PowCon POWER DRIVE II User manual

~PowCori
POWER DRIVE II
OWNER'S MANUAL
IMPORTANT READ THIS MANUAL BEFORE
INSTALLING,
OPERATING, OR SERVICING THIS PRODUCT

EQUIPMENT IDENTIFICATION - The unit's identification number (either a Specifi-
cation number, or an Assembly number), model, and serial number usually appear •)n
a nameplate attached to its control panel.
SAFETY WAR.'iiNGS
OWNER'S MANUAL NO. 201006-00lA
Power
Drive II Semiautomatic Solid-State
Control Wire Feeder
This manual covers units displaying any
one
of the following specification num-
bers:
601104-001 2-Roll Drive, 60-600 IPM
Other documentation to cover components
used in this raodel wire feeder:
Control oox 601104-00SA
Feedhead Assembly 601104-006
Base 601104-007
Wire Spool
Support Assembly 601106-001.
Issued: Aug 7/85
Taeie of Contents
Page
MAINTENANCE
CHAPTER l - INSTRUCTIONS
1
1
l
1
1
2
2
2
2
2
CHAPTER 2 - GOMPONENTS SPECIFIC !0
wiRE FEEDER MODEL
POWER DRIVE ti
RECEIPT OF EQUIPMENT
DESCRIPTION OF EQUIPMENT
General
Feedhead Assembly
Control Box Assembly
Wire Reel
Support Assemb2.y
Baseplate
Options
IN'STALLATION
OPERATION
Prewelding Checks
Weldia.g
3
3
3
Control Box
Feedhead Assembly
Baseplate
~Jire Spool Support Asst:!mbl;•
CHAPTER 3 - PARTS LISTS
CHAPTER 4 - DIAGRAMS
WARRANTY
Page
3

SAFETY INSTRUCTIONS AND WARNINGS
FOR OPERATION OF ARC WELDING EQUIPMENT
IMPORTANT - R!AD AND UNDERSTAND THESe INSTRUCTIONS. 00 NOT LOSE 1"REM. ALSO
READ OPERATING/INSTRUCTION MANUAL BEFORE !~lSTALLING, OPERAT!NG, OR SERVICING
THIS eQUIPMENT.
A. ~l':NJ:;RAL
Wel ing products and ~lding proces-
ses can cause serious injury or
death, or damage to other equipment
ot property, if ·the operator does
not strictly observe all safety
rules and take precautionary ac-
tions.
Safe practices have developed from
past experience in the use of weld-
ing and cutting. These practices
must be learned through study and
training before using this equip-
ment. Anyone not hiving extensive
training ·in welding and cutting
practices should not attempt to
weld. Certain of the practices ap-
ply to equi~ment connected to power
lines; other practices apply to en-
gine driven equipment.
Safe practices are outlined in the
American National Standard Z49 .1 en-
titled: SAFETY IN' WELDING AND
CUTTING. This publication and other
~uides to torhat you should learn be-
~ore operating this equip~nt are
listed in Section J for ·your con-.
venience in ordering them.
a. SliDa< PREVJ:;NUON
Bare. conductors, or terminals in the
output circuit, or ungrounded,
electrically-live equil)ment can
fatally shock a person. To protect
against shock, have a co1!1petent
electrician verify that the euuip-
ment is adequately grounded~ Oo
not make contact W'i:h terminals and
?arts that are electri.cally HOT.
The body's electrical resistance· is
decreased W'hen wet, permitting dan-
gerous currents to flow through the
body. Do not work in damp area
~ithout being extremely careful.
Stand on dry rubber tnat O'=' dry <.JOod
and use insulatiltg gloves when datlli)-
ness or sweat cannot be avoided.
!<.ef!l) clothing dry.
1. Installation and Grounding of
Electrically Powered Equipment -
Electrical equipment must be in-
stalled and maintained in accordance
with the National Electrical Code,
NFPA 70, and local codes. A power
disconnect SW'it~h must be located at
the equipment. Check name-;>late for
voltage and phase requirements. tf
only 3-ph~se potorer is available,
connect St;n.g7,e-ph.ase equipment to
only two W'ires of the 3-phase line.
DO NOT CONNECT the equipment
~ounding conductor ( lead) to the
third live wire of the 3-phase line
as this makes the equipment frame
electrically OOT, ~hi~n can cause a
fatal shock..
tf a grounding lead (conductor) is
part ot the potorer supply cable, be
sure to connect it to a properly
grounded switch box or building
ground.. !f not part of the supply
cable, use a separate grounding leaa
(conductor). Do not remove a ~ound
prong from any plug. Use correct
uting receptacles. . Check ground
for electrical continuity before us-
ing equipment.
'-· ~lectrode Holders -Use only
fully insulated electrode holder.
l(eep in good condition. Tighten
screws so handle and other insulated
parts stav in place. ~ever dip
holder !n'water to cool it, "r lay
it down on ground or on work sur-
face. no not touch holders con-
nected to two welding machines at
the same time, or touch· other people
W'ith the holder or electrode.
3. welding Leads -
often for damage to
Replace or repair
leads immediately.
around your body.
welding current in
lead capacity, as
overheat.
!nst:ect leads
the insulae ion.
cracked or worn
Oo not loo!) lead
Do not use a
excess c,f rated
the lead will
4. Output Terminals - Oo not touch
output terminals or make contact
with machine while equipment is
operating.
5. Electrode Wire -The ~lectrode
wire is electr:.ca:!.ly 1-lOT when the
equipment potorer switch f.s in Ol'i po-
sition and the gun trigger is de-
pressed. Oo not toucn electrode
torire or .. live.. parts of '.¥ire
feeder.
6. Service and Maintenance - Shut
OFF all power at the disconaect
switch or line breaker befo~e in-
specting or servid.ng the equipment.
Lock switch OPEN (or remove line
fuses) so that po~er cannot be
turned ON acciden tall v. 11isconnec t
power to equipment it it is to be
left unattended or out of service.
Page 1

SAFETY !NSTRUCTIONS AND WARNINGS
7. Replace fuses
sizes.
with equivalent
C. BUIH PUVENIION
The wetding · arc is very bright and
hot. Sparks go everywhere weld-
ments are hot, and ultraviolet and
infrared radiation is present.
These arc rays penetrate lightweight
clothing ana are reflected from
light-colored surfaces. The arc
rays can injure the eye.s pe"'f'l'fft1..1'Ztt.y
ani:! burn the skin, just as in too
lllUCh sunburn. r.fever look at an
electric arc without eye protec-
tion. lie sure that there is suf-
ficient distance between personnel
welding so sparks will not strike
other personnel in the area.
1. Protect1.'M! Clothing - TlElar dry
gloves, iackets or sleeves, and
<~nrons of chrome leather, safety
shoes t.Telding helmet, and other
articles needed to shield . the skin
and to prevent iniury from arc
burns. Wear ear plugs if welding
overhead or in a confined space.
Wear a ·r.ard hat if others are work-
ing above you.
2. Eye and Read ProteCltion - Protect
. your eyes and head by wearing a
welding helmet fitted with a double
. lens; use a clear lens . outside and a
colored, arc""t"ay lens inside as
follows:
SUGGEST!D LENS SHADE NUMBERS are 10,
11 , 12. This recoll'lllf!ndation may be
varied to suit the individual's
'leeds.
------------------------
tvARNI NG: THE USE OF GAS
WELDING GOGGLES CAN CAUSE
1!:YE DAMAGE WHEN ARC WELD-
!:rG OR crrm.NG. Use hel-
met with proper J.ene
shade instead.
~lways lower the helmet before
striking the arc. wear safety
glasses with side shields ander the
r.~lmet to protect the eyes from fly-
ing particles and side arc flashes
t.Tnen t.he helmet is t1l'.
?rotect the ey~s of oth--r peo~le in
the area by use of opaque, non-
reflecting and non-flammable screens
around your welding :Jtatiott. Allow
good air circulation, es'f)ecially at
floor level. Do not permit anyone
to view the arc unless he uses a
correct handsh:i.eld, or helmet.
A. special hazard to eyes are flying
particl'!s caused by ltrinding,
chipping and removing slag from
weli:is. r.kar safety goggle.s with
side shields. Instruct others in
the area to use them.
For eyeburn, see Section a. on page
Page 2
3.
D. F!RE AND E:O'tOS!QN" PUVENUO~
Fire and ex~loslon are cause by
combustible material being ignitei:i
by the welding arc or flame, flying
sparks, hot weld slag, electrical
short circuits, hot engine exhaust
piping, and misuse of compressed
gases, batteries, and gasoline.
Sparks and oolcen metal can travel a
considerable distance.
1. Welding Area - Do N'O'r weld or cut
if combustible materials are in area
or while ~ervicing batteries (see
Para. 5 belot.T) • "1ove the ~Jork. or
the combustibles. !f combustibles
cannot be Tti)Ved~ protect ~o~ith Eire-
resistant cover. Do not ·~ld in lo-
cations with a flammable atmosphere,
such as produced by degreasing,
cleaning, ~ray painting operations,
or in atmoSl)heres containing ex-p lo-
sive vapors, gases, mists, or
dusts.
2. Fire tJatcher - If welding or
cutting on cornbustible walls, ceil-
ings and floors, or if contbust i b le s
cannot be moved, provide a fire
watcher and fire extinguishers dur-
ing and after the operation. Check
that area is free of glowing or
smoldering material before leaving
the area.
3. Containers - Do not :Jtrike an arc
on a eo1'111)ressed gas cylinder or
other p~essure vessel. ~is may
creata bri!:tle areas 'llhich nay rup-
ture. no not weld or c.uc CO'ltainers
1.n which flammable 1'lotteriai ila\•e
been stored. !f absolutely neces-
sary to dG so, clean ccn taine:r thor-
oughly as described in AWS Standard
A6 .0. Se:e 5ection .J for ordering
information for this Standard.
4. Engine F·~el -1Jse only a:ppro"·ed
f~el container or fueling ~·stem.
Snut unit OOWN before removing fuel
tanY. ca'P. 1)~ !"lot co1'111)letel:r fill
tank, ":>ecause heat from t:he equip-
ment may e."<p and the fue 1 enough to
cause it to overflow. !f fuel
spillage does occur, '-"ipe up all
fuel bl!fore startil'.$( the engtne. 1. f
fuel oenetrates t:ne enclosure or
canopy, remove enough parts to per-
adt complete clean·up. Open canopy
doors and blow compressed air over
equipment to clear away the fumes.
'5. Battery - Batteries give off
flammable hydrogen gas. !.fuen ser~
vicing. do not smcke. cause spark-
i-.:lg, or use ooen flame 'lear the
l-attery.
6. Disposable ~utane Lighters - :Jo
not carry since tne leaking fumes
:=.an be ig:n~ted from StJarks or moltan
slag.

SAFETY INSTRUCITONS AND WAR..\TINGS
7. Pipe Thawing Battery Charging,
And Other Non-welding At>p lic:ations -
Use of a welding machine to thaw
frozen water pipes or to do other
non-welding work can cause fire, ex-
plosion, personal injury . and damage
to builaings, other equipment, and
the welding machine. 1)o not use any
welding equipment for any purpose
other than welding.
E. mHc FUt1! e'EVENnQN
Breat ng t~umes created during
welding or cutting can cause illness
or death, if adequate ventilation is
not provided. Provide ventilation
in accordance with ANSI Standard
Z4 9 •1• See Sect ion J for where to
order. Also read warnings located
on the containers of welding elec-
trodes and wires and on welding
equipment. T)o NOT ventilate with
oxygen.
Some FUME SOURCES are:
l. Weldments- Metals containing
lead cadmium, zinc, T!lercury, and
beryllium can Qroduce harmful toxic:
fumes when welded or cut. Adequate
local exhaust ventilation must be
used for the operator and persons in
the are a. TJ se both an air-supplied
respirator and exhaust ventilation
when welding· or cutting bet"yllium.
2. Coated Weldments -Remove coat•
ings that emit toxic fumes when
heated or use exhaust ventilation
and/or an air-supplied respirator.
'1-
3. Vessels That Rse Contained Toxic
Materials -V&l)ors from chlorinated
solvent:s can be decon~posed by the
arc to forTil the highly toxic: gas
called PHOSGENE or other damaging
products. The ultraviolet radiant
energy of the arc can also decompose
tricfiloroethylene and perchloro-
ethylene vapors to fort11 PHOSGENE.
Do not weld or cut unless such con-
tainers have been thoroughly cleaned
as per AWS Standard A6.0. See Sec-
tion J for ordering information.
4. Welding Area - Do not weld or cut
in locations close to chlorinated
va~ors coming from degreasing,
cleaning or spr~ing t>perations.
The heat and rays from the arc react
with the vapors to form hi~hly: toxic
PHOSGENE. Work in a c:onfl.nea space
only if it is being adequately ven-
tilat:ed, and if ventilation is not
adequate, wear an air-supplied res-
pirator (see ANSI 2.37). Do not
weld/cut in an area where gas leaks
are suspected.
5. Carbon Monoxide -Engine exhaust
fumes can kill. Carbon !IX)noxide gas
is odorless, colorless, and highly
toxic:. Pipe or vent the exhaust
fumes to a suitable exhaust duct or
to the outdoors. Never locate the
engine exhaust near an intake duct
or air conditioner.
r. SOD!LY UUURY PR£VEffiQN
Serious injury cart resut from con-
tact TNith fans, belts, pulleys, or
hot surfaces ·tnside the equipment.
Shut OOWN equipment for inspection
and routine maintenance. f1se ex-
treme care when equipment is in
operation for necessary trouble-
shooting and adj '.ls.t:men t. 'Re sure
arc guards are in place and doors
are secured before starting to
weld.
G.· COMPRESSED GAS EQ~oMEN1'
Foilow precautions ~low and those
outlined in ~A Standard P-1 Pre-
cautions For Safe Handling Of Com-
pressed Gases !n Cylinders. See
Section J for ordering inforTIUltion.
1. Cylinders - Randle carefully to
prevent damage. lteep away from
welding cabl~s or other electrical
circuits. Use only cylinders with
name of gas marked on them; 00 NOT
rely on color identification. Close
valves on empties and return prompt-
ly. Secure cylinders so they cannot
be knocked over. T<eep temperature
below l30°F.. Do not t'efill any cyl-
inder.
2. Rose -Use the type hose designed
for the particular gas to be used.
Color identification of hoses is:
Green for oxygen, black for inert
. gases, red for fuel gas. l'revent
damage to hoses. Replace or repair
if worn or cracked. Use recot'lltDended
fittings.
3. Pressure Regulators -Use the
cort'ec:t re~ulator for the gas and
cylinder at hand. Remove any sus-
pected faulty regulator and return
to manufacturer's service center for
repair.
4. Cylinder Valves -Open slowly so
that regulator oressure increases
slowly. When gage is pressurized,
leave cylinder valve in these posi-
tions: 'or inert gases and oxygen,
open fully; for fuel gas, open to
less than one turn so valve can be
quickly closed in an emergency.
'fi. MEDICAL AND FIRST AID TREATMEN1'
First aid facilities and a qualified
first aid person should be available
for each shift for immediate treat-
ment of electrical shock victims. A
medical facility should be close bv
for immediate treatment of flash
burns of the eye and skin burns.
Page 3

SAFETY INSTRUCTIONS AND WARNINGS
EMERGENCY FIRST AID
Call physician and ambulance im-
mediately. Use First Aid techniques
recommended by American Red Cross.
DANGER - ELECTRIC SHOCK CAN BE
FATAL. If person is unconscious and
electric shock is suspected, do not
touch person if P.e or she is in eon-
tact with welding leads, welding
equipment~ or other live electrical
parts. uisconnec.t (open) power at
wall switch and then use First Aid.
1 Dry wood, wooden broom, and other
insulating material can be used to
move cables, if necessary, away from
person.
IF BREATHING IS DIFFICULT iive ox-
ygen• IF NOT BR.EA'!HING , BEG IN AR'I'I-
~ICIAL BREATHING such as mouth-
to-mouth. IF PULSE IS ABSENT, BEGIN
ARTIFICIAL CIRCULATION, such as ex-
ternal heart massage.
IN CASE OF EY!3URN, obtain profes-
sional medical attention im-
mediately.
I. !QU!PMENT W~"iiNG . LABELS
Inspect ail precautionary lahels on
the equipment. Order and replace
all labels that cannot be easily
read. Also replace all warning and
caution labels when replacing shee~
metal parts.
J. JEITIONAL SAF!'I'Y AND J3.MLTH IN-
FO ___liON
For :llOre information, order the fol-
lowing standards or their latest re-
visions. Take action as applicab.i.e:
1•
.ANSI Standard Z49 .1, SAFETY L"t
WELDING AND CUT'l'ING. Order from.
the American Welding Society.
Page 4
P.O. Box 351040, 550 N.Y. LeJeune
Rd •• Miami, Fla. 33125.
2.
ANSI Standard Z87.1, SAFE PRAC-
TICE FOR OCCUPATION AND EDUCA-
TIONAL EYE A..'ID FACE PROTECTION.
Order from American National
Standards Institute, 1430 Broad-
way,
New York, N.Y. 10018.
3. ANSI Standard Z41.1, Standard for
Men's Safety-Toe Footwear. Order
from
same as Item 2.
4. American Welding Society Standard
F4.1-80, WELD!NG AND CUTTING CON-
TA!NE&S WHICH HAVE HELD COM-
BUSTIBLES. Order same as for
Item 1.
5. OSHA Standard 29 CFR~ Par~ 1910,
S~b~art Q~ WELDING, CUTTING AND
BRAZING. Order fro·m Superinten-
dent of Documents, U.S. Govern-
ment
Printing Office, Washington,
D.C. 20402.
6. NF?A
Standard 51 i OXYGEN-FUEL GAS
SYSTEMS FOR w~LD NG AND CUTTING.
0l:'der fl:'om the Naciona! Fire Pro-
tection Association, Batterymarch
Park, ~ncy, Mass. 02269.
7. NFPA Standard 513, CUTTING AND
WELDING PROCESSES. Order same as
for Item 6.
8. CGA Pamphlet P-1. SAFE HANDLING
OF COMPRESSED GASES tN CYLINDERS.
Ol:'der from :he ComEressed Gas As-
sociation, 1235 Je~! Davis Hwg.,
Arlington, Virg1nia 22202.
9. CSA Standard Wll7.2, CODE FOR
SAFETY IN WELD!HG A."'D CUTTING.
0l:'der from Canadian Standards As-
sociation, 178 Rexdale Boulevard,
Raxdale, Ontario, Canada X9W
la.3.
Revised
Revised
Revised
Instruceion 910081
Sept 10/79
Oct 17/75 -Vl509
Jan 21/81 - XOC56
J~n 17/83 ZOCS2
1\.c•rised May 30/ 84
- • 1 "" _ ...... .., '- I ~ £.

201006-00lA.
Instructions
C'd.APTER 1
RECEIPT OF EQUIPMENT
Check the equipment received against
the invoice to make certain that the
shipment is complete and undamaged.
If the equipment has been damaged in
transit, notify the carrier (railroad,
trucking company, etc.) at once and
file a claim for damages. If you re-
quire assistance with a damage claim,
furnish PowCon Incorporated with
full information about the claim. If
the shipment is in error, contact:
Shipping Department, at PowCon
Incorporated 8123 Miralani Drive,
San Diego, CA 92126.
Give the MODEL, SPECIFICATION', and
SERIAL numbers of the equipment, and a
full description of the part:s in er-
ror.
Best results will be obtained with
this equipment ONLY if the responsible
operating and maintenance personnel
have access to this manual, and are
familiar with the instructions con-
tained herein. Additional copies may
be obtained at a small cost per copy
by
writing to: Pow Con I nco r p or ate d
8123 Miralani Drive, San Diego, CA
92126. Be sure and give the SPECIFI-
CATION', SERIAL, and MODEL numbers of
your equipment, the number vf this
manual, and number of copies desired
when ordering additional ~nuals.
Generally, it is good practice to move
the equipment to the site of installa-
tion before uncrating. Use care in
uncrating in order to avoid damage to
the equipment when bars, hammers,
etc. , are used.
DESCRIPTION' OF EQUIPMENT
GENERAL
'fhe---p'Qwer Dt'i ve II Wire Feeder is a
modular unit, consisting of a Control
Box Assembly, Feed head Assembly, and
Wire
Spool Support mounted on a coi1Ullon
baseplate. The components are covered
by a sheet metal wrapper, which pro-
vides protection for the control com-
ponents, and the wire feedhead as-
sembly. The control box is not com-
plete in itself, but needs the feed-
head mounting plate to close in the
side of the box where the feedhead as-
sembly attaches. (An optional side
panel may be secured to close in this
side for remote mounting.)
FEED WIRE FEED I
ROLLS RATE
-:...-:-..::-=====:= -=--~
2 60-600 IPM
Table 1
Aug 7/85
FEEDHEAD ASSEMBLY
The feed roll drive motor is solid-
state controlled on these units. One
of either of two different ~otors
(see Parts List for numbers of each)
are used, depending upon which Nire
feed rate is desired. See Table l tor
correlation of numbers.
The
assemblies consist of Feed Ralls
(which are made up of a Gear and Feed
Roll) for various wire types and/ or
sizes, Wire Input Guide:, Output Guide,
Feedhead Mounting Plate, and Pressure
Arm assembly. The drive motor is 115
volt DC. See Feedhead Assembly sec-
tion for details on the Feedhead As-
sembly. See Feed Roll Kit drawing
601102-X in Chapter 2 for selecting
part numbers for the Feed Rolls, Wire
Guides, Contact Tubes, etc.
Page 1

FEEDHEAD ASSEMBLY (Continued)
Sase
Wire Spool Suppor1 Asumbly
~ c.n., ....
wire Feeder Assembly
Figure 1
CONTROL BOX ASSEt1BLY
The Control Box contains control and
connection for the operation and com-
ponent hook-up with the particular
we:ding system it is being used with.
WIRE REEL SUPPORT ASSEMBLY
The Support boi ts in place at the rear
of che baseplate. See Addendum in
Cha?ter 2 for letails on the installa-
tion and operation of the wire support
assembly.
BASEPLATE
See Baseplate Assembly section for 1e-
tails on the baseplate used for this
wi.re feeder when assembled to make the
subject model configuration.
OPTIONS
The following list
available to be used
of options are
with this wire
feeder and. control box assembly. Some
options are kits, while others are in-
dividual items.
1. Wire Feeder Base Assy 6011.04-007
2. Caster Assembly for Base 601105-001
Page 2
3.
4.
5.
6.
7.
Swivel Assembly for Base
Spool
Support Assembly
Reel Support Assembly
Spool
Kit
Reel Kit
8. Coil Adapter - 6011
9. Coil Adapter- 10#
10. Coil Adapter 141!
11. Coil Adapter -15#
12. Spool Cover -30#
13. Spool Cover - 60#/
201006-00lA
601105-002
601106-001
601105-003
601107-001
601108-001
601105-004
601105-005
601105-006
601105-007
601105-008
Lifting Eye 601105-009
14. Lifting Eye 601105-010
15. Burnback Timer 601105-011
16. Preflow/Postflow/Burnback 601105-012
17. Preflow/Postflow/Burnback/
Spot 601105-013
18. Spot-Burnback/Stitch 601105-014
19. Inch/Purge Switch
(Variac)
20. Inch/Purge Switch
(Solid-State)
21. Forward/Reverse Switch
22. Ground Fault Protection
23. Remote Speed Control 15'
24. Remote Speed Control 25'
25. Remote Speed Control SO'
26. Handle
27. Control Cable Ext. 15 Ft.
28. Control Cable Ext. 25 Ft.
29. Control Cable Ext. 50 Ft.
30. Control Cable Ext. 75 Ft.
31. -Power Cable Ext. 15 Ft.
32. Power Cable Ext. 25 Ft.
33 • Power Cable Ext. 50 Ft •
34. Power Cable Ext. 75 Ft.
35. Feed Roll Kits
36. Water Valve
37. Control Lock
38. MIG-KWIK 5 Gun
Adapter !{it
601105-015
601105-016
601105-017
601105-018
601105-019
601105-020
601105-021
601105-022
601105-023
601105-024
601105-025
601105-026
601105-027
601105-028
601105-029
601:1.05-030
601102-X
60UJ5-031
601105-032
601103-001.
NOTE: For
installation and
operation instructions for
the above options, see draw-
ings and instructions fur-
nished with each kit. The
Welding Gun ana Cable assem-
bly used with the Feedhead
in this manual will be
covered by an Owner's Man-
ual.
Aug 7/85

201006-00lA
INSTALLATION
The components which comprise the Pow-
er Drive II Wire Feeder (see Figure 1)
are documented separately in
Chapter 2. Only the components which
are utilized for this model Wire Feed-
er are located there.
OPERATION
PREWELDING CllECKS
Before attempting to operate the Power
Drive II Wire Feeder, make certain
that all installation instructions,
including those for the welding ma-
chine (power source), and the welding
gun and cable, have been carried out.
1 .. With the power source turned ON and
the Wire Feeder connected to power
supply (115 volts, 3 amp, 50/60 Hz),
adjust the flow of shielding gas.
WARNING: When the gun
switch is depressed, the
electrode (welding wire) is
electrically "hot". Do not
permit it to touch any metal
or a welding arc roay be es-
tablished which rnay be in-
jurious to someone's eyes
(flash) to skin (burn).
2. Adjust the Weld Power setting on
the power source to desired value.
The gun switch must be triggered to
close power source contactor.
NOTE: The Weld Power
setting is independent of
the open circuit voltage.
This is because of the con-
verter technology used in
the PowCon line of power
supplies. See the instruc-
tion manual for the power
source to determine various
connections and settings for
the desired operation.
3. Adjust the wire feed speed to the
desired value by means of the Wire
Feed Speed
Control.
NOTE: Maximum and minimum
feed rates are established
at the factory. For any
change, consult a factory
representative, or contact
the PowCon Inc. Technical
Service Department.
WELDING
1. Position the gun
piece and pull the
ger.
above the work-
gun
switch trig-
2. Releasing the gun switch trigger
will cause the wire to stop feeding.
If Burnback feature is present, the
welding contactor will open, and the
gas will stop flowing, after a fixed
time delay.
3. When the welding has heen com-
pleted, or at the end of the work day,
it is recommended that the gas be shut
OFF at the cylinder, and the welding
power source be turned OFF.
MAINTENANCE
Maintenance of this equipment is dealt
with in the publication sheets for
each component. See these sections in
Chapter 2 of this manual.
Aug 7/85
Parts Lists for the composite assem-
bly and the various components will
be found in Chapter 3 of this
manual.
Page 3

201006-00lA
CHAPTER2
COMPONENTS SPECIF!C TO WIRE FEEDER POWER DRIVE II
This chapter contains various publica-
tion sheets or material specifically
related to components comprising the
wire feeder by the model number
shown on
the Front Sheet,
and in the opening statement
under DESCRIPTION OF EQUIPMENT in
Chapter 1.
rage 4
These
sections will not have page num-
ber continuity, but are numbered in
each separate section by assembly num-
ber. In some cases, a Parts List will
accompany the publication, but us-
ually the Parts List for these compo-
nents will be f.ound in Chapter 3 1,1t1der
PARTS LISTS.
Aug 7/85

Parts List
CONTROL BOX ASSEMBLY
601104-00SA
DESCRIPTION
INSTALLATION
OPERATION
MAINTENANCE
601104-00SA

601104-QOSA
CONTROL BOX ASSEMBLY NO. 601104-00SA DESCRIPTION, INSTALLATION, OPERATION,
MAINTENANCE
DESCRIPTION
The Control Box assembly is the con-
trol medium far the operation of the
Feedhead. Wire Feed Speed rate (IPM
Inches-per-minute) is selected and
regulated by the knob (potentiometer)
on the front panel. The box is de-
signed to function as a component of
the Power Drive II Wire Feeder com-
posite assembly, or as remote-mounted
control medium, not situated close to
the Feedhead. A side panel is avail-
able to replace the Feedhead Mounting
Plate (see Fig. 1) when used in a re-
mote situation.
CONTROLS AND CONNECTIONS
WIRE FEED SPEED Control (On front
panel) - Controls rate in IPM of the
wire feeding through the feed rolls.
POWER ON-OFF
Switch
(On front
panel) - This red transparent rocker
switch/lamp controls only the wire
feeder, and not the welding machine.
It is used as an ON-OFF power switch,
but also serves as a circuit breaker.
To reset power to the wire feeder,
allow for a several second time de-
lay.
GUN SWITCH Receptacle - Connection
paint far the gun switch leads to con-
trol wire feeding function from the
welding gun.
START CONTROL Switch (On rear
panel) - Determines the acceleration
time for wire speed (.25 second for 0
to Wire Feed Speed Control setting in
FAST; .4 second in SLOW).
SHIELDING GAS INLET - Connection
point for supply of shielding gas to
the solenoid gas valve, located inside
the control box. The solenoid valve
then regulates the gas to the welding
gun.
A.ug 7/85
•ootlonal•May be removed for installinq Tlrner
Options.
Figure 1
POWER AND CONTROL CABLES - One of
the cables connects onto the Remota
Control receptacle on the front panel
of the welding machine, and the other
one is the 115 volt power supply
cable, to be plugged into the 115 volt
supply receptacle on the welding ma-
chine front panel.
e 0
P<twer and ShieldinQ Gas Inlet
Control CaiJtes Connection
Figure 2
Page 1

OPTIONS - There are a number of
controls, switches, and a control
panel cover (see Fig. l) which can be
replaced (either factory or field-
installed) to provide for the in-
stallation of several timers. These
optional timers, located on the
panels, are shown below in Figures 3,
4, 5, and 6. These may be obtained in
kit form (see Kit part numbers in text
below), to replace the blank cover.
OPTIONAL TIMERS - On
the solid-
state Control Box, there are four com-
binations available. (l) BURNBACK TIM-
ER (Kit /1601105-011) as shown in Fig-
ure 3; (2) PREFLOW/POSTFLOW/BURNBACK
TIMERS (Kit #601105-012), as shown in
Figure 4; (3) PREFLOW/POSTFLOW/BURN-
BACK/SPOT TIMERS (Kit #601103-013), as
shown in Figure 5, (4) STITCH ON-ARC
SPOT TIME/STITCH OFF-BURNBACK TIME/
SPOT-CONTINUOUS-STITCH Switch (Kit
1,!601105-014), as shown in Figure 6.
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:~~~
• "\\{,JJ .•
.. ,
suaMU.CX T1MC
0
Kit 601105-0ll
Figure 3
0
BURUBACK TIMER (OPTION) - Select
the time allowed for wire burnback at
the conclusion of the arc. This helps
to overcome the wire "sticking" at the
end of a weld. Adjustment of the
burnback time may be made f::om .1 to
:...o se::onds.
PREFLOW TIMER - Controls time dura-
tion (.2-2 seconds) of gas flow prior
to astablishm&nt of the welcing arc.
Page 2
601104-QOSA
... "'
tl. J0"
~ l ~ I
-I •
• ••
fiiiiC"-''W , ..
0
'®., ...
" I .'0 t
I • ~
• ••
Kit 601105-012
Figure 4
0
POSTFLOW TIMER - Controls time
duration ( .2-2 seconds) of gas flow
following the extinguishing of the
welding arc.
BURNBACK TIMER -See BURNBACK TIMER
above (.1 to .9 seconds).
NOTE: Turning these k~obs
clockwise will increase the
time duration of each func-
tion • .,
~
ti:i ! ·~ .•
OV::!J~
1 0~ tt
" 'd. 0 •
• ••
. ,.
~Titd ~T1MC
Kit 601105-0lJ
Figure 5
PREFLOW T!MER ·- See above.
POSTFLOW TIMER -See above.
BURNBACK TIMER See above o
ARC SPOT TIME - This control regu-
lates time duration of a spot weld
cycle to .2-2 seconds. Make sure that
the SPOT-CONTINUCUS Switc.h i.s in the
SPOT position for spct welding.
,.,
1\ug 7/85

SPOT-CONTINUOUS Switch - Place this
switch in SPOT position for spot weld-
ing, and in CONTINUOUS position for
regular or FCAW welding.
0
1 •®" (of.,
"' .
. ..
. ..
,•0' .. .,
.. '
• t
• ••
ST1TCM CJM STITCH en
AltC SPOT Tlloll: SUJINUCX ~MC 0
SPGT
CONTINUOUS ~
STITCH
i<it 601105-014
·Figure 6
SPOT-CONTINUOUS-STITCH Switch -
This switch selects one of the three
modes of operation made possible by
this option. Switch position deter-
mines which of the two timers (below)
will function. Note the switch posi-
tions, and the related timing ·func-
tions.
SPOT position - In this mode of
operation, the STITCH ON/ARC TIME Con-
trol (upper left on panel) is used to
control the Spot time with a range of
.2 to 2.0 seconds. The STITCH
OFF/BURNBACK Control (upper right on
panel) is used to control Burnback
time, with a range of .03 to .3
seconds.
CONTINUOUS position - In this mode
of operation, the above controls are
inoperative. However, a fixed Burn-
back time of approximately .2 seconds
is designed into the unit.
STITCH position - In this mode of
operation, the STITCH ON/ARC SPOT TIME
Control is used to control the ON time
of the wire feeder with a range of .2
to 2.0 seconds. The STITCH OFF/BURN-
BACK TIME Control is used to control
Aug 7/85
601104-00SA
the OFF time of the wire feeder with a
range of .2 to 2.0 seconds. The unit
will cycle OFF and ON as tong as the
gun switch is kept ene~gized. When
the gun switch is deene~~zed, a fixed
Burnback time of .2 seconds results.
Since the power source is always
turned ON during the OFF time (of the
cycle), this mode of operation is not
recommended for welding processes
and/or power sources where the open-
circuit voltage exceeds 30 volts.
INCH-PURGE Switch (Optional) -See
Fig. 1. When held in the INCH posi-
tion, wire will feed at the rate de-
termined by the WIRE FEED SPEED Con-
trol. When it is in the PURGE posi-
tion, shielding gas will flow through
the welding gun.
FORWARD-REVERSE Switch (Optional) -
See
Fig. 1. When in the FORWARD po-
sition, the wire will feed out of the
welding gun, when r:NCH Switch is
actuated. In REVERSe, the wire will
retract from the gun and cable, and
back thcoug~ the feed rolls, when INCH
Switch is actuated.
OPTIONS ON TliE REAR PANEL
GUN SWITCH (HOLD/MOMENTARY) -See
Figure 2 - In HOLD position, wire
electrode will feed continuously after
pressing gun switch (on the welding
gun) momentarily, then releasing it.
To stop wire feeding, and break the
arc, press gun switch again ~omen
tarily, and release. In MOMENTARY po-
sition, the wire electrode will feed
only when gun switch is depressed.
WIRE FEED Switch - (LOCAL-REMOTE) -
In LOCAL position, the wire feed speed
will be regulated by the WIRE FEED
SPEED Control en the front panel of
the Control Box. In REMOTE position,
it will be regulated by a contro~ in a
remote pendant, foot switch, or other
control medium.
Page 3

INSTALLATION
LOCATION - For best operating
characteristics and longest unit life,
take care in selecting an installation
site. Avoid locations exposed to high
humidity, dust, high ambient tempera-
tures, or corrosive fumes. Moisture
can condense on electrical components,
causing corrosion or shorting of cir-
cuits. Dirt on components helps re-
tain this moisture and also increases
wear on moving parts.
CONNECTION TO POWER SOURCE - Two
cables are hard-wired into the control
box, and exit from the rear panel.
Both are tied into one housing, which
plugs into the REMOTE connector on the
front 1)r rear panel (depending on the
model you have purchased) of the power
supply. This cable provides 115 V
power to the wire feeder, and .:tlso
provides contactor ~ontrol via the gun
switch.
AS A REMOTE CONTROL BOX
This Control Box may be remotely lo-
cated (away from the Feedhead and
Spool Support assembly} at some dis-
tance from the weld site. In this
case, the side of the Control Box
which accoram.oda·tes the Feedhead Mount-
ing Plate (when used as a composite
wire feeder) has an optional side
panel supplied, which closes the box
in. Extension cables must then be
used to connect the Control Box to the
Wire Feedhead and the Power Source.
OPERATION
This Control Box is not an entity com-
ponent in itself, but must be used
with other components in the above
situation or as part of the composite
wire feeder. See the Owner's Manual
supplied for the particular applica··
tion where the Control Box is used.
THEORY OF OPERATION -See Connec-
tion Diagram 601104-0ll -These units
use a solid-state control circuit.
Ar:uature ·toltage feedback and lR com-
pensation fur~ish a very constant wire
Page 4
601104-00SA
feed speed independent of line voltage
variation or load. Selectable ramp
rates are provided to control the run-
in speed of the motor. (See START
CONTROL Switch under DESCRIPTION.) In
the FAST position (see switch location
on Fig. 2) it requires approximately
0.25 seconds to go from ~o speed to
sele~ted speed (as set by the Wire
Feed Speed
Control), and in SLOW posi-
tion it takes <ipproximately 0.4
seconds. A current limit circuit
limits the maximum motor cur~ent to
approximately 2.7 ~mperes.
With the wire feeder plugged into a
120
volt power supply (P2), depress
the upper part of the Power ON-OFF
Switch (Circuit Breaker, Sl) co turn
the unit ON. Power is supplied to the
co~trol ~ransformer (Tl) and to the
solid-state control 'lOdule through
CRl.
NOTE: If Circuit Breaker
trips, it turns the Power
Switch 31 to OFF posit.ion.
A short cooling perivd
must be allowed befor~ an
attempt is made to reset
the unit.
When the gun switch is depressed, re-
ceptacle (Jl) is shorted, the gas
valve (Ll), anri a relay on the PC
Board are energized by ?OWer supplied
from the t~ansformer ~!l). the relay
provides a closure to turn ON the pow-
er sourct! ( 1M<alci.ing •uachine) through
pins A and Bon the control plug (Pl).
Another ~et of contacts on the relay
enables the solid-state control cir-
cuit, and applies power to the motor
terminals via TB3-2 and T'B3-l~ through
the current feedback resistor (R4).
R2 and Cl provide curr~nt filtering
for the motor. Current feedback is
provided by R4, and voltage feedback
is pro,•ided by R3 • Releasing the guo.
switch (removing the shcr.t acrcss Jl)
stops all functions.
Aug 7/85

THEORY OF OPERATION (Continued)
When the gun switch is deenergized,
the solid-state power supply is dis-
abled and a solid-state switch is
turned ON and shorts the armature
through the braking resistor (Rl) and
current feedback resistor (R4) to pro-
vide dynamic braking.
Provision for changing the wire feeder
from operating on a standard Pow
Con power source to a power source
which requires 120 volts AC power to
be supplied to the contactor is made
by use of terminal strip (TB2) termi-
nals 14, 15, and 16. For standard
PowCon power source, connect unit
per Connection Diagram. This is the
way it is wired at the factory. To
Aug 7/85
601104-00SA
ahange
to 120 volt AC aontaatoro in ~
welding maahine (powero souroae), ~move
white 1viroe froom TB2-14 and aonneat it
to TB2-15; .,.emove ~d a:nd oronge ,,n_ roes
froom T32-14 and move them to TB2-16.
MAINTENANCE
CLEANING - Periodically blow out
the Control Box with clean, dry, com-
pressed air with no more than 25 psi
(172 kPa) pressure. Use care not to
strike any of the parts (switches,
controls, etc.) with the air hose noz-
zle.
See Troubleshooting
follows for details
that area.
on
Chart
which
problems
in
Page S

601104-00SA
TROUBLESHOOTING
The following chart contains information which can be used to diagnose and cor-
rect unsatisfactory operation or failure of various components of the unit.
Each malfunction is followed by a suggested checking or inspection procedure.
MALFUNCTION
TEST OR L~SPECTION
CORRECTIVE ACTION
1. Wire feed motor does not operate; pilot light is lit.
Step 1: Check for tripped circuit breaker.
Reset ON-QFF switch.
Step 2: Check for power to wire feeder.
Check 115 V input power cable connections at power
source.
Must ~asure 115 V AC from TB2-16 to TB2-15 in
feeder.
2. Wire feed motor does not operata and pilot lig~t is lit.
Step 1: Check to see if control relay on motor control board is
operating.
Check control cable connection from gun to feeder.
Check gun switch.
Step 2: Check to see why feedrolls are mechanically restricted and
control is operating at current limit.
Check feedrolls and related items f.Jr restrictions
and correct condition.
Step 3: Check for faulty 24 volt transformer or. loose connections.
Check output of 24 volt transformer. Must have
24 V AC from TB2-l2 to TBl-6. Check connections
between transformer, terminal st~ip, gun switch
rac~ptacle and mater control board.
Step 4: Check for defective motor control board or wiring.
With contr'll at max. and with gU'.l swit-:.h energized,
check the following:
?age 6 Aug 7/85