Miller Electric Tandem Systems User manual

Millerfi
OWNERS
MANUAL
Read
and
follow these instructions and
all
safety
blocks
carefully.
Have
only
trained and
qualified
persons
install,
operate,
or
service this unit.
Call
your
distributor
if
you do
not
understand
the
directions.
''~~
__~'
~'~1~3
April
1993
Effective
With
Style
No.
JD-25
Form:
OM-1553
Tandem
Systems
U
U
U

For
help,
call
your
distributor

or:
MILLER
ELECTRIC
Mfg.
Co.,
P.O. Box
1079,
Appleton,
WI
54912
414-734-9821
cover
8/92
-
ST
I
10
784-A
PRINTED
IN
USA

u-I.
MILLERS
TRUE BLUETM
LIMITED
WARRANTY
Effective January
1,
1992
(Equipment
with
a
serial
number
preface
of
ICC
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
warranties and is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
ii
LIMITED
WARRANTY
-
Subject
to
the
terms
and
conditions below.
MILLER Electric
Mtg.
Co..
Appleton.
WIsconsin,
warrants to
its
original
retail
purchaser
that new
MILLER
equipment
sold after the effective
date
of this
limited
warranty
is free of de
lads
in
material and
workmanship
at
the
time
it
is
shipped
by
MILLER. TIltS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
IMPLIED,
INCLUDING TNE WARRANTIES OF MERCHANTABILITY AND
FIT
NESS.
Within the
warranty
periods
listed
below.
MILLER
will
repair
or
replace
any
war
ranted
parts
or
components
that
tail
due
to
such
defects
in matenal
or
workmanship.
MILLER must
be
notified
in
writing
within
thIrty
130)
days
ot
such
defect
or
tsilure,
at
which
time
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
followed.
MILLER
shall honor
warranty
claims
on
warranted
eguloment
lIsted
below
in
the
event
ot
such
a
lailure
within
the
warranty
time
periods.
All
warranty
time
periods
start
on
the
date
that the
equipment
was
delivered
to
the
original
retail
purchaser.
or
one
year
after the
equipment
is
sent
to
the distributor
t.
5 Years
Parts 3 Years
Labor
*
Original
main
power
rectifiers
2. 3 Years

Parts
and Labor
*
Transtormer/Ractifler Power Sources

Plasma
Arc
Cutting
Power
Sources

Semi-Automatic
and Automatic Wire
Feeders
Robots
3.,
2
Years

Parts
and Labor

Engine
Driven
Welding
Generators
(NOTE
Engines
are
warranted
separately
by
the
engine
manufacturer.)

Air
Compressors
4.
t
Year

Parts
and Labor

Motor
Driven
Guns

Process
Controllers

Water
Coolant
Systems

HF
Units

Grids

Soot
Welders

Load Banks

SDX Transtormers

Running
Gear/Trailers

Field
Options
(NOTE.
Field
options
are
covered
under
True
Bluer
for
the
remaining
warranty
period
of
the
product
they
are
installed
in,
or
for
a
minimum
of
one
year

whichever
is
greater
I
6 Months

Batteries
90
Days

Pans
and Labor

MIG Guns/TIG
Torches

Plasma
Cutting
Torches

Remote Controls

Accessory
Kits

Replacement
Pans
MILLERS True
Bluer
Limited
Warranty
shall
not
apply
to:
1.
Items
tumished
by
MILLER,
but
manutactured
by
others,
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
if
any.
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzles,
contactors
and
relays
or
pans
that tail
due
to
normal
wear
3.
Equipment
that has been modified
by
any
party
other
than
MILLER.
or
equip
ment
that has been
improperly
installed,
improperly
operaled
or
misused
based
upon
industry
standards.
or
equipment
which has
not
had
reasonable
and
necessary
maintenance,
or
equipment
which has
been used
tor
operation
outside of the
specifications
for
the
equipment.
MILLER PRODUCTS ARE INTENDED FOR
PURCHASE AND
USE
BY
COMMER
CIAL/INDUSTRIAL USERS
AND
PERSONS
TRAINED AND
EXPERIEHCED
IN
THE
USE
AND
MAINTENANCE OF WELDING EQUIPMENT
In
the
event
ot
a
warranty
claim covered
by
this
warranty,
the exclusive
remedies
shall
be,
at MILLERS
option
(1)
repair;
or
(2)
replacement;
or.
where
authorized
in
writing by
MILLER
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replace
ment at
an
authorized
MILLER
service
station;
or
(4)
payment
of
or
credit
for
the
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
usel
upon
return
of
the
goods at
customers
risk
and
expense.
MILLERS
option
of
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton,
Wisconsin.
or
F.O. B.
at
a
MILLER
authorized
ser
vice
tacility
as determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
transportation
costs
ot
any
kind
will
be
allowed.
TO THE EXTENT PERMItTED BY
LAW.
THE
REMEDIES
PROVIDED
HEREIN
ARE THE
SOLE
AND
EXCLUSIVE REMEDIES.
IN
NO EVENT
SHALL
MILLER BE
LIABLE FOR
DIRECT, INDIRECt
SPECIAL, INCIDENTAL
OR CONSEQUENTIAL
DAMAGES
(INCLUDING
LOSS OF
PROFIT).
WHETHER
BASED
ON CON
TRACt TORT
OR.ANY
OTHER LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT PROVIDED HEREIN AND
ANY
IMPLIED
WAR
RANTY.
GUARANTY
OR
REPRESENTATION
AS TO
PERFORMANCE.
AND
ANY
REMEDY FOR BREACH OF CONTRACT TORT OR
ANY
OTHER LEGAL
THEORY
WHICH.
BUT FOR THIS
PROVISION,
MIGHT ARISE BY
IMPLICATION,
OPERATION
OF
LAW.
CUSTOM
OF TRADE OR
COURSE OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR PURPOSE,
WITH
RESPECT TO
ANY
AND ALL
EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED
BY MILLER.
Some
states
in
the
U.S.A.
do
not
allow limitations
ot
how
long
an
implied
warranty
lasts, or the exclusion ot incidental, indirect,
special
or
consequential
damages.
so
the
above limitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
spa
cilic
legal
rights,
and other
rights may
be
available,
but
may vary
from
slate
to state.
In
Canada,
legislation
in
some
provinces provides
(or certain
additional
warranties
or
remedies
other than
as
stated
herein,
and
to
the
extent
that
they
may
not
be
waived,
the
limitations
and
esclusions
set out
above
may
not
apply.
This
Limited
Warranty
provides specific
legal rights,
and other
rights
may
be
available,
but
may
vary
from
province
to
province.
5.
6.
al-
RECEIVING-HANDLING
Before
Unpacking
equipment,
Check
carton
for
any
damage
that
may
have
occurred
during
shipment.
File
any
Claims
for
loss
or
damage
with the
delivering
carrier. Assistance
for
filing
or
settling
claims
may
be obtained
from
distributor and/or
equipment
manufacturers
Transportatton
Department.
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number of
your
unit,
The
information
is
located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No,
Date of
Purchase
miller
5/93a

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
6
SECTION
2
-
INTRODUCTION
2
-
1.
General
Information
And
Safety
7
2
-
2.
Receiving-Handling
7
2
-
3.
Description
7
SECTION
3
-
INSTALLATION
3-1.
Location
8
3
-
2. Drive
Roll
And
Wire
Guide
Installation
8
3
-
3.
Welding
Gun
Connections
9
3
-4.
Drive
Motor
Connections
9
3
-
5.
Trailing
Gun Position
Adjustment
9
3
-
6.
Flux
Hopper
Connections
10
3
-
7.
Flux
Nozzle
Adjustment
10
3
-
8. Gun
Component Changes
When
Changing
Wire
Size 10
3
-
9.
Weld
Cable
Connections
11
SECTION
4
-
SEQUENCE
OF OPERATION
4
-
1.
Welding
Wire
Threading
11
4
-
2.
Submerged
Arc
Welding
(SAW)
12
4
-
3.
Shutting
Down
12
SECTION
5
-
MAINTENANCE
5
-
1.
Inspection
And
Upkeep
13
5
-
2.
Cleaning
Of
Drive
Rolls:
.
-
13
5
-
3.
Brush
Inspection
&
Replacement
13
SECTION
6
-
TROUBLESHOOTING
6-1.
General
14
6
-
2.
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
un
wise. Let
the
experience
of others teach
you.
Safe
practices
developed
from
experience
in
the
use
of
welding
and
cutting
are
described
in
this
manual.
Research,
development,
and
field
experience
have
evolved
reliable
equipment
and
safe
installation,
opera
tion,
and
servicing
practices.
Accidents
occur
when
equipment
is
improperly
used
or
maintained. The
reason
for the
safe
practices
may
not
always
be
given.
Some
are
based
on
common
sense,
others
may
require
technical
volumes
to
explain.
It
is wiser
to
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
serious
injury
or
death.
When
safety
becomes
a
habit,
the
equipment
can
be used
with
confidence.
These
safe
practices
are
divided
into
two
Sections:
1
-
General
Precautions,
common
to
arc
welding
and
cutting;
and
2
-
Arc
Welding
(and
Cutting)
(only).
Reference
standards:
Published
Standards
on
safety
are
also
available
for
additional
and
more
complete
pro
cedures
than
those
given
in this
manual.
They
are
listed
in
the
Standards
Index
in this
manual.
ANSI
Z49.1
is
the
most
complete.
The National
ElectricalCode,
Occupational
Safety
and
Health
Administration,
local
industrial
codes,
and
local
inspection
requirements
also
provide
a
basis
for
equip
ment
installation,
use,
and
service.
1-2.
GENERAL
PRECAUTIONS
Different
arc
welding
processes,
electrod.
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 alec
trode
manufacturers
for
specific
technical
data
and
precautionary
measures
concerning
their
material.
A.
Burn Prevention
Wear
protective
clothing
-
gauntlet
gloves designed
for
use
in
welding,
hat,
and
high
safety-toe
shoes. Button
shirt
collar
and
pocket flaps,
and
wear
cuftless
trousers
to
avoid
entry
of
sparks
and
slag.
Wear
helmet with
safety
goggles
or
glasses
with side
shields
underneath,
appropriate
filter
lenses
or
plates
(protected
by
clear
cover
glass).
This is
a
MUST
for
welding
or
cutting,
(and
chipping)
to
protect
the
eyes
from
radiant
energy
and
flying
metal.
Replace
cover
glass
when
broken,
pitted,
or
spattered.
See
1
-3A.2.
Avoid
oily
or
greasy
clothing.
A
spark
may
ignite
them.
Hot
metal
such
as
electrode
stubs
and
workpieces
should
never
be
handled
without
gloves.
Medical
first
aid and
eye
treatment.
First
aid
facilities
and
a
qualified
first aid
person
should
be
available
for
each
shift unless
medical facilities
are
close
by
for
im
mediate
treatment
of flash
burns
of the
eyes
and
skin
burns.
Ear
plugs
should be
worn
when
working
on
overhead
or
in
a
confined
space.
A
hard hat
should
be
worn
when
others
work overhead.
Flammable
hair
preparations
should
not
be
used
by
per
sons
intending
to
weld
or
cut.
B.
Toxic Fume Prevention
Severe
discomfort,
illness
or
death
can
result from
fumes,
vapors,
heat,
or
oxygen
enrichment
or
depletion
that
welding
(or
cutting)
may
produce.
Prevent
them
with
adequate
ventilation
as
described
in
ANSI Stan
dard.Z49.1
listed
1
in
Standards
index.
NEVER
ventilate
with
oxygen.
Lead
-,
cadmium
-,
zinc
-,
mercury
-,
and
beryllium
-
bearing
and
similar
materials,
when
welded
(or
cut)
may
produce
harmful
concentrations
of toxic
fumes.
Ade
quate
local
exhaust
ventilation
must
be
used,
or
each
person
in
the
area as
well
as
the
operator
must
wear an
air-supplied
respirator.
For
beryllium,
both
must
be
us
ed.
Metals
coated with
or
containing
materials
that
emit
toxic
fumes
should not
be
heated
unless
coating
is
removed
from
the
work
surface,
the
area
is
well
ven
tilated,
or
the
operator
wears
an
air-supplied
respirator.
Work
in
a
confined
space
only
while it is
being
ven
tilated
and,
if
necessary,
while
wearing
an
air-supplied
respirator.
Gas
leaks
in
a
confined
space
should
be avoided.
Leaked
gas
in
large
quantities
can
change
oxygen
con
centration
dangerously.
Do
not
bring
gas
cylinders
into
a
confined
space.
Leaving
confined
space,
shut
OFF
gas
supply
at
source
to
prevent
possible
accumulation
of
gases
in
the
space
if downstream
valves
have
been
accidently
opened
or
left
open.
Check
to
be
sure
that the
space
is
safe before
re-entering
it.
Vapors
from chlorinated
solvents
can
be
decomposed
by
the
heat
of
the
arc
(or
flame)
to
form
PHOSGENE,
a
OM-1553
Page
1

highly
toxic
gas,
and other
lung
and
eye
irritating
pro
ducts. The
ultraviolet
(radiant)
energy
of
the
arc
can
also
decompose
trichioroethylene
and
per
chloroethylene
vapors
to
form
phosgene.
DO
NOT
WELD
or
cut
where
solvent
vapors
can
be
drawn
into
the
welding
or
cutting
atmosphere
or
where
the
radiant
energy
can
penetrate
to
atmospheres
containing
even
minute
amounts
of
trichioroethylene
or
per
chioroethylene.
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,
yen
.tilators.
If
the
work
cannot
be
moved,
move com
bustibles
at
least
35 feet
away
Out
of reach
of
sparks
and
heat;
or
protect
against ignition
with
suitable
and
snug-fitting,
fire-resistant
covers or
shields.
Walls
touching
combustibles
on
opposite
sides should
not
be welded
on
(or
cut).
Walls,
ceilings1
and
floor
near
work
should be
protected
by
heat-resistant
covers or
shields.
Fire
watcher
must
be
standing
by
with
suitable fire
ex
tinguishing
equipment
during
and
for
some
time
after
welding
or
cutting
if:
a.
appreciable
combustibles
(including
building
construction)
are
within
35 feet
b.
appreciable
combustibles
are
further
than 35
feet
but
can
be
ignited by
sparks
c.
openings
(concealed
or
visible)
in
floors
or
walls
within
35 feet
may
expose
com
bustibles
to
sparks
d.
combustibles
adjacent
to
walls,
ceilings,
roofs,
or
metal
partitions
can
be
ignited
by
radiant
or
conducted heat.
Hot work
permit
should
be
obtained before
operation
to
ensure
supervisors
approval
that
adequate
precautions
have
been
taken.
After
work
is
done,
check
that
area
is
free of
sparks,
glowing
embers,
and
flames.
An
empty
container
that
held
combustibles,
or
that
can
produce
flammable
or
toxic
vapors
when
heated,
must
never
be
welded
on
or
cut,
unless
container
has
first
been
cleaned
as
described
in
AWS
Standard
A6.O,
listed
3
in
Standards
index.
This
includes:
a
thorough
steam
or
caustic
cleaning
(or
a
solvent or
water
washing,
depending
on
the
com
bustibles
solubility)
followed
by
purging
and
inerting
with
nitrogen
or
carbon
dioxide,
and
using
protective
equipment
as
recommended
in
A6.O.
Waterfilling just
below
working
level
may
substitute
for
inerting.
A
container
with unknown
contents
should be
cleaned
(see
paragraph
above).
Do NOT
depend
on
sense
of
smell
or
sight
to
determine
if
it is
safe
to
weld
or
cut.
Hollow
castings
or
containers
must
be
vented before
welding
or
cutting. They
can
explode.
Explosive
atmospheres.
Never weld
or
cut
where
the
air
may
contain
flammable
dust,
gas,
or
liquid
vapors
(such
as
gasoline).
D.
Compressed
Gas
Equipment
Standard
precautions. Comply
with
precautions
in
this
manual,
and those detailed
in
CGA Standard
P-i,
PRECAUTIONS
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
regulator
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
in
cluding
third
rails,
electrical
wires,
or
welding
cir
cuits.
They
can
produce
short
Circuit
arcs
that
may
lead
to
a
serious
accident.
(See i-3C.)
OM-1553
Page
2

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
content.
Notify supplier
if
unmarked.
NEVER
DEFACE
or
alter
name,
number,
or
other
markings
on a
cylinder.
It
is
illegal
and
hazardous.
Empties: Keep
valves
closed,
replace
caps
securely;
mark
MT;
keep
them
separate
from
FULLS
and
return
promptly.
Prohibited
use.
Never
use
a
cylinder
or
its
contents
for
other than
its
intended
use,
NEVER
as
a
support
or
roller.
Locate
or secure
cylinders
so
they
cannot
be
knocked
over.
Passageways
and
work
areas.
Keep
cylinders
clear
of
areas
where
they
may
be struck.
Transporting cylinders.
With
a
crane,
use
a secure
sup
port
such
as a
platform
or
cradle.
Do
NOT
lift
cylinders
off the
ground
by
their
valves
or
caps,
or
by
chains,
slings,
or
magnets.
Do
NOT
expose
cylinders
to
excessive
heat,
sparks,
slag,
and
flame,
etc.
that
may
cause
rupture.
Do
not
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
exchang
ed.
Coil
excess
hose
to
prevent
kinks
and
tangles.
Protect hose
from
damage by
sharp
edges,
and
by
sparks,
slag,
and
open
flame.
Examine
hose
regularly
for
leaks,
wear,
and loose
con
nections.
Immerse
pressured
hose
in
water;
bubbles in
dicate leaks.
Repair
leaky
or
worn
hose
by
cutting
area
Out
and
splic
ing
(1-2D3).
Do
NOT
use
tape.
4.
Proper
Connections
Clean
cylinder
valve outlet of
impurities
that
may
clog
orifices
and
damage
seats
before
connecting regulator.
Except
for
hydrogen,
crack
valve
momentarily, pointing
outlet
away
from
people
and
sources
of
ignition.
Wipe
with
a
clean
lintless cloth.
Match
regulator
to
cylinder.
Before
connecting,
check
that
the
regulator
label and
cylinder
marking
agree,
and
that
the
regulator
inlet and
cylinder
outlet match.
NEVER
CONNECT
a
regulator
designed
for
a
particular
gas
or
gases
to
a
cylinder
containing
any
other
gas.
Tighten
connections.
When
assembling
threaded
con
nections,
clean and
smooth
seats
where
necessary.
Tighten.
If connection
leaks, disassemble, clean,
and
retighten
using
properly
fitting
wrench.
Adapters.
Use
a
CGA
adapter
(available
from
your
sup
plier)
between
cylinder
and
regulator,
if
one
is
required.
Use
two
wrenches
to
tighten
adapter
marked
RIGHT
and
LEFT
HAND
threads.
Regulator
outlet
(or
hose)
connections
may
be
iden
tified
by
right
hand
threads for
oxygen
and
left hand
threads
(with
grooved
hex
on
nut
or
shank)
for fuel
gas.
5.
Pressurizing
Steps:
Drain
regulator
of residual
gas
through
suitable
vent
before
opening
cylinder
(or
manifold
valve)
by
turning
adjusting
screw
in
(clockwise).
Draining
prevents
ex
cessive
compression
heat
at
high
pressure
seat
by
allowing
seat to
open
on
pressurization.
Leave
adjusting
screw
engaged
slightly
on
single-stage
regulators.
3. Hose
Stand
to
side
of
regulator
while
opening
cylinder
valve.
Prohibited
use.
Never
use
hose
other
than that
designed
for
the
specified
gas.
A
general
hose
identification
rule
is:
red
for fuel
gas,
green
for
oxygen,
and
black
for inert
gases.
Use
ferrules
or
clamps
designed
for the hose
(not
or
dinary
wire
or
other
substitute)
as
a
binding
to connect
hoses
to
fittings.
No
copper
tubing
splices.
Use
only
standard brass
fit
tings
to
splice
hose.
Avoid
long
runs
to
prevent
kinks
and
abuse.
Suspend
hose off
ground
to
keep
it
from
being
run
over,
stepped
on,
or
otherwise
damaged.
Open cylinder
valve
slowly
so
that
regulator
pressure
in
creases
slowly.
When
gauge
is
pressurized
(gauge
reaches
regulator
maximum)
leave
cylinder
valve
in
following
position:
For
oxygen,
and
inert
gases,
open
fully
to
seal
stem
against
possible
leak.
For fuel
gas,
opento
less
than
one
turn to
permit
quick
emergency
shutoff.
Use
pressure
charts
(available
from
your
supplier)
for
safe and
efficient,
recommended
pressure
settings
on
regulators.
Check for
leaks
on
first
pressurization
and
regularly
there-after.
Brush
with
soap
solution
(capful
of
Ivory
OM-1553
Page
3

Liquid
or
equivalent
per
gallon
of
water).
Bubbles
in
dicate
leak.
Clean
off
soapy
water
after
test;
dried
soap
is
combustible.
E.
User
Responsibilities
Remove
leaky
or
defective
equipment
from
service
im
mediately
for
repair.
See
User
Responsibility
statement
in
equipment
manual.
F.
Leaving Equipment
Unattended
Close
gas
supply
at
source
and
drain
gas.
G.
Rope
Staging-Support
Rope
staging-support
should
not
be
used
for
welding
or
cutting
operation;
rope
may
burn.
1-3. ARC
WELDING
-
Comply
with
precautions
in
1-1,
1-2.
and this
section. Arc
Welding,
properly
done,
is
a
safe
process,
but
a
careless operator
invites trouble.
The
equipment
carries
high
currents at
significant
voltages.
The
arc
is
very
bright
and hot.
Sparks
fly,
fumes
rise,
ultraviolet
and
infrared
energy
radiates,
weidments
are
hot,
and
compressed
gases
may
be
us
ed.
The wise
operator
avoids
unnecessary
risks and
pro
tects
himself
and others
from accidents. Precautions
are
described
here and
in
standards referenced
in
index.
A.
Burn
Protection
Comply
with
precautions
in
1-2.
The
welding
arc
is intense and
visibly
bright.
Its
radia
tion
can
damage
eyes,
penetrate
lightweight
clothing,
reflect from
light-colored
surfaces,
and burn
the skin
and
eyes.
Skin
burns resemble
acute
sunburn,
those
from
gas-shielded
arcs are
more
severe
and
painful.
DONT GET
BURNED;
COMPLY
WITH PRECAU
TIONS.
1.
Protective
Clothing
Wear
long-sleeve
clothing (particularly
for
gas-shielded
arc)
in
addition
to
gloves,
hat,
and
shoes
(1-2A).
As
necessary,
use
additional
protective
clothing
such
as
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
prevent entry
of
sparks.
2.
Eye
and
Head
Protection
Protect
eyes
from
exposure
to
arc.
NEVER
look
at
an
electric
arc
without
protection.
Welding
helmet
or
shield
containing
a
filter
plate
shade
no.
12
or
denser
must
be
used
when
welding.
Place
over
face
before
striking
arc.
Trademark
of
Proctor
&
Gamble.
Protect
filter
plate
with
a
clear
cover
plate.
Cracked
or
broken
helmet
or
shield
should
NOT
be
worn;
radiation
can
pass
through
to
cause
burns.
Cracked,
broken,
or
loose
filter
plates
must
be
replaced
IMMEDIATELY.
Replace
clear
cover
plate
when
broken,
pitted,
or
spattered.
Flash
goggles
with
side
shields
MUST
be
worn
under
the helmet
to
give
some
protection
to
the
eyes
should
the helmet
not
be
lowered
over
the
face before
an
arc
is
struck.
Looking
at
an arc
momentarily
with
unprotected
eyes
(particularly
a
high
intensity
gas-shielded
arc)
can
cause a
retinal
burn
that
may
leave
a
permanent
dark
area
in
the
field
of
vision.
3.
Protection of
Nearby
Personnel
Enclosed
welding
area.
For
production
welding,
a
separate
room
or
enclosed
bay
is best. In
open
areas,
surround the
operation
with
low-reflective,
non-
combustible
screens or
panels.
Allow for free air
circula
tion,
particularly
at
floor
level.
Viewing
the
weld.
Provide
face shields
for all
persons
who
will
be
looking
directly
at
the weld.
Others
working
in
area.
See
that all
persons
are
wearing
flash
goggles.
Before
starting
to
weld,
make
sure
that
screen
flaps
or
bay
doors
are
closed.
B. Toxic Fume
Prevention
Comply
with
precautions
in
1-2B.
Generator
engine
exhaust
must
be vented
to
the
outside
air.
Carbon
monoxide
can
kill.
C.
Fire
and
Explosion
Prevention
Comply
with
precautions
in
1
-2C.
Equipments
rated
capacity.
Do
not
overload
arc
welding
equipment.
It
may
overheat cables and
cause
a
fire.
Loose cable
connections
may
overheat
or
flash
and
cause a
fire.
Never strike
an arc on
a
cylinder
or
other
pressure
vessel. It
creates
a
brittle
area
that
can cause a
violent
rupture
or
lead
to
such
a
rupture
later under
rough
handling.
D.
Compressed
Gas
Equipment
Comply
with
precautions
in
1
-2D.
OM1553
Page
4

E.
Shock
Prevention
2.
Electrode
Holders
Exposed
hot
conductors
or
other
bare metal
in
the
welding
circuit,
or
in
ungrounded,
electrically-HOT
equipment
can
fatally
shock
a
person
whose
body
becomes
a
conductor.
DO
NOT
STAND,
SIT,
LIE.
LEAN
ON,
OR
TOUCH
a wet
surface
when
welding,
without
suitable
protection.
To
protect
against
shock:
Keep body
and
clothing
dry.
Never
work
in
damp
area
without
adequate
insulation
against
electrical
shock.
Stay
on a
dry
duckboard,
or
rubber
mat
when
damp
ness
or
sweat
can
not
be avoided.
Sweat,
sea
water,
or
moisture
between
body
and
an
electrically
HOT
part
-
or
grounded
metal
-
reduces
the
body
surface
electrical
resistance,
enabling
dangerous
and
possibly
lethal
currents
to
flow
through
the
body.
1.
Grounding
the
Equipment
When
arc
welding
equipment
is
grounded
according
to
the
National
Electrical
Code,
and the
work
is
grounded
according
to
ANSI
Z49.1
Safety
In
Welding
And
Cut
ting,
a
voltage
may
exist
between
the electrode
and
any
conducting object.
Examples
of
conducting
objects
include,
but
are
not
limited
to,
buildings,
electrical
tools,
work
benches,
welding
power
source
cases,
workpieces,
etc.
Never
touch
the
electrode
and
any
metal
object
unless
the
welding
power
source
is
off.
When
installing,
connect
the frames
of each unit
such
as
welding
power
source,
control,
work
table,
and
water
circulator
to
the
building
ground.
Conductors
must
be
adequate
to
carry
ground
currents
safely.
Equipment
made
electrically
HOT
by
stray
current
may
shock,
possibly
fatally.
Do
NOT
GROUND
to
electrical
conduit,
or
to
a
pipe
carrying
ANY
gas
or a
flammable
li
quid
such
as
oil
or
fuel.
Three-phase
connection.
Check
phase
requirements
of
equipment
before
installing,
if
only
3-phase
power
is
available,
connect
single-phase
equipment
to
only
two
wires
of the
3-phase
line. Do
NOT
connect
the
equip
ment
ground
lead
to
the
third
(live)
wire,
or
the
equip
ment
will
become
electrically
HOT
-
a
dangerous
condi
tion
that
can
shock,
possibly
fatally.
Before
welding,
check
ground
for
continuity.
Be
sure
conductors
are
touching
bare
metal
of
equipment
frames
at
connections.
If
a
line cord
with
a
ground
lead
is
provided
with the
equipment
for
connection
to
a
switchbox,
connect
the
ground
lead
to
the
grounded
switchbox.
If
a
three-
prong
plug
is added
for
connection to
a
grounded
mating
receptacle,
the
ground
lead must
be
connected
to
the
ground
prong
only.
If
the
line
cord
comes
with
a
three-prong
plug,
connect
to
a
grounded
mating
recep
tacle.
Never
remove
the
ground
prong
from
a
plug,
or
use
a
plug
with
a
broken
oft
ground
prong.
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
a.
Equipment
with
output
on/off control
(con
tactor)
Welding
power
sources
for
use
with
the
gas
metal
arc
welding
(GMAW),
gas
tungsten
arc
welding
(GTAW)
and
similar
processes
normally
are
equipped
with devices
that
per
mit on-off control of the
welding
power
out
put.
When
so
equipped
the
electrode
wire
becomes
electrically
HOT when the
power
source
switch
is ON
and
the
welding
gun
switch
is closed. Never touch the
electrode
wire
or
any
conducting object
in
contact
with
the
electrode
circuit
unless the
welding
power
source
is off.
b.
Equipment
without
output
on/off
control
(no contactor)
Welding
power
sources
used with
shielded
metal
arc
welding
(SMAW)
and similar
pro
cesses
may
not
be
equipped
with
welding
power
output
on-off control
devices.
With
such
equipment
the electrode
is
electrically
HOT
when
the
power
switch is turned ON.
Never
touch
the electrode unless
the
welding
power
source
is
off.
7.
Safety
Devices
Safety
devices
such
as
interlocks
and
circuit
breakers
should
not be
disconnected
or
shunted
out.
Before
installation,
inspection,
or
service,
of
equip
ment,
shut
OFF
all
power
and
remove
line
fuses
(or
lock
OM-1553
Page
5

or
red-tag
switches)
to
prevent
accidental
turning
ON
of
power.
Disconnect
all
cables
from
welding
power
source,
and
pull
all
115 volts
line-cord
plugs.
Do
not
open
power
circuit
or
change
polarity
while
welding.
If,
in
an
emergency,
it
must
be
disconnected,
guard
against
shock
burns,
or
flash from
switch
arcing.
Leaving
equipment
unattended.
Always
shut
OFF
and
disconnect
all
power
to
equipment.
Power
disconnect
switch
must
be
available
near
the
welding
power
source.
F.
Protection
For
Wearers Of
Electronic
Life
Support
Devices
(Pacemakers)
Magnetic
fields
from
high
currents
can
affect
pacemaker. operation.
Persons
wearing
electronic life
support
equipment
(pacemaker)
should
consult with
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
1-4.
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,
550
Le Jeune
Rd.
P.O.
Box
351040,
Miami,
FL
33135.
2.
NIOSH,
SAFETY
AND HEALTH
IN
ARC
WELDING
AND GAS
WELDING AND
CUTTING
obtainable
from
the
Superintendent
of
Documents,
U.S.
Government
Printing
Office.
Washington,
D.C.
20402.
3.
OSHA,
SAFETY
AND HEALTH
STANDARDS,
29CFR
1910,
obtainable
from
the
U.S.
Govern
ment
Printing
Office,
Washington,
D.C. 20402.
4.
ANSI
Standard
Z87.1,
SAFE
PRACTICES FOR
OCCUPATION
AND
EDUCATIONAL
EYE
AND
FACE
PROTECTION
obtainable
from the
American
National
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
Broadway,
New
York,
NY
10018.
6.
ANSI Standard
Z49.2,
FIRE
PREVENTION
IN
THE
USE
OF
CUTTING
AND
WELDING PRO
CESSES
obtainable from
the
American National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
7.
AWS
Standard
A6.0,
WELDING
AND CUT
TING
CONTAINERS
WHICH
HAVE HELD
COM
BUSTIBLES
obtainable
from
the
American
Welding
Society,
550
Le
Jeune
Rd.
P.O.
Box
351040,
Miami FL
33135.
8. NFPA
Standard
51,
OXYGEN
-
FUEL
GAS
SYSTEMS
FOR WELDING
AND
CUTTING
ob
tainable
from
the
National Fire Protection
Association,
470
Atlantic
Avenue,
Boston,
MA
02210.
9. NFPA
Standard
70-1978,
NATIONAL
ELEC
TRICAL
CODE
obtainable
from
the National Fire
Protection
Association,
470 Atlantic
Avenue,
Boston,
MA
02210.
10. NFPA
Standard
51
B,
CUTTING
AND
WELDING
PROCESSES
obtainable from the
National
Fire
Protection
Association,
470 Atlantic
Avenue,
Boston,
MA
02210.
ii.
CGA
Pamphlet
P-i,
SAFE HANDLING OF COM
PRESSED
GASES
IN
CYLINDERS obtainable
from the
Compressed
Gas
Association,
500
Frfth
Avenue,
New
York,..NY
10036.
12.
CSA Standard
Wi
17.2,
CODE FOR
SAFETY
IN
WELDING AND CUTTING
obtainable from
the
Canadian
Standards
Association,
Standards
Sales,
178 Rexdale
Boulevard, Rexdale,
Ontario,
Canada M9W 1R3.
13.
NWSA
booklet,
WELDING SAFETY
BIBLIOGRAPHY
obtainable from the
National
Welding
Supply
Association,
1900 Arch
Street,
Philadelphia,
PA
19103.
14.
American
Welding
Society
Standard
AWSF4.1
Recommended
Safe
Practices
for
the
Prepara
tion for
Welding
and
Cutting
of
Containers
and
Piping
That Have Held Hazardous
Substances,
obtainable
from the
American
Welding Society,
560
LeJeuneRd.
P.O.
B~351040,
Mam,
FL33135.
15.
ANSI Standard
Z88.2
Practice
for
Respiratory
Protection
obtainable from
the American Na
tional
Standards
Institute,
1430
Broadway,
New
York,
NY 10018.
OM-1553
Page
6

SECTION
2
-
INTRODUCTION
Model
Speed Range
Per Minute
Electrode Wire
Diameter
Capacity
Dimensions
Weight
Net
Ship
Al
20
to
190
in.
(0.5
to
4.8
m)
5/64
thru
5/32
in.
(2
thru 4
mm)
Height:
20-7/8
in.
(530
mm)
Width: 11-1/2
in.~
(292
mm)
Length:
13-3/4 in.
(349
mm)
41
lb.
(19
kg)
44 lb.
(20
kg)
Al D
15
to
200
in.
(0.4 to
5
m)
2
-
1.
GENERAL
INFORMATION
AND SAFETY
A.
General
Information
presented
in this
manual
and
on
various
labels,
tags,
and
plates
on
the
unit
pertains
to
equip
ment
design,
installation,
operation,
maintenance,
and
troubleshooting
which should
be
read, understood,
and
followed for safe and
effective
use
of this
equipment.
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
______
which
identify
L~iL1:hll~cI
statements
include
installation,
operation,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed could result
in
serious
personal injury
or
loss of
life.
CAUTION
____________
statements
include
installation,
operation,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could result
in minor
personal injury
or
damage
to
this
equipment.
A
third
signal
word,
Il~I~I1~1f~Il
highlights
instruc
tions
which need
special
emphasis
to
obtain
the
most
efficient
operation
of this
equipment.
2
-
2.
RECEIVING-HANDLING
-
Before
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
will
be
furnished
by
the
manufacturer
on re
quest
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
it is
essential
that
Model
Description
and
Style
Number
of
the
equipment
be
supplied.
2
-
3. DESCRIPTION
Tandem
wire drive
systems
are
designed
for
Submerg
ed
Arc
Welding
(SAW).
Two
welding
electrodes
are
fed
into
one
weld
puddle
by
two
separate
wire
drive
units
and
welding
guns.
Each
unit
requires
its
own control
and
power
source.
This
allows
different
parameters
to
be
set
on
each wire
if
required.
Both wire
drive
assemblies
are
mounted
on a
common
bracket.
The
lead
assembly
is
mounted
in
a
fixed
posi
tion
while
the
trailing
assembly
has swivel and
up/down
adjustment.
Wire drive units
are
available
with
two
drive
rolls
only
and
can
be
ordered for
use
with
standard
(nondigital)
and
digital
controls.
System
includes 2
wire drive
assemblies,
2
guns,
and
a
common
mounting
bracket. Order
contact
tubes
separately.
Al
models
are
for
use
with
Automatic
1
or
Automatic
2
weld
controls
(nondigital
controls).
Al
D
models
are
for
use
with
Automatic
1
D
weld
con
trols
(digital
controls).
*Add
7/8
in.
(22.2 mm)
For
D
Models
Figure
2
-
1.
Specifications
WARNING
words
different
levels
of hazard.
and
CAUTION
OM-1553
Page
7

Add
7/8
in.
(22.2
mm)
for
D
Modele.
SECTION
3
-
INSTALLATION
i
Gun
TC-I
10764
Figure
3
-
1. Overall Dimensions
And
Mounting
Hole
Layout
3
-
1.
LOCATION
The
service life and
efficiency
of
this
system
and
associated
components
are
reduced when
they
are
sub
jected
to
high
levels of
dust,
dirt,
moisture,
corrosive
vapors,
and
extreme
heat.
The location
should
allow
room
for
installation,
inspec
tion,
adjustments,
maintenance,
and
repair
functions.
Lead
lengths
must
be considered
when
locating
the
wire
drive
assembly.
Mounting
holes
are
provided.
Figure
3-1
gives
overall
dimensions
and
mounting
hole
layouts.
The
mounting
bracket
can
be
installed
directly
onto
a
fixture
or
can
be mounted to
a
cross
slide,
weld
oscillator,
or
swivel
mount
installed
onto
a
fixture.
3
-
2.
DRIVE
ROLL
AND
WIRE
GUIDE
INSTALLA
TION
-
Upon
initial
installation,
or as a
result
of
changes
in wire size
and
type,
it
is
necessary
to
install
the
required
drive
rolls
and wire
guides.
Procedures
are
the
same
for both
wire
drive
assemblies.
Having
selected
the
appropriate
drive rolls
and
wire
guides,
proceed
to
the
following
installation
instruc
tions.
A. Drive
Roll
Installation
(Figure
3-2)
Figure
3
-
2.
Drive
Roll
Installation
TB-ill
203
1.
Loosen
pressure
adjustment
knob,
and
pivot
it
free
of
the
cover.
2.
Pivot
gear
cover
away
to
expose pressure
gear.
Gun Connector
Opening
OM-1553
Page
8

3.
Loosen
and
remove
the three
securing
screws on
each
gear.
4.
Align
holes
on
each
pair
of
split
drive
rolls,
insert
a
securing
screw
and
slide
a
drive
roll
Onto
the
drive
gear
and
pressure
gear
with
screw
in
line
with
one
of
the
threaded
holes.
Insert
remaining
screws
and
tighten.
IMPORTANT
______________
The
split
drive rolls
are
of the
double
usage
type.
When the knurled
groove
of the drive rolls
becomes
worn,
the
spilt
halves
may
be reversed
so
that
the unused
edges
provide
a new
knurled
groove.
B.
Inlet
Wire
Guide
(Figure
3-2)
1. Loosen the inlet wire
guide
securing
screw.
2.
Insert
the
inlet
wire
guide
into drive
assembly.
Secure
by
tightening
screw.
IMPORTANT
______________
Drive roll
alignment
has been
factory
set,
but
if
readjustment
is
necessary,
rotate
the
drive
gear
securing
bolt
thereby
moving
the
drive
roll
in
or
out
to
the
desired
position.
The
drive
roll
on
the
pressure
gear
will
locate
itself
on
the wire when the
gear
cover
is
replaced
and
the
gears
mesh
together.
3
-
5.
TRAILING
GUN
POSITION
ADJUSTMENT
(Figure
3-3)
-
Trailing
gun
angle
and
height
can
be
ad
justed
to
provide
required
weld
penetration
and
bead
width.
The
trailing
gun
position
can
be
adjusted
vertically
by
moving
the
motor
mounting
bracket
up
or
down.
The
distance and
angle
between
leading
gun
and
trailing
gun
can
be
adjusted
by
rotating
the
entire
trailing
gun
motor
assembly.
L~~E
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can cause
puncture
wounds;
HOT
SURFACES
can
burn
skin.

Do
not
touch live
electrical
parts.

Shut
down weld control
and
welding power
source
and
disconnect
input
power
employing
lockout/tagging
procedures
before
making
gun
adjustments.
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
disconnecting
device..

A/low
gun
to
cool before
touching.
The
welding
wire and all metal
parts
in
contact
with
it
carry
weld
current
when the
welding
power
source con
tactor
is
energized.
IMPORTANT: The
outlet
guides
should
be
installed
so
that
the
tip
of
the
guide
is
as
close
to
the drive roll
as
possible
without
touching.
2.
Insert
leading
(flux)
gun
into
the
fixed
position
drive
assembly
opposite
the
inlet
guide.
Tighten
securing
knob.
3.
Insert
trailing
gun
into the
adjustable
position
drive
assembly opposite
the
inlet
guide. Tighten
securing
knob.
3
-
4.
DRIVE
MOTOR
CONNECTIONS
-
Connect
the
proper
plug
from
the weld
control
to
the
plug
from
the drive
motor
for
both
wire
drive
assemblies
(see
weld
control
Owners
Manual).
A.
Angle
Adjustment
1. Loosen
motor
hold-down
clamp
screws
(see
Figure
3-3).
2.
Rotate
assembly
to
desired
position.
3.
Tighten
motor
hold-down
clamp
screws.
B.
Vertical
Adjustment
1.
Loosen
the four
motor
mounting
bracket
nuts
(see
Figure
3-3).
2. Move
assembly
up
or
down
to
desired
position.
3.
Tighten
motor
mounting
bracket
nuts.
IMPORTANT
Each wire drive
housing
is
made with
mounting
ho/es of sufficient
clearance to
provide
ad
justment
of
the
wire
guides
up
or
down
in
relation
to
the
drive rolls. This
adjustment
has
been
factory
set,
but
if
readjustment
becomes
necessary,
loosen
mounting
bolts,
weld terminal
nut
and bolt.
Slide
the
wire
drive
housing
upward
or
downward
until the
wire
can
be
fed
straight through
the
guides
while seated
in
the
drive roll
groove.
Tighten
mounting
bolts,
weld terminal bolt and
Motor
Hold-down
p
Screws
nut.
3
-
3.
WELDING GUN
CONNECTIONS
(Figures
3-1
and
3-2)
IMPORTANT
)
The
outlet wire
guide
is
provided
as
part
of
gun
assembly.
1.
Loosengun
securing
knobs.
Motor
Hold-Down
Clamp
Screws
Figure
3
-
3.
Trailing
Gun
Adjustments
OM-1553
Page
9

3
-
6.
FLUX
HOPPER
CONNECTIONS
-
Connect
the
flux
hopper
or
flux
dispensing
tube
to
the
flux
inlet
on
the
leading
gun.
The
flux flow
can
be
regulated
by
the valve
on
the
gun
or
by
the
valve
on
the
hopper
(if
applicable).
If
an
electric
or
manual valve
is
provided
on
the flux
hopper
and
is
used
for
flux
flow
control,
place
the
gun
flux valve
in the
open
position.
3
-
7.
FLUX
NOZZLE
ADJUSTMENT
(Figure
3-4)
L~~U~E
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can
cause
puncture
wounds;
HOT
SURFACES
can
burn
skin.

Do
not
touch live electrical
parts.

Shut
down weld
i.ontro/
and
we/ding
power
source
and
disconnect
input
power
employing
lockout/tagging
procedures
before
changing
gun
components
or
wire
size.
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
disconnecting
device.

Allow
gun
to
cool before
touching.
The
welding
wire
and
all
metal
parts
in
contact
with it
carry
weld
current
when
the
welding
power
source
con
tactor
is
energized.
ul~I~s11~I~
As
a
starting
point,
position
nozzle
so
that
bottom
of
nozzle
is
flush with
end
of
contact
tube.
Increase
or
decrease
flux
depth
to
a
point
where
arc
flash-throughs
do
not
occur.
The
nozzle extension
with
flux
guide
can
be moved
ver
tically
and
rotationally
to
the
desired
position
by
loosen
ing
the nozzle
mounting
nut
and
rotating
extension
noz
zle.
Secure
nozzle
extension
by
tightening
mounting
nut.
3
-
8. GUN
COMPONENT
CHANGES
WHEN
CHANGING
WIRE
SIZE
-
As
a
result
of
component
wear,
or
when
changing
welding
wire
size,
it
is
necessary
to
change
components.
Obtain
the
proper
replacement
parts,
and
proceed
with
the
following
in
structions.
L~1
a.1~I
fA~I
~
The
monocoil
liner
is
used for
5/64
in.
(2
mm)
wire
only.
A.
Leading
(Flux)
Gun
(Figure
3-4)
1.
Disassembly
a.
Release
drive
roll
tension,
cut
off
tip
of
welding
wire,
and
manually
retract
welding
wire
from
gun.
b.
Disconnect
flux
supply
hose from
flux
inlet.
c.
Remove
gun
from
drive
assembly.
d.
Remove
the nozzle.
e.
Remove
contact
tube.
f.
Remove monocoil liner
if
applicable.
2.
Assembly
a.
Reverse
preceding
Steps
a
through
f
replac
ing
monocoil liner
if
applicable.
b.
See Section
3-7 for
flux
nozzle
adjustment
information.
L~~E
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can cause
puncture
wounds;
HOT
SURFACES
can
burn skin.

Do
not
touch
live
electrical
parts.

Shut
down
weld
control
and
welding
power
source
and
disconnect
input
power
employing
lockout!
tagging
procedures
before
changing
gun
components
or
wire
size.
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
disconnecting
device.

Allow
gun
to cool before
touching.
The
welding
wire
and
all metal
parts
in
contact with it
carry
weld
current
when
the
welding
power
source
con
tactor
is
energized.
ni
Feeder Connector
Tube
Nozzle
Mounting
Nut.
Contact
Nozzle
Extension
Guide
TB-049
~77.B
Figure
3
-
4.
Leading
(Flux)
Gun
OM-1553
Page
10

IMPORTANT:
The flux
gun
can
be used
with
a
grav,~
ty
feed
or a
pressurized
flux
delivery
system.
When
used
with
a
pressurized
flux
system,
install
bushing
(see
Figure
3-4)
on
flux
hose, c/amp
flux inlet
adapter
tube
on
flux
inlet,
and
clamp
bushing
on
flux
hose
in
adapter
tube.
If
flux
inlet control
binds,
shut
off flux
supply
at
source
and
move
lever
back
and
forth.
If
control
will
not
move,
disconnect
flux
hose and
remove
nozzle
exten
sion
portion
(has
control
in
it)
from
head
tube.
Disassemble
inlet
control,
clean,
and
reassemble.
b. Remove
gun
from drive
assembly.
c.
Remove
contact tube
adapter.
d.
Remove
monocoil
liner
if
applicable.
2.
Assembly:
reverse
preceding Steps
a
through
d
replacing
monocoil liner
if
applicable.
3
-
9.
WELD CABLE
CONNECTIONS
(Figure
3-2)
a.
Release drive
roll
tension,
welding
wire,
and
manually
wire
from
gun.
WARNING:
_____
ELECTRIC
SHOCK
can
kill.

Do
not
touch live
electrical
parts.

Shut
down
weld
control
and
welding
power
source
and
disconnect
input
power
employing
lockout/tagging
procedures
before
making
weld cable
connections.
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
disconnecting
device.
A
weld
cable
terminal
is
provided
on
each
wire
drive
housing
for
connecting
the
weld
cable
from the
welding
power
source.
CAUTION
__________
WELD
CURRENT
present
on
ground
ed wire
feeder
parts
can cause
equipment
damage.

Do
not
allow
welding
cable
to
touch
grounded
feeder
parts.
If
the
welding
cable
lug
orexposed
welding
cable is
in
contact
with
any
grounded
feeder
components
during
operation,
the
115
Volts/Contactor
Control
cord and
plugs
may
be
damage.
Route and
connect
the
weld
cable
from the
welding
power
source
to
the weld
cable
terminal
on
the
wire
drive
housing
as
instructed in
the weld
control
Owners
Tube
Adapter
Manual.
IMPORTANT
______________
Ensure that
the
weld cable terminal is
kept
clean
at
all
times. Also
ensure
that the
nut
on
this
terminal is
secure.
If
either
one
of
these conditions is
not
met,
erratic
weld
current
may
result.
SECTION
-
SEQUENCE
OF
OPERATION
4
-
1.
WELDING
WIRE
THREADING
L~~U~E
ELECTRIC
SHOCK
can
kill.
WELDING
WIRE
can
cause
puncture
wounds.

Do
not
touch live
electrical
parts.

Do not
energize
welding
power
source
and
weld
control
until instructed
to
do
so.-

Do not
point
gun
toward
any
part
of
the
body,
any
conductive
surface,
or
other
personnel
when
threading
welding
wire.
The
welding
wire and
all
metal
parts
in
contact
with
it
are
energized
while
welding.
IMPORTANT:
The
welding
wire
threading
procedure
is the
same
for
both
guns.
1.
Connect
the
gun
to
the
drive
assembly,
if
ap
plicable.
2.
Install
the
wire
(reel-type
or
spool-type)
as
in
structed
in the
weld
control
Owners
Manual.
3.
Loosen
the
knob(s)
on
the
drive
roll
pressure
ad
justment(s),
pivot
the
pressure
adjustment(s)
free of
the
cover(s),
and
pivot
the
pressure
gear
assembly(ies)
away
to
an
open
position.
B.
Trailing
Gun
(Figure
3-5)
1.
Disassembly
cut
off
tip
of
retract
welding
~OutIet Guide
Feeder
Connector
~
TA-i
10783
Figure
3
-
5.
Trailing
Gun
OM-1553
Page
11

t~I~1:If1~L~
Spooled
wire
has
a
tendency
to
unravel
when
loosened
(rain
the
spool.
Maintain
a
firm
grip
on
the
wire
during
the
threading
operation.
4.
Cut
off
any
portion
of
the
free
end
of
the wire
which
is
not
straight.
If
necessary,
straighten
wire
to
remove
cast.
Ensure that
the
cut
end
is
free
from
rough
surfaces
to
permit
proper
feeding.
5.
Feed
the
wire
through
the
inlet
wire
guide
past
the
drive
rolls,
and
on
into
the
outlet
wire
guide.
Feed
approximately
4
in.
(102
mm)
of
wire
into
the outlet wire
guide.
6. Pivot
the
pressure gear
assembly(ies)
closed
making
sure
the
teeth
on
the
pressure
gear
mesh
with
the
teeth
on
the
drive
gear.
The
welding
wire
must
also
be
in
the
grooves
of
the
drive
rolls.
7. Pivot the
pressure
adjustment
knob(s)
until the
washer(s)
on
the
pressure
adjustment(s)
is
seated
on
top
of
the
cover(s).
8.
Turn
the
pressure
adjustment
knob(s)
in
a
clockwise direction until
the
drive
rolls
are
tight
against
the
welding
wire. Do
not
overtighten.
Further
adjustment
to
attain
desired
clamping
pressure
can
be
made
after
the
welding
power
souce
and the
weld
control
are
put
into
opera
tion.
9.
Energize
the
welding
power
source.
10. Place
the
welding
control
POWER
switch
in
the
ON
position.
11.
Set
the
CRATER
&
JOG
SPEED
control
to
desired
position.
Place
the
RETRACT-
ADVANCE switch
in the
ADVANCE
position.
12.
Depress
the
JOG
switch.
This
will
run
the
welding
wire
through
the
gun
without
placing
weld
current
on
the
welding
wire.
Release the
JOG
switch
when
welding
wire
extends
approx
imately
one
inch
(25
mm)
out of
gun
tip.

Do
not
use
wet
or
damp
flux.

Do
not
pinch
flux
feed
hose.

Keep
foreign
matter
Out
of flux
system.
The
welding
wire and
all
metal
parts
in
contact
with
it
are
energized
while
welding.
FUMES
AND
GASES
can
seriously
harm
your
health.

Use
enough
ventilation
to
keep
fumes and
gases
from
the
breathing
zone.
HOT
METAL.
SLAG.
AND HOT
SURFACES
can
cause
fire
and
burns.

Watch
for
fire.

Have
a
fire
extinguisher
nearby
and know
how
to
use
it.

Allow work
and
equipment
to
cool
before handl
ing.

Wear
proper
eye,
hand,
and
body protection.
WELDING
WIRE
can cause
puncture
wounds.

Do
not
point
gun
toward
any
part
of
the
body
or
other
personnel.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.

Wearers
should
consult
with
their doctor before
going
near
arc
welding, gouging,
or
spot
welding
operations.
See
Section
1
-
Safety
Rules
For
Operation
Of Arc
Welding
Power
Source for basic
welding
safety
infor
mation.
1.
Mount
and
position
all
components.
2.
Make
all
necessary
connections
as
instructed in
Section
3 and associated
equipment
Owners
Manuals.
3.
Set
all weld control
adjustments
as
instructed in
weld
control
Owners
Manual.
4.
Energize
the
welding
power
source
and
weld
control,
and
turn
on
all
associated
equipment.
5. Turn
on
flux
supply.
6.
Begin
welding.
The
trailing
gun
angle
and
height
can
be
adjusted
to
provide
required
penetration
and
bead
width
(see
Section
3-5).
IMPORTANT
4
-
2.
SUBMERGED ARC WELDING
(SAW)
WARNING:
ELECTRIC SHOCK
can
kill;
MOVING
PARTS
can
cause
serious
injury;
EXPOSED
ARC
RAYS
can
burn
eyes
and
skin.

Do
not
touch
live electrical
parts.

Keep
clear
of
moving
parts.

Do
not allow flux
flow
to
stop.
4
-
3.
SHUTTING
DOWN
1.
Shut
down
the
welding
power
source,
weld
con
trol,
and all
associated
equipment.
2.
Turn
off
flux
supply.
OM-1553
Page
12

SECTION
5
-
MAINTENANCE
5
-
1.
INSPECTION
AND
UPKEEP
-
Usage
and
shop
conditions
will
determine
the
frequency
and
type
of
maintenance.
Inspect
equipment
as
follows:
L~~U~E
ELECTRIC
SHOCK
can
kill;
WELDING
WIRE
can cause
puncture
wounds;
HOT
SURFACES
can
burn skin.

Shut
down
weld
control
and
welding
power
source
and
disconnect
lAput
power
employing
lockout/tagging
procedures
before
inspecting,
maintaining,
or
servicing.
Lockout/tagging
procedures
consit
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.

Allow
gun
to
cool
before
touching.
1.
Inspect
gun
for
broken
areas,
cracks,
and
loose
parts:
tighten,
repair,
and
replace
as
required.
2.
Carefully
remove
any
weld
spatter
or
foreign
matter
which
may
accumulate
around
the nozzle
orifice.
Use a
hardwood
stick,
never
a
metal tool.
3.
Repair
or
replace,
as
required,
all hose
and
cable;
give
particular
attention
to
frayed
and
cracked
in
sulation
and
areas
where it
enters
equipment.
4. Remove
grease
and
grime
from
components,
moisture
from
electrical
parts
and
cable.
CAUTION
________
FLYING
DIRT AND
METAL PAR
TICLES
can
injure
personnel
and
damage
equip-
Point
gun
liner
only
in
a
safe
direction
away
from
personnel
and
equipment
when
cleaning
with
compressed
air.
Remove
and
clean
the
drive
roll(s)
(see Section 3-2
for
removal and
installation
instructions).
I
WaI
1
. f..~kI
~
Failure
to
properly
maintain
the
drive
rolls
can
result in
a
buildup
of
wire
particles
which
decreases
the
efficiency
of
the wire
feeding
operation.
5
-
3.
BRUSH
INSPECTION
&
REPLACEMENT
(Figures
5-1
and
5-2)
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not touch
five
electrical
parts.
Shut
down weld control
and
welding
power
source
and
disconnect
input
power
employing
lockout/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
disconnecting
device.
Work
on
internal
parts
to
be
performed
only by
qualified
persons.
CAUTION
_________
DISASSEMBLY
OF
MOTOR
FIELD
MAGNETS
can
result in
personal
injury
and
equip
ment
damage.

Limit
drive
motor
repairs
to
brush
replacement.
The
field
magnets
are
very strong.
If
disassembly
is
at
tempted, injury
to.
fingers
and hands
may
result
from
the
rotor
being
drawn
back
into
the
motor.
The
field
magnets
are
matched
sets
and
operation
may
be
af
fected
if
the
magnets
are
tampered
with.
Warranty
is
void if
the
motor
is
tampered
with.
1.
Open
brush
cap
by
sliding
screwdrive
under
catch and
lifting.
Remove
brush
cap.
6. Blow Out
the
gun
wire
guide
liner
with
compress
ed air
when
changing
wire.
This will
remove
any
metal
chips
and
dirt
thay
may
have
accumulated.
5
-
2.
CLEANING
OF DRIVE
ROLLS
-
Occasionally
it
will
become
necessary
to
clean
the
wire
groove
on
the
drive rolls.
This
cleaning
operation
can
be
performed
with
a
wire brush.
WARNING
_________
HIGH
ROTATIONAL
SPEED
may
cause
damage
to
drive
rolls
and
injure
personnel.

Do
not
allow
drive
rolls
to rotate
at
high
speed
if
compressed
air
is
used
for
cleaning
the drive roll
assembly.
WARNING
__________
ELECTRIC
SHOCK
can
kill.

Do
not
touch
live
electrical
parts.

Shut
down
weld control
and
welding
power
source
and
disconnect
input
power
employing
lockout/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
disconnecting
device.
2.
Grasp
spring
retaining
bracket with
long-nose
pliers.
Box
TA-046
226
Figure
6
-
1.
View
Of
Spring
Assembly
And
Brush
When
Brush
Cap
Is
Open
3.
Push
spring
retaining
bracket
in
slightly
and
move
towards
brush.
This
should
release
the
spr
ing
assembly
and
it
can
be
removed.
4.
Pull brush
out
using
brush
pigtail.
ment.
.
Spring
Brush
Pigtail
OM-1553
Page
13

Figure
5
-
2.
View
Of
Spring
Assembly
And
Brush
From Armature
End Of
Motor
5.
If
the
brushes
are
less
than 1/4
in.
(6.4
mm)
long,
replacement
is
necessary.
Disconnect
brush
pigtail
from
brush box
tab
and
remove
brush.
6.
Connect
new
brush
pigtail
to
brush
box
tab.
7.
Route
pigtail
through
slot
in
brush
box. Ensure
that
the
pigtail
will
not
come
into
contact
with
a
metal
surface.
8.
Insert brush into
brush
box.
Ensure that
the
low
end
of the bevel
on
the
top
of the brush is
towards
the
spring.
9.
Using
long-nose
pliers,
insert
spring
assembly
beside brush
sliding
spring retaining
bracket
along
brush box
wall.
The
spring
retaining
bracket hooks
on
the
brush
box wall
as
il
lustrated
in
Figure
5-2.
10.
If
spring
retaining
bracket is
in
place,
it will be
against
the brush box wall when
pliers
are
releas
ed.
11.
Ensure
that
the
spring
is
in
proper
position
as
il
lustrated
in
Figures
5-1
and
5-2.
12.
Replace
and latch
the
brush
cap.
13. Reconnect
power
to
all
equipment
and
resume
operation.
SECTION
6
-
TROUBLESHOOTING
6
-
1.
GENERAL
-
It is
assumed that
proper
installa
tion has
been
made,
according
to
Section 3
of
this
manual,
and
that the
unit has
been
functioning
properly
until
trouble
developed.
6
-
2.
TROUBLESHOOTING
CHART
WARNING:
____
ELECTRIC
SHOCK
can
kill.

Do
not
touch
live
electrical
parts.

Shut
down
weld
control and
welding
power
source
and disconnect
input
power
employing
lockout/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
disconnecting
device.
MOVING
PARTS
can
cause
serious
injury.

Keep
c/ear of
moving parts.
HOT
SURFACES
can cause
severe
burns.

Allow
cooling
period
before
servicing.
Troubleshooting
to
be
performed
only by
qualified
per
sons.
The
following
chart
is
designed
to
diagnose
and
provide
remedies
for
some
of
the troubles
that
may
develop
in
this
unit.
Use
this
chart
in
conjunction
with
the
instructions
in
this
manual while
performing
troubleshooting
procedures.
If
the
trouble is
not
remedied
after
performing
these
pro
cedures,
the
nearest
Factory
Authorized Service Sta
tion~should
be contacted.
In
all
cases
of
equipment
malfunction,
the manufacturers
recommendations
should
be
strictly
followed.
CAUTION
_________
DISASSEMBLY
OF
MOTOR
FIELD
MAGNETS
can
result
in
personal
injury
and
equip
ment
damage.

Limit
drive
motor
repairs
to
brush
replacement.
The
field
magnets
are
very
strong.
If
disassembly
is
at
tempted,
injury
to
fingers
and
hands
may
result
from
a
magnet
being
drawn back
into
the
motor.
the
field
magnets
are
matched
sets
and
operation
may
be af
fected
if
the
magnets
are
tampered
with.
Warranty
is
void
if
the
motor
is
tampered
with.
IMPORTANT:
Spring
TA-046
228
assembly
hooks
here.
OM-1553
Page
14

t
Figure
6
-
1.
Circuit
Diagram
For
Motor
Tach
Board
Circuit
Diagram
No.
A-094
456
TROUBLE
PROBABLE CAUSE
REMEDY

Wire feeds
erratically.
Obstruction in
gun
contact
tube.
Clear
obstruction.
Drive
motor
plug
not
secure
to
cord
plug.
Secure
plug
connection.
Incorrect
pressure
on
drive
rolls.
Rotate
pressure
adjustment
knob(s)
clockwise in
1/4
turn
increments until wire
slippage
stops.
If
excess
pressure
is
required,
check
gun
contact
tube for obstructions.
Drive roll is
too
large
for
wire size
being
used.
Change
to
proper
size drive
roll
(see
Section
3-2).
Worn
drive
roll.
Replace
drive
roll
(see
Section
3-2).
Dirt in drive roll.
Clean
drive roll
as
instructed in
Section
5-2.
Incorrect
hub
tension.
Readjust
hub tension
(see
weld
control
Owners
Manual).
Wire
stops
feeding
while
welding.
Drive rolls
misaligned.
Realign
drive rolls
(see
Section
3-2).

Motor.
Replace
motor.
Wire
feeds
at
maximum
speed only
(D
models).
Motor
tach
board
not
work-
ing.
Replace
tach board.
OM-1553
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15