
and
grease,
and
protected
from
hot
metal
and
sparks.
5.
Terminals And
Other
Exposed
Parts
Terminals
and other
exposed
parts
of
electrical
units
should
have
insulating
covers
secured
before
operation.
6.
Electrode
Wire
Electrode
wire
becomes
electrically
HOT
when
the
power
switch
of
gas
metal-arc
welding
equipment
is
ON
and
welding
gun
trigger
is
pressed.
Keep
hands
and
body
clear
of
wire and
other
HOT
parts.
7.
Safety
Devices
Safety
devices
such
as interlocks
and
circuit
breakers
should
not
be disconnected
or
shunted
Out.
Before
installation,
inspection,
or
service,
of
equipment,
shut
OFF
all
power
and
remove
line fuses
(or
lock
or
red-tag
switches)
to
prevent
accidental
turning
ON
of
power.
Discon
nect
all
cables from
welding
power source,
and
pull
all 115
volts
line-cord
pIu~.
Do
not
open power
Circuit
or
change
polarity
while
welding.
If,
in
an
emergency,
it
must
be
disconnected,
guard
against
shock
burns,
or
flash
from
switch
arcing.
Leaving
equipment
unattended.
Always
shut
OFF
and
dis
connect
all
power
to
equipment.
Power
disconnect switch
must
be
available
near
the
welding
power
source.
1-4.
STANDARDS
BOOKLET
INDEX
For
more
information,
refer
to
the
following
standards
or
their
latest
revisions
and
comply
as
applicable:
1.
ANSI Standard
Z49.1,
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from the
American
Welding
Society,
2501 NW
7th
St..
Miami,
Fla.
33125.
2.
ANSI
Standard
Z87.1,
SAFE
PRACTICE
FOR
OCCUPA
TION
AND
EDUCATIONAL
EYE
AND
FACE
PROTEC
TION,
obtainable from
American
National
Standards
institute,
1430
Broadway,
New
York,
N.Y. 10018.
3.
American
Welding Society
Standard
A6.0,
WELDING
AND
CUTTING
CONTAINERS
WHICH
HAVE
HELD
COMBUSTIBLES,
obtainable
same as
item 1.
4.
NFPA
Standard
51.
OXYGEN-FUEL
GAS
SYSTEMS
FOR WELDING
AND
CUTTING.
obtainable
from
the
National
Fire
Protection
Association,
470
AtlantIc
Avenue, Boston,
Mass. 02210.
5.
NFPA
Standard
51B,
CUTTING
AND
WELDING
PRO
CESSES,
obtainable
same
as
item 4.
6.
CGA
Pamphlet
P-i.
SAFE
HANDLING
OF
COM
PRESSED
GASES
IN
CYLINDERS,
obtain~,Ie
from the
Compressed
Gas
Association,
500 Fifth
Avenue,
New
York,
N.
Y. 10036.
7.
OSHA
Standard 29
CFR,
Part
1910,
Subpart
0,
WELD
ING,
CUTTING
AND
BRAZING.
8.
Code
for
Safety
in
Welding
and
Cutting,
CSA
Standard
W117.2.
Page
4

SECTION
2
-
INTRODUCTION
Dimensions
Weight
Height
Width
Depth
Weld
Control
17-1/2
in.
(445 mm)
13-7/8
in.
(352
mm)
8
in.~
(203
mm)
32-1/2
lbs.
(14.7
kg)
Gas Control
4-1/8
in.
(105 mm)
5-1/8
in.
(130
mm)
10-1/2
in.
(267
mm)
4-1/2
lbs.
(2.0
kg)
Wire Feed
Speed
Range
50 in.
(1.3 m)
to
780
in.
(19.8 m)
per
minute
*Add 1 in.
(25.4
mm)
for front
panel
controls.
Figure
2-1.
Specifications
2
-
1.
GENERAL
INFORMATION
AND SAFETY
A. General
IMPORTANT
A third
signal
word,
______________,
highlights
instruc
tions
which
need
special emphasis
to
obtain
the
most
efficient
operation
of
this
equipment.
WARNING
CAUTION
Information
presented
in this manual
and
on
various
labels,
tags,
and
plates
provided
on
the unit
pertains
to
equipment design,
installation,
operation,
maintenance,
and
troubleshooting
which should
be
read,
understood,
and
followed
for
the safe and effective
use
of
this
equip
ment.
B.
Safety
The
installation,
operation,
maintenance,
and
troubleshooting
of
arc
welding
equipment requires
practices
and
procedures
which
ensure
personal safety
and the
safety
of others.
Therefore,
this
equipment
is
to
be
installed,
operated,
and
maintained
only
by
qualified
persons
in accordance
with
this
manual and
all
ap
plicable
codes
such
as,
but
not
limited
to,
those
listed
at
the end of
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source.
Safety
instructions
specifically
pertaining
to
this
unit
ap
pear
throughout
this
manual
highlighted
by
the
signal
words
___________
and
___________
which
identify
different
levels of
hazard.
~
:
statements
include
installation,
operating,
and
maintenance
procedures
or
practices
which if
not
carefully
followed could
result in serious
personal injury
or
loss of
life.
~UIl.1~I
statements
include
installation,
operating,
and maintenance
procedures
or
practices
which if
not
carefully
followed
could result
in
minor
personal injury
or
damage
to
this
equipment.
2
-
2.
RECEIVING-HANDLING
-
Prior
to
installing
this
equipment,
clean
all
packing
material from around
the
unit and
carefully
inspect
for
any
damage
that
may
have occurred
during
shipment. Any
claims for
loss
or
damage
that
may
have
occurred in
transit
must
be filed
by
the
purchaser
with the carrier.
A
copy
of the
bill
of
lading
and
freight
bill will
be
furnished
by
the carrier
Ofl
request
if occasion
to
file claim
arises.
When
requesting
information
concerning
this
equip
ment,
it
is
essential
that Model
Description
and Serial
(or
Style)
Number of the
equipment
be
supplied.
2
-
3. DESCRIPTION
-
This
weld control
provides
digital
meter
display
of
voltage
and
wire
speed
and
allows
preselection
and
meter
display
of
welding
condi
tions before
operation
begins
as
well
as
continuous
display
during
the
weld
cycle.
This
unit is
also
designed
to
automatically
cycle
preprogrammed welding
events
and
provide
a
constant wire feed
speed
and
arc
voltage
regardless
of
conditions. This
unit is
to
be
used with
the
Deltaweld
series of
power
sources.
The
standard
weld control
has
provisions
to
select
the
PREFLOW
TIME,
RUN-IN
WIRE
SPEED,
WELD
VOLTAGE,
WELD WIRE
SPEED,
CRATER
&
INCH
WIRE
SPEED,
CRATER
VOLTAGE,
CRATER
TIME,
SPOT
TIME,
BURNBACK
TIME,
and
POSTFLOW
TIME,
with RUN-IN
VOLTAGE
and
RUN
IN TIME
con
trols
optional.
Normally-open
and
normally-closed
con
tacts
are
provided
on
each
time
control
to
interface
with
other
equipment
(for
example,
starting
and
stopping
a
welding
fixture).
For
information
on
the
wire
drive
and
spool
support
assemblies,
see
Owners
Manual
1538.
OM-1 536
Page
5

SECTION
3
-
INSTALLATION
4-1/8
in.
5/16
in.
(7.9
mm)
(105
mm)
~LI
ameter
2 Holes
li
~
9-7/8
in.
-
(251
mm)
10-1/2
in.
__________
(267
mm)
3
-
1.
LOCATION
(Figure
3-1)
-
The
service
life and
efficiency
of this unit and
associated
components
will
be
reduced when
they
are
subjected
to
high
levels
of
dust,
dirt, moisture,
corrosive
vapors,
and
extreme
heat.
The location
should
allow
room
to
open
the front
panel
and
to
remove
wrapper(s)
for
installation,
inspection,
maintenance,
and
repair
functions.
Provisions have been
made
for
mounting
the
gas
con
trol
assembly
on
the bottom
of
the
weld
control.
The
gas
control
assembly
may
also
be mounted
anywhere
in
line
with
the
welding
gun
thereby
avoiding routing
the
weld cables and
gas hoses
back
to
the
weld
control.
Lead
lengths
must
be
considered
when
locating
all
com
ponents
of the
weld control.
Mounting
holes
are
provided
in the
gas
assembly
and
weld
control.
Figure
3-1
gives
overall
dimensions
and
mounting
hole
layout.
3
-2.
SHIELDING GAS
CONNECTIONS
(Figure
3-5)
-
Connect
a
hose
(not
supplied)
of
proper
length
and construction from
shielding
gas
supply (regulator
flowmeter)
to
fitting
on
the
IN
panel
of
gas
control
assembly.
The
gas
fitting
is
a
5/8-18
connector
with
right-hand
threads. The
gas
flow
must
be
accurately
controlled
by
a
regulator
and
flowmeter
at
the
source.
Connect
supplied
gas
hose
from
remaining fitting
on
gas
control
assembly
to
barbed
fitting
on
wire
drive
housing.
3
-
3.
WATER
CONNECTIONS
(Optional)
C MJTIION
_________
OVERHEATING
Gas Metal-Arc
Welding
(GMAW)
gun
can
damage
gun.

If
using
a
water-cooled
gun
and
recirculating
coolant
system,
make connections from
the
coolant
system
directly
to
the
gun
hoses.
Do
not
use
water
connections
on
the
gas
control
assembly.
Check
system
periodically
for
proper
coolant flow.
When
a
recirculating
coolant
system
is
not
employed,
and
use
of
the
provided
solenoid
valve
is
desired,
make
TA-080
485
water
connections
at
gas
control
assembly.
The
water
fittings
are
5/8-18
connectors
with
left-hand threads.
Connect
water
hose
from
supply
to
fitting
on
IN
pane)
of
gas
control
assembly.
Connect another hose bet
ween
remaining
fitting
on
gas
control
and
gun
IN
fitting.
Connect and
route
a
hose
from
gun
OUT
fitting
to
a
proper
drain.
Check
system
periodically
for
proper
coolant flow.
7-3/4
in.
(197 mm)
(130
mm)
Coolant
will
flow
as soon as
the
POWER
switch
on
the
weld
control is
placed
in the
ON
position.
If coolant flow
is desired
only
in
conjunction
with
shielding
gas
flow,
1~A-O8O 429
proceed
as
follows:
Locate the lead connected from
pin
8 of
receptacle
RC9
to
terminal
B
on
terminal
strip
2T.
Figure
3-1. Overall Dimensions
And
Mounting
Disconnect this
lead
from
terminal
B
on
2T,
and
recon
Hole
Layout
nect
it
to
terminal
C
on
terminal
strip
iT.
Page6